Why Are Tubular Batteries So Expensive?

In the world of energy storage solutions, tubular batteries stand out for their durability and efficiency, but their price often raises eyebrows. A tubular battery is 40% more expensive than a normal flat plate battery.

Here’s a deeper look into why tubular batteries come with a premium cost tag.

1. Design and Construction

Tubular batteries are engineered with a robust design aimed at longevity and reliability. Unlike traditional flat plate batteries, tubular batteries use tubular positive plates made of lead oxide filled with lead alloy or antimony. This design enhances their structural integrity, making them less prone to damage from deep discharges, vibration, and thermal fluctuations. The intricate assembly of these components requires precision manufacturing processes, contributing significantly to their higher cost.

The below figure shows the structure of the pasted flat plate, these plates are made by pasting the lead oxide active mass on a mesh grid.

Also, the below picture shows the frame structure of the tubular plate. It consists of a series of vertical spines connected to a common bus bar. Each spine of this frame structure is covered by non-conductive tubes and filled with a paste of lead oxide.

2. Performance and Efficiency

One of the key selling points of tubular batteries is their superior performance and efficiency compared to conventional batteries. They offer higher charge acceptance rates, faster recharge capabilities, and better cycle life. These attributes make them ideal for applications requiring reliable and sustained power supply, such as inverter systems for backup power, renewable energy storage, and industrial operations. The advanced chemistry and engineering that enable these performance advantages contribute to the overall expense of tubular batteries.

3. Longevity and Maintenance

Tubular batteries are known for their extended lifespan, often lasting significantly longer than other battery types. Manufacturers typically provide longer warranties due to their confidence in the battery's durability. This longevity reduces the frequency of replacements, making them a cost-effective choice over the long term despite their initial high cost. Additionally, tubular batteries require minimal maintenance, further adding to their appeal for commercial and industrial users looking to reduce operational downtime and maintenance costs.

4. Materials and Manufacturing

The materials used in tubular batteries, such as high-grade lead alloys and specialized separators, are chosen for their durability and performance characteristics. The manufacturing processes involved are more complex and demanding than those for conventional batteries, requiring specialized equipment and skilled labor. These factors contribute to higher production costs, which are passed on to consumers.

5. Application Specificity

Tubular batteries are often preferred in critical applications where reliability and performance are paramount. Industries such as telecommunications, railways, and data centers rely on tubular batteries to ensure uninterrupted power supply. The cost of downtime and the necessity for dependable energy storage justify the initial investment in these high-quality batteries.

---

Comparison between tubular battery and normal flat plate batteries.  

	Tubular Battery	Flat Plate Battery
Charge Cycles [at 80% DOD]	800-1400	50-1000
Self-discharge rate	Low	High
Float current	Low	High
Maintenance	Low	High
Thermal management property	Good	Poor
Electrical resistance	Low	High
Deep-Cycle Capability	Deep discharge	Low-Discharge

>> Learn more, Check our blog on FLAT Plate Battery vs. Tubular Battery 

Conclusion

While tubular batteries may appear expensive upfront, their superior performance, longevity, and reliability make them a worthwhile investment for many applications. As technology advances and manufacturing processes improve, the cost of tubular batteries may decrease over time. However, for now, their price reflects the value they provide in terms of efficiency, durability, and peace of mind for users requiring dependable energy storage solutions.

In summary, the cost of tubular batteries is a reflection of their advanced design, superior performance, and reliability, making them indispensable for industries and applications where uninterrupted power supply is critical.

An updated version of tubular batteries is also available called tall-tubular, which has better thermal as well as electrical properties than both tubular and flat plate batteries. Click here to learn more about tall tubular Vs tubular batteries.