Case Study #20: Sulfuric Acid Dilution in Battery Production
Initial situation
In battery manufacturing, sulfuric acid (H₂SO₄) is a key electrolyte. While it’s delivered in highly concentrated form, it must be diluted before bottling and use. However, the dilution process releases significant heat (dilution enthalpy), which can cause the temperature of the mixture to spike—sometimes exceeding the boiling point at specific concentrations. This thermal reaction can damage tanks and other equipment if not properly controlled..
Challenge
Design a heat exchanger capable of withstanding sulfuric acid concentrations up to 90% and temperatures as high as 80°C (176°F), while ensuring that the temperature of the diluted acid mixture remains below 60°C (140°F) throughout the process.
Solution
A precise dosing system meters the concentrated acid into a water reservoir based on real-time temperature monitoring. The partially diluted acid is continuously recirculated from the mixing tank through a Calorplast PVDF tube plate heat exchanger, where it is cooled in-line. This process continues until the target concentration and temperature are safely achieved.
Result
Calorplast PVDF heat exchangers provide a reliable, corrosion-resistant solution for controlling heat during sulfuric acid dilution. These systems are now deployed globally in battery production facilities, ensuring safe operation, equipment longevity, and consistent product quality.
