Novel battery design for industrial energy storage

In recent years, lithium-ion batteries have emerged as dominant energy storage systems; however, they are known to suffer from critical safety issues. In this regard, zinc-ion batteries based on water-based electrolytes offer a promising alternative; they are inherently safe and environmentally friendly. They also mitigate fire risks and thermal runaway issues associated with their lithium-based counterparts, which makes them suitable for grid-scale energy storage. Zinc also has high capacity, ample abundance and low toxicity. Unfortunately, current collectors utilised in zinc-ion batteries, such as graphite foil, are difficult to scale up and suffer from relatively poor mechanical properties, limiting their industrial use.

Now, researchers from Dongguk University in Korea have proposed graphene-coated stainless steel foil as a novel alternative current collector. Their research findings have been published in the journal Advanced Energy Materials.

Associate Professor Geon-Hyoung An said the core innovation of the study is the use of graphene-coated stainless steel foil, or G@SSF-400, as a current collector for zinc-ion batteries. Unlike conventional collectors, the material can be produced through a simple graphene coating and heat treatment for surface oxide removal. This enables industrial scalability and high electrochemical performance.

This innovation overcomes the challenges of corrosion and poor conductivity seen in water-based systems and operates stably under high-mass loading conditions, which is essential for practical use. The battery also exhibited high specific capacities exceeding 1 mAh cm^-2, while retaining 88.7% of its capacity after 1500 cycles. Because this technology supports roll-to-roll manufacturing, it opens the door to large-scale production, bringing zinc-ion batteries closer to commercialisation in the energy storage sector.

“This technology is suitable for grid-scale energy storage systems, especially in the context of renewable energy integration. By enabling the use of water-based zinc-ion batteries, our approach provides a non-flammable, cost-effective and environmentally friendly alternative to traditional lithium-ion systems,” An said.

The research finding could contribute to the global shift towards clean and resilient energy systems, as it addresses key barriers in energy storage, such as cost, scalability and safety. By reducing dependence on expensive or hazardous materials, such as those used in lithium-ion batteries, this technology supports the development of a more sustainable and circular battery economy. It could also improve access to affordable energy storage.

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