What causes an explosion of tubular and pasted plate lead acid batteries?
By the author of the Amazon Bestseller Book 'Batteries Demystified', Podcaster, & Expert in Lead Acid Battery Manufacturing Processes and Machines
The possible reasons for the explosion of a lead-acid battery can be either one or a combination of the following:
✅The battery can explode if it is subject to an overcharge, i.e., continuously after being fully charged. When a battery is fully charged, the active material has converted to sponge lead on the negative plates & lead dioxide on the positive plates. In such a condition, no lead sulfate active material can be converted chemically on both positive & negative plates. The electrical energy fed by the charger, which is supposed to be converted to chemical energy, is converted to heat energy. The electrolyte is heated, & the evolving explosive hydrogen gas generated builds up pressure under the vent plugs, causing the vent plugs to pop up or build up pressure sufficient enough to explode the battery.
✅ The battery can explode if an improper charger is used to charge it. When a battery is connected to a charger meant for charging a larger capacity, the charger starts charging the battery at a higher-than-recommended current. The battery life is affected in such cases, and the active plate material starts shedding, creating an internal short. The internal short causes heat and an explosion. In this case, the internal short is not due to a manufacturing defect but incorrect charger selection.
✅ The battery can explode if sources of static electricity cause a spark in the vicinity of the batteries. Also, naked flames, welding sparks, or any other sparks near batteries while batteries are on charge can cause a fire or explosion. As and when batteries are on charge, hydrogen gases are evolved. Hydrogen gas is very flammable and yields explosive mixtures with air and oxygen. Since hydrogen gas is flammable, a spark with oxygen from the atmosphere can lead to a fire and an explosion of the battery. Hence, even smoking cigarettes is not recommended in rooms where batteries are on charge.
✅ The battery can explode if the battery is on charge in a room with improper ventilation. When batteries are on charge, hydrogen & oxygen are both evolved as gases. They do recombine to form water, but not fully. If the hydrogen gas is developed to such an extent that the concentration of hydrogen gas is greater than 4%, it can cause an explosion of the battery. Hence, batteries must be charged in an atmosphere where the gases can escape. The manufacturers usually recommend that battery charging areas or rooms have adequate ventilation with at least six air changes per hour.
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✅The battery can explode if batteries smaller than the recommended size or lower Ah capacity are used. At times, due to the non-availability of correct capacity batteries or cost considerations, batteries of lower capacity are fitted to equipment or vehicles. In such cases, the charger, being of a much larger capacity than required by the battery, tends to overcharge the battery, heating the battery, causing bubbling & gassing with a possible explosion of the battery due to pressure buildup within the battery container.
✅ The battery can explode if the battery terminals are shorted externally with any metal object or conducting substance.
✅ The battery can explode if the battery has an internal shorting due to a manufacturing defect.
✅The battery can explode if the vent plugs’ holes are clogged due to the battery being kept or used in a dusty/dirty environment. Batteries with such clogged vent holes as vent plugs shall not allow gases to escape, leading to pressure buildup and an explosion.
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