Pb + PbO2 + 2H2SO4 —><—electricity + 2PbSO4 + 2H2O

During charging, the amorphous lead sulfate is easily converted back to lead, lead dioxide, and sulfuric acid, in essence returning the battery to its former state. Unfortunately, there is no “perfect machine”, and with repeated use, the ability of a battery to reach a full charge diminishes.

As batteries are “cycled” through numerous charge and discharge sequences, particularly if the batteries are not charged fully, or are allowed to remain in a partially discharged stare for extended periods, the amorphous lead sulfate is converted to a very stable crystalline form. This process, called sulfation, is the primary cause of declining performance over time, and is ultimately the leading cause of battery failure.

How can you tell if your battery is suffering from excessive sulfation? Higher temperatures are observed during both charging (since higher charge voltages are needed to overcome the higher internal cell resistance), and discharging (since a sulfated battery puts out a lower voltage, but power requirements remain the same so the current increases). The net result is that running times of battery powered equipment are shorter, electrolyte specific gravity decreases, CCA (cold cranking amps) output is reduced, and charge acceptance is slower and less efficient. Terminal corrosion also increases because the higher operating temperatures increase water loss and the generation of sulfuric acid mist.

Hard sulfate, large lead sulfate crystals that do not decompose during charging, are non-conducting and dramatically increasing the electrical resistance of the battery. The crystalline lead sulfate coating also reduces the capacity of the battery, both by permanently reduce plate surface area, and also by separating the active material (lead and lead dioxide) from the electrochemical reaction sites. Thus, the rate at which current can be supplied (Cold Cranking Amp output, quantified by a CCA Test) is diminished significantly. As the lead sulfate crystals cover more of the surface area of the battery plates, load voltage, which correlates with battery storage capacity (amp-hours), and CCA (ability to deliver peak current) continue to decline.

The electrochemical driving force of a battery declines with decreasing temperature, so that in extreme cold, the energy available to start a vehicle is substantially less than at room temperature. In addition, the viscosity of the lubricating oil in the engine increase as temperature decreases, so more energy is required to start it. Sulfation exacerbates cold weather starting problems by further reducing the available energy in a battery. All of these factors combine to increase the rate of battery failures in cold weather.

Typical charging voltages cannot breakdown the crystalline lead sulfate buildup, so sulfation gradually gets worse, and the performance of the battery declines. Battery users believe they can reverse sulfation by “equalization charging”, which raises peak charging voltages. It is possible that, depending on crystal particle size, some of lead sulfate is converted to sulfuric acid, but probably most of the ‘benefit’ comes from the physical separation of the crystalline coating due to the vigorous gassing which occurs at such elevated voltages. Fresh plate surface is exposed at the expense of losing active material which simply falls to the bottom of the cell. Battery temperature increases dramatically during equalization charging. The higher charging temperature increases positive grid corrosion, water loss through gassing (the electrical conversion of water to hydrogen and oxygen, which can re-combine violently causing an explosion), and sulfuric acid ‘misting’ which, in turn, causes terminal corrosion. All of these phenomena reduce battery life significantly.

To improve a battery’s performance and extend its life significantly, sulfation must be eliminated. Dial a Battery is the world’s leading supplier of the most effective desulfation technology. Its patented  battery energizers revitalize and extend the useful life of lead-acid batteries by preventing and even reversing the sulfation process.

Our battery energizers connect to a battery or charging system and emit a high frequency electrical pulse that reverses the lead sulfate crystallization process. Hundreds of tests and actual field installations have shown that Dial a Battery’s Advanced Desulfation Technology improves battery performance by eliminating sulfate build up on older batteries, and preventing it from forming on new batteries.

Our  battery energizers help maintain batteries in “like new” condition. Batteries operating at peak voltage absorb voltage spikes from the alternator and other equipment, and deliver clean, stable power, protecting the entire electrical system.