Introduction: Aluminium Sulfate Lead Acid Battery Conversion

Picture of Aluminium Sulfate Lead Acid Battery Conversion

quick how to on aluminum sulfate electrolyte for lead acid batteries.

Step 1: Purchase Ingredients.

Picture of Purchase Ingredients.

you will need aluminium sulfate, a hydrometer, distilled water and a two buckets.

also you will need a face mask. long sleeves, safety goggles and water on hand.

this job could cause death or serious harm from explosions and acid spills.

you will also need a battery charger, applicator bulb and common sense.

Step 2: Drill Holes Into Vent Caps or Remove Caps.

Picture of Drill Holes Into Vent Caps or Remove Caps.

if you have a sla battery you will need to drill into the plastic.

use a pneumatic drill a regular drill could cause sparking or explosions.

you have two choices.
1.fully flatten the battery to sulfate the plates. this will produce a super saturated acid.

2. fully charge the battery. check with hydrometer that the electrolyte is 12.5 to 13.00. this indicates 80 to 100% charge.

Step 3: Create Saturated Aluminum Sulfate Solution.

Picture of Create Saturated Aluminum Sulfate Solution.

you will need room temperature distilled water. add aluminium sulfate slowly to water while stiring. check with hydrometer.
it takes a long time but you should be able to get a reading of 12.5 or more specific gravity easily.

if you heat the water or add too much the aluminum sulfate will precipitate when the electrolyte cools.

Step 4: Tip Out the Acid From Battery.

Picture of Tip Out the Acid From Battery.

pour out acid from the battery into a large bucket. be carefull not to spill any on yourself.

Step 5: Add Electrolyte

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add aluminium sulfate solution to each cell. use a bulb designed for this purpose. about 5 bucks from auto store.

feel free to use any ratio. I have found 20% sulfuric acid to aluminium sulfate works the best.

100% tends to precipitate and provide low cca.

Step 6: Charging

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you will need to charge the battery to 16.8v. this electrolyte solution doesnt off gas as much as battery acid.

gassing starts at 14.7v and gets rapid at 15v plus.

I use a turnigy charge set to 7 cell mode. it will cut out at 17.1v. but the battery only reaches 16.8v so you need to turn it off manually.

Step 7: Testing and Final Thoughts

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I have mixed results. all my batteries were dead or used batteries and performed less than originally specified.

for example 710cca produces 540 hca. this battery is 90ah and 160 rc. I got 60 mins rc.

only notable improvement is less heat produced and less off gassing.

you can't buy sulfuric acid in Australia now but you can still buy aluminium sulfate which works ok.

pic shows resting voltage and cca rating of two batteries of the same make and capacity.

one is pure aluminium sulfate. the other has 150ml of battery acid added per cell (100ml of aluminum sulfate solution at 12.75 sg in each cell).

the latter has higher cca and lower resting voltage. the former has higher resting voltage and lower cca.

batteries converted with 20% to 60% sulfuric acid added seem to produce about the same CCA and about 80% the Ah capacity. not magical results but note worthy.

a resting converted battery that is flat will still read 12v. but when loaded will drop instantly. specific gravity only changed by 50 to 80 points between fully charged and flat. also sulfation doesnt appear on plates as dramatically as with battery acid.

I would appreciate real professional testing of this electrolyte. it is hard to produce meaningful analysis with the junk I am using.

try it out and post your results.


mikes26 (author)2016-12-03

I have made several of these Alum batteries and use a inverter to plug in a lamp during power outages. Depending on how bad your battery is sulfated they work well, holds 11 volts for hours

JanP21 (author)2016-09-27

well after going through this , hubby would need a 6x4 shed the other end of the block . As for my phone battery and laptop battery that wouldn't hold a charge I wrapped it in plastic and put it in the freezer for a day then fully recharged it been good as gold since freezer wipes the memory so it takes a full charge

ZachS11 (author)JanP212016-10-10

Im looking into if there is any fact or logic in this considering there is not such thing as Li-ion batteries having ANY kind of memory whatsoever, there are different control factors at play here

MatH2 (author)2016-03-10

How can you trust someone who doesn't even know how to rotate a pic...

JanP21 (author)MatH22016-09-27

hahah beat that turned the laptop

sudoukpong (author)2016-07-14

is aluminium sulfate epsom salt?

JanP21 (author)sudoukpong2016-09-27

Epson is magnesium

Steinzel (author)2016-04-28

According to what I have been reading, you dont need to add any sulphuric acid. Just use the alum and water.

VijayK66 (author)2015-12-03

very goog tips

mougoumi (author)2015-03-31

prof.braino (author)2014-07-02

In step 5 I see:
"feel free to use any ratio. I have found 20% sulfuric acid to aluminium sulfate works the best."

1) there should be NO sulfuric acid; lead alum is an Alkiline battery, not an acid battery
2) "any ratio" often in chemistry, a very specific ratio is required. This may be the cause of your results. One source says 10% alum to distilled water, by weight; and NO sulfuric acid.

speakerbox (author)prof.braino2014-07-02

try it and see how it goes. im no longer interested in this subject. I figured the sponge lead fatigue was the major cause of failure. nothing you can do to put the powder back on the plate so why bother?

its like trying to put rust back on your car and hope it turns to steel.

my experiments were riddled with holes but actually doing it debunked it sufficiently for me. if you think there is more to it I wish you the best.

jolshefsky (author)2013-12-23

Any idea what the chemical reactions are? As far as I know, a sulfuric acid and lead battery discharges when the negative electrode combines with the acid to make lead(II) sulfite (PbSO4) and gives off some electrons; the positive electrode is lead oxide (PbO2) when charged and takes some electrons with the acid to make lead(II) sulfate (PbSO4).

speakerbox (author)jolshefsky2013-12-23

I dont know. I put a lead and lead oxide plate in the solution and discharged them to see what it was.

The plates did not go white. I think it may be aluminum.

But as a layman I cant say for sure. Wish I knew...

Btw there is little or no charge when you add the solution. Also they self discharge in a matter of weeks.

This was my last experiment after trying to resurrect dead batteries. The whole battery rejuvenation idea is bunk imo.

Moving on to hho to see if there is anything to that.

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