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1. Introduction

In the fields of modern logistics, warehousing and industrial production, forklifts have become indispensable important equipment due to their efficient handling capabilities. As the main power source of forklifts, the performance and safety of lead-acid batteries directly affect the operational efficiency and safety of forklifts. The electrolyte in lead-acid batteries mainly consists of sulfuric acid and water, which is highly corrosive, toxic and has a certain risk of flammability and explosion. If the safety protection measures for the electrolyte are not in place during storage, use and maintenance, it is very likely to cause serious accidents such as burns, poisoning, fire and explosion of personnel. This not only threatens the life and health of the workers, but also brings huge economic losses and damage to the reputation of the enterprise. Therefore, formulating and strictly implementing the safety protection specifications for the electrolyte of lead-acid batteries in forklifts is of crucial practical significance.

2. Analysis of the Characteristics of Electrolyte in Forklift Lead-Acid Batteries

(1) Chemical Composition and Physical Properties

The electrolyte of forklift lead-acid batteries is usually prepared by mixing pure sulfuric acid and distilled water in a certain proportion, with the concentration of sulfuric acid generally ranging from 27% to 37%. Sulfuric acid is a colorless and transparent oily liquid with high corrosiveness. When it comes into contact with skin, clothing, etc., it will undergo a rapid chemical reaction, causing severe burns. Its density is relatively high, approximately 1.84g/cm³ at room temperature, and it has a high boiling point, about 337℃. Meanwhile, the dilution process of sulfuric acid releases a large amount of heat. If not operated properly, it may cause the solution to splash, posing a safety hazard.

(2) Hazard Analysis

1. ** Corrosiveness ** : The sulfuric acid in the electrolyte has a strong corrosive effect on human skin, eyes, respiratory tract, etc. Once in contact with the skin, it will cause the skin tissue to dehydrate and carbonize, resulting in chemical burns. Splashing into the eyes can cause severe damage to the cornea and conjunctiva, and even blindness. Inhaling sulfuric acid mist can irritate the respiratory tract, causing symptoms such as coughing and breathing difficulties. Long-term exposure may also lead to respiratory diseases.

2. ** Toxicity ** : During the charging and discharging process of lead-acid batteries, the sulfuric acid in the electrolyte undergoes a chemical reaction with the lead plates, generating a small amount of lead ions and harmful substances such as lead sulfate. Lead is a toxic heavy metal that can enter the human body through the respiratory tract, digestive tract or skin. Long-term exposure can accumulate in the human body, damaging the nervous system, blood system and digestive system, and having a serious impact on the intellectual development of children and the physical health of adults.

3. ** Flammability and Explosiveness ** : During the charging process of lead-acid batteries, especially when overcharged, water in the electrolyte is electrolyzed to produce hydrogen and oxygen. Hydrogen is a flammable and explosive gas. When the hydrogen content in the air reaches 4.0% - 75.6% (by volume), it will explode upon encountering a fire source or static sparks, causing a fire accident.

3. Safety Protection Specifications for Electrolyte Storage

(1) Storage environment requirements

1. ** Independent Storage Area ** : The electrolyte should be stored in a specially designated independent storage area, which must be kept away from fire sources, heat sources, power sources, as well as other flammable, explosive items and corrosive substances. The storage area should have good ventilation to prevent hydrogen accumulation and explosion, and at the same time reduce the harm of sulfuric acid mist to the environment and personnel.

2. ** Temperature and Humidity Control ** : The temperature of the storage environment should be controlled between 5℃ and 35℃ to prevent the electrolyte from evaporating more rapidly due to excessively high temperatures or freezing due to excessively low temperatures, which could affect its performance and usage safety. The relative humidity should be maintained at 40% to 70% to prevent the storage container from being corroded by a humid environment and causing electrolyte leakage.

3. ** Anti-leakage Measures ** : The ground of the storage area should be treated for anti-corrosion, and anti-leakage cofferdams or collection tanks should be set up. The volume of the cofferdam or collection tank should be capable of holding at least 110% of the maximum storage container capacity of the electrolyte to prevent the spread of the electrolyte in case of accidental leakage, which could cause more extensive pollution and harm.

(2) Selection and Management of Storage Containers

1. ** Container Material ** : The electrolyte storage container should be made of materials resistant to sulfuric acid corrosion, such as high-density polyethylene (HDPE), polypropylene (PP), and other plastic materials, or metal containers lined with acid-resistant rubber. It is strictly prohibited to store electrolyte in ordinary metal containers or plastic containers that are not corrosion-resistant to prevent the containers from being corroded and damaged, which may lead to electrolyte leakage.

2. ** Container sealing performance ** : The storage container must have good sealing performance to prevent the evaporation and leakage of the electrolyte. The container lid should be equipped with a sealing gasket, and the integrity of the gasket should be checked regularly. If aging or damage is found, it should be replaced in time. During handling and storage, make sure the container lid is tightened to prevent the electrolyte from overflowing due to shaking.

3. ** Identification Management ** : Each storage container should be clearly marked with warning labels such as "Corrosive Liquid" and "Sulfuric acid", and information such as the concentration of the electrolyte and the storage date should be noted. The identification should be made of acid-resistant and wear-resistant materials to ensure that the identification is clear and distinguishable during long-term storage. Meanwhile, obvious safety warning signs should be set up in the storage area to remind personnel to pay attention to safety.

4. Safety Protection Specifications for the Use and Operation of Electrolyte

(1) Personnel protective equipment

1. ** Protective Clothing ** : When performing operations such as adding or replacing electrolyte, workers should wear acid and alkali resistant protective clothing. This protective clothing should cover the entire body, including long-sleeved shirts, long pants, aprons, etc., to prevent electrolyte from splashing onto the skin. Protective clothing should be inspected regularly and replaced in time if any damage is found.

2. ** Protective gloves ** : Wear acid and alkali resistant gloves. The material of the gloves should have good anti-corrosion performance and flexibility to ensure that the workers can operate flexibly. The length of the gloves should be at least 10 centimeters longer than the wrist to avoid exposing the wrist area to danger.

3. ** Protective glasses and face mask ** : Wear closed protective glasses or face masks to prevent electrolyte from splashing into the eyes and face. Protective glasses and face masks should have good optical performance and impact resistance to ensure clear vision for the workers and effectively block splashing liquids at the same time.

4. ** Mask ** : Choose to wear an acid mist mask or gas mask to prevent inhaling harmful substances such as sulfuric acid mist and lead dust. Masks should be replaced regularly according to the degree and duration of pollution in the working environment to ensure protective effectiveness.

(2) Standardized operation procedures

1. ** Electrolyte Addition ** : When adding electrolyte, the lead-acid battery of the forklift should first be removed from the forklift and placed on a well-ventilated, flat and stable workbench. Use a dedicated electrolyte filling tool to add the electrolyte slowly to prevent it from overflowing. During the addition process, pay attention to observing the electrolyte level and keep it between the upper and lower liquid level lines marked on the battery case. It is strictly prohibited to directly contact the electrolyte with metal containers or tools to prevent chemical reactions and the generation of sparks.

2. ** Electrolyte Replacement ** : When the electrolyte of a lead-acid battery needs to be replaced, the old electrolyte in the battery should first be discharged into a dedicated collection container. The discharge process should be carried out slowly to prevent the electrolyte from splashing out. After collecting the old electrolyte, it should be properly treated as hazardous waste and must not be dumped at will. Before replacing the new electrolyte, the interior of the battery should be rinsed with distilled water to ensure it is clean and free of residual impurities. After rinsing, add new electrolyte in accordance with the prescribed proportion and method.

3. ** Charging Operation ** : When charging lead-acid batteries, they should be placed in a dedicated charging area, which should be equipped with good ventilation facilities and fire prevention equipment. Before charging, check whether the connection between the charging equipment and the battery is correct and firm to prevent sparks caused by poor contact. During the charging process, it is necessary to strictly control the charging current and voltage to avoid overcharging. At the same time, the hydrogen concentration in the charging area should be checked regularly. When the hydrogen concentration exceeds 20% of the lower explosive limit, charging should be stopped immediately, ventilation should be enhanced, and the hydrogen concentration should be reduced.

5. Emergency Response Specifications for Electrolyte Leakage

(1) Leakage Detection and Alarm

In the places where forklift lead-acid batteries are used and stored, sulfuric acid mist detection alarms and hydrogen concentration detection alarms should be installed. These testing devices should be calibrated and maintained regularly to ensure their sensitivity and accuracy. Once electrolyte leakage or hydrogen concentration exceeds the standard is detected, the alarm should immediately issue an audible and visual alarm signal to remind the on-site personnel to take emergency measures.

(2) Emergency Response Procedures

1. ** Personnel Evacuation ** : In the event of electrolyte leakage, on-site personnel should immediately cease operations and quickly evacuate the leakage area. During the evacuation process, it should be carried out in an orderly manner along the pre-determined evacuation routes to avoid congestion and stampede accidents. At the same time, it is necessary to promptly notify the surrounding personnel to evacuate to ensure the safety of all people.

2. ** Leakage Isolation ** : Under the condition of ensuring personnel safety, emergency response personnel should promptly use sandbags, adsorption cotton and other materials to isolate the leakage area to prevent the further spread of the electrolyte. For a small amount of electrolyte leakage, adsorption cotton can be used for direct adsorption. For large-scale leakage of electrolyte, dedicated collection containers should be used to collect the leaked electrolyte to prevent it from flowing into sewers or soil and causing environmental pollution.

3. ** Neutralization treatment ** : After collecting the leaked electrolyte, the leakage area should be neutralized. Alkaline substances such as sodium bicarbonate (baking soda) can be used to neutralize sulfuric acid to reduce its corrosiveness. During the neutralization process, it is necessary to wear protective equipment properly to avoid contact of alkaline substances with the skin. After the neutralization reaction is completed, use a large amount of clean water to rinse the leakage area to ensure that the remaining chemical substances are completely removed.

4. ** Waste Treatment ** : Both the leaked electrolyte and the waste generated from neutralization treatment are classified as hazardous waste and should be collected, stored and disposed of in accordance with the regulations on hazardous waste management. The collected hazardous waste should be entrusted to qualified units for treatment and must not be discarded or discharged at will.

6. Personnel Training and Safety Management

(1) Personnel training

1. ** Pre-job Training ** : All personnel involved in the operation, maintenance and management of forklift lead-acid battery electrolyte must receive specialized safety training before taking up their posts. The training content should include the characteristics of the electrolyte, safety protection knowledge, operating procedures, emergency handling methods, etc. After the training is completed, the trainees should be evaluated. Only those who pass the evaluation can start working.

2. ** Regular Refresher training ** : To ensure that the workers always keep abreast of the latest safety knowledge and skills, they should undergo refresher training regularly. The refresher training cycle is generally once a year. In addition to consolidating basic knowledge and skills, the refresher training should also provide targeted training in combination with new problems and situations that arise in actual work.

(2) Safety Management System

1. Responsibility System: Enterprises should establish and improve the safety management system for electrolytes, clearly defining the responsibilities and authorities of each department and position in the safety management of electrolytes. Assign safety responsibilities to specific individuals to form a safety management pattern where all levels are responsible and everyone works together.

2. ** Daily Inspection and Maintenance ** : Establish a detailed daily inspection and maintenance system, and regularly inspect and maintain electrolyte storage containers, protective equipment, detection and alarm devices, etc. The inspection contents include the sealing of the container, the integrity of the protective equipment, the accuracy of the testing equipment, etc. Problems discovered should be dealt with promptly to ensure that all safety facilities are in good operating condition.

3. ** Accident Reporting and Handling ** : Establish an accident reporting and handling system. Once an accident such as electrolyte leakage or personnel burns occurs, the on-site personnel should immediately report to the enterprise's safety management department. Enterprises should promptly organize rescue and investigation and handling in accordance with the accident emergency response plan, identify the cause of the accident, and take effective preventive measures to prevent similar accidents from happening again. At the same time, the accident situation should be reported to the superior administrative department in accordance with the regulations. Concealment or delay in reporting is strictly prohibited.

7. Conclusion

The safety protection of lead-acid battery electrolyte for forklifts is a systematic and comprehensive task, involving multiple links such as storage, use, operation, emergency handling and personnel training. By strictly implementing the safety protection regulations for electrolytes, controlling risks from the source, strengthening process management, and enhancing the safety awareness and emergency response capabilities of operators, it is possible to effectively prevent and reduce the occurrence of safety accidents related to electrolytes, ensuring the life and health of operators and the safe production of enterprises. Enterprises should attach great importance to the safety protection of electrolyte, constantly improve the safety management system, increase safety investment, ensure the safe and stable operation of forklift lead-acid batteries, and provide a solid guarantee for the sustainable development of the enterprise.