Relatively few people understand battery sulfation, but many have experienced it.

Symptoms include:

  • Reduced battery capacity
  • Longer charging times
  • Difficulty starting the engine of your car, jet ski, or whatever you’re operating
  • Increased self-discharge rate
  • Swelling or bulging battery casing
  • Corrosion around terminals
  • Poor performance in cold weather

These are telltale signs of sulfation. It happens when lead-acid batteries are left sitting in a discharged state for extended periods.

In this blog, we’ll examine battery sulfation in detail and discuss how to prevent it.

How Lead-Acid Batteries Work

The structure of a lead-acid battery includes:

  • Positive Plates: Made of lead peroxide, these plates carry a positive electrical charge.
  • Negative Plates: Made of sponge lead, these plates have a negative electrical charge.
  • Electrolyte Solution: A sulfuric acid solution that surrounds the lead plates.

When a battery discharges, the following occurs:

  • Lead sulfate crystals form on the positive and negative plates when the battery discharges.
  • This reaction happens as sulfate from the sulfuric acid combines with the lead in the plates.
  • The battery’s total charge is exhausted once lead sulfate formation peaks.

To restore functionality, you have to recharge the battery:

  • During recharging, the lead sulfate crystals dissolve into the sulfuric acid solution.
  • This process allows the lead plates to regain their positive and negative charges.

What Is Battery Sulfation?

Sulfation is the accumulation of lead sulfate crystals on a battery’s lead plates. It’s a natural byproduct of the chemical reactions during discharge and charging cycles.

While sulfation is a standard process in the life of a lead-acid battery, it becomes problematic when the crystals can’t be dissolved back into the electrolyte solution during recharging. This permanent buildup leads to reduced battery capacity, longer charging times, and, ultimately, battery failure.

Deep-cycle and stationary lead-acid batteries are more susceptible to sulfation. They’re frequently subjected to partial discharges and not fully recharged before being used again. This causes a greater buildup of lead sulfate over time.

The sulfation can become irreversible without regular and complete charging, significantly reducing the battery’s performance and longevity.

  • Sulfation occurs every time you use your battery.
  • Lead sulfate crystals accumulate temporarily during normal use.
  • They dissolve during the recharging cycle.
  • Problems arise when the lead sulfate coating becomes permanent.
  • It fails to dissolve during recharging.

When Sulfation Becomes Permanent

Permanent sulfation can trigger a range of problems in a lead-acid battery, including:

  • A substantial increase in charging times
  • Loss of starting power
  • Abnormally high temperatures inside your battery
  • The need to recharge your battery more often

Permanent sulfation is the primary reason for premature failures in lead-acid batteries.

How Battery Sulfation Occurs

The causes of sulfation include:

  • Too much time between battery recharge cycles
  • A battery that’s left at less than 100% capacity after recharging
  • Improper settings on recharging equipment
  • Lack of adequate sulfuric acid solution inside a battery
  • Exposure of lead battery plates to air
  • Storing a battery without access to an energy source

Allowing a vehicle to idle increases the odds of recharging to less than 100%. Heavy use of power-consuming vehicle plugins can also contribute to the problem.

Dealing with Sulfation & Preventing Permanence

Regular maintenance is the best way to avoid permanent sulfation. During storage, a battery must keep at a charge of at least 12.4 volts.

You should also avoid storing a lead-acid battery in an environment hotter than 75 F. Every 10-degree increase above that temperature will double the discharge rate of stored batteries.

Sulfation may be reversible if a battery’s plates have a light coating of lead sulfate crystals.

For safety reasons, only a professional with experience in lead-acid batteries should attempt to reverse severe sulfation.

  • Ensure your battery is fully charged after each use to dissolve lead sulfate crystals before they can harden.
  • Use the battery regularly to prevent it from being discharged for too long.
  • Employ a smart charger designed to monitor battery status and adjust charging rates to optimize performance.
  • Periodically check and top up the sulfuric acid solution in your battery to keep it within the recommended levels.
  • Avoid deep discharges during use to reduce the likelihood of sulfation.
  • If storing a battery, keep it in a cool, dry place and charge it beforehand.
  • Use desulfating equipment that applies electrical pulses to break down lead sulfate crystals and restore battery health.

And if you ever need a new lead-acid battery, please call us at Powertron! We offer the largest selection of batteries in Orange County at very affordable prices.

FAQs: Battery Sulfation

Q: Is battery sulfation dangerous?

It’s not inherently dangerous but can reduce battery performance and potentially cause failure. If a severely sulfated battery is mishandled, there’s a risk of acid leaks or explosions. Always exercise caution when working with lead-acid batteries, and seek professional help if you’re unsure.

Q: Can battery sulfation be reversed?

It depends on the severity of the sulfation. Mild sulfation can be reversed, but severe sulfation may not be reversible.

Q: How do I know if my battery has sulfation?

Some signs include increased self-discharge rate, swelling or bulging of the battery casing, corrosion around terminals, and poor performance in cold weather.

Q: What causes permanent sulfation?

Permanent sulfation occurs when lead sulfate crystals can’t dissolve back into the electrolyte solution during recharging. This leads to reduced battery capacity and, ultimately, failure.

Q: How can I prevent sulfation in my lead-acid battery?

Perform regular maintenance, avoid long periods of discharging, and use a smart charger. Ensure the sulfuric acid solution is at the correct levels and store the battery correctly. Desulfating equipment can reverse mild sulfation.

Q: What do I do if my battery has permanent sulfation?

Seek professional assistance from someone experienced with lead-acid batteries. They may be able to reverse the sulfation, but in severe cases, you may need a new battery.

Q: How often should I check my battery’s acid levels?

We recommend checking the sulfuric acid levels in your battery at least once every month. Maintaining proper acid levels is crucial for optimal performance and longevity.

Q: Can extreme temperatures affect my battery’s performance?

Extreme temperatures can significantly reduce a lead-acid battery’s performance. High temperatures can accelerate the discharge rate, while low temperatures reduce the battery’s capacity and ability to deliver power.

Q: Is it safe to recharge a sulfated battery?

Recharging a mildly sulfated battery may be possible using a purpose-designed smart charger. If the sulfation is severe, consult a professional to prevent potential damage or safety hazards.

Q: What tools do I need for maintaining my lead-acid battery?

Essential maintenance tools include a hydrometer to measure electrolyte-specific gravity, a multimeter to check voltage, and the appropriate tools for cleaning terminals. A smart charger is your best bet for optimal recharging.

Q: How can I tell if my battery is nearing the end of its life?

Signs that your battery may be approaching failure include:

  • Frequent need for recharging
  • Compromised voltage output
  • Visible corrosion around terminals
  • Swelling or deformation of the battery casing

If you notice these symptoms, it may be time to replace your battery.