Iron-based alkaline rechargeable batteries such as iron-air and nickel-iron batteries are particularly attractive for large-scale energy storage because these batteries can be relatively inexpensive, environment-friendly, and also safe. Therefore, our study has focused on achieving the essential electrical performance and cycling properties needed for the widespread use of iron-based alkaline batteries in stationary and distributed energy storage applications. We have demonstrated for the first time, an advanced sintered iron electrode capable of 3500 cycles of repeated charge and discharge at the 1-hour rate and 100% depth of discharge in each cycle, and an average Coulombic efficiency of over 97%. Such a robust and efficient rechargeable iron electrode is also capable of continuous discharge at rates as high as 3C with no noticeable loss in utilization. We have shown that the porosity, pore size and thickness of the sintered electrode can be selected rationally to optimize specific capacity, rate capability and robustness. These advances in the electrical performance and durability of the iron electrode enables iron-based alkaline batteries to be a viable technology solution for meeting the dire need for large-scale electrical energy storage. Electrical energy storage systems will enable the seamless integration of the electricity generated from wind turbines and solar photovoltaics into the electricity grid. Rechargeable batteries are particularly good candidates for such large-scale energy storage because of their high round-trip efficiency, inherent scalability, and flexibility for being located almost anywhere.1-6 Batteries such as vanadiumredox, lead-acid and lithium-ion are under consideration for this application because of their commercial availability. Yet, the widespread deployment of these battery systems is limited by their materials cost, lifetime, safety concerns, and the high cost of delivered energy.
7,8Rechargeable iron-based alkaline batteries such as nickel-iron and iron-air have unique advantages that make them particularly attractive for meeting the emerging demands of grid-scale electrical energy storage systems.6,9-12 Iron, the primary raw material for these battery systems, is globally abundant, relatively inexpensive, eco-friendly and is recycled readily. Thus, iron is particularly attractive as a raw material for batteries required at such a large scale.6 Iron-based batteries such as the nickel-iron battery are historically well known for their extraordinary robustness to thousands of cycles of charge and discharge, and tolerance to overcharge and over-discharge. [13][14][15][16] Such robustness is generally uncommon among rechargeable batteries; other types of batteries in use today degrade in about 1000 cycles.17 For example, lead-acid batteries typically offer 500-800 cycles, and lithium-ion batteries usually last no more than 1000 cycles especially when subjected to deep discharge.18 Despite these striking attributes of iron-based batteries, the large-scale use of these batteries ...