Rechargeable battery using iron negative electrode and manganese oxide positive electrode

Patent metadata

Field	Value
Publication number	US-2021028452-A1
Application number	US-202016938924-A
Country	US
Kind code	A1
Filing date	Jul 25, 2020
Priority date	Jul 26, 2019
Publication date	Jan 28, 2021
Grant date	—

Abstract

Materials, designs, and methods of fabrication for iron-manganese oxide electrochemical cells are disclosed. In various embodiments, the negative electrode is comprised of pelletized, briquetted, or pressed iron-bearing components, including metallic iron or iron-based compounds (oxides, hydroxides, sulfides, or combinations thereof), collectively called “iron negative electrode.” In various embodiments, the positive electrode is comprised of pelletized, briquetted, or pressed manganese-bearing components, including manganese (IV) oxide (MnO2), manganese (III) oxide (Mn2O3), manganese (III) oxyhydroxide (MnOOH), manganese (II) oxide (MnO), manganese (II) hydroxide (Mn(OH)2), or combinations thereof, collectively called “manganese oxide positive electrode.” In various embodiments, electrolyte is comprised of aqueous alkali metal hydroxide including lithium hydroxide (LiOH), sodium hydroxide (NaOH), potassium hydroxide (KOH), cesium hydroxide (CsOH), or combinations thereof. In various embodiments, battery components are assembled in prismatic configuration or cylindrical configuration.

First claim

What is claimed is:

1 . A battery, comprising:
a first electrode, comprising a manganese oxide; an electrolyte; and a second electrode, comprising iron.

2 . The battery of claim 1 , wherein the iron comprises direct reduced iron (DRI).

3 . The battery of claim 1 , wherein the electrolyte is a liquid electrolyte.

4 . The battery of claim 3 , wherein the electrolyte comprises an alkali metal hydroxide comprising lithium hydroxide (LiOH), sodium hydroxide (NaOH), potassium hydroxide (KOH), cesium hydroxide (CsOH), or mixtures thereof.

5 . The battery of claim 4 , wherein the electrolyte comprises alkali metal sulfide or polysulfide comprising lithium sulfide (Li 2 S) or polysulfide (Li 2 S x , x=2 to 6), sodium sulfide (Na 2 S) or polysulfide (Na 2 S x , x=2 to 6), potassium sulfide (K 2 S) or polysulfide (K 2 S x , x=2 to 6), cesium sulfide (Cs 2 S) or polysulfide (Cs 2 S x , x=2 to 6), or mixtures thereof.

6 . The battery of claim 1 , wherein the second electrode is pelletized and comprises a multimodal distribution.

7 . The battery of claim 1 , wherein the manganese oxide comprises manganese (IV) oxide (MnO 2 ), manganese (III) oxide (Mn 2 O 3 ), manganese (III) oxyhydroxide (MnOOH), manganese (II) oxide (MnO), manganese (II) hydroxide (Mn(OH) 2 ), or mixtures thereof.

8 . The battery of claim 1 , wherein the second electrode further comprises iron oxides, hydroxides, sulfides or mixtures thereof.

9 . The battery of claim 1 , wherein the second electrode further comprises one or more secondary phases including silica (SiO 2 ) or silicates, calcium oxide (CaO), magnesium oxide (MgO) or mixtures thereof.

10 . The battery of claim 1 , wherein the second electrode further comprises an inert conductive matrix comprising carbon black, activated carbon, graphite powder, carbon steel mesh, stainless steel mesh, steel wool, nickel-coated carbon steel mesh, nickel-coated stainless steel mesh, nickel-coated steel wool, or mixtures thereof.

11 . The battery of claim 1 , wherein the second electrode further comprises one or more hydrogen evolution reaction suppressants.

12 . The battery of claim 1 , wherein the first electrode has a specific surface area less than about 50 m 2 /g.

13 . The battery of claim 1 , wherein the first electrode has a specific surface area less than about 1 m 2 /g.

14 . The battery of claim 1 , wherein the second electrode has a specific surface area less than about 5 m 2 /g.

15 . The battery of claim 1 , wherein the second electrode has a specific surface area less than about 1 m 2 /g.

16 . The battery of claim 1 , wherein the first electrode comprises a binder comprising polytetrafluoroethylene (PTFE), polyvinylidene difluoride (PVdF), polypropylene (PP), polyethylene (PE), fluorinated ethylene propylene (FEP), polyacrylonitrile, styrene butadiene rubber, carboxymethyl cellulose (CMC), sodium carboxymethyl cellulose (Na-CMC), polyvinyl alcohol (PVA), polypyrrole (PPy), or combinations thereof.

17 . The battery of claim 1 , wherein the first electrode comprises an additive comprising bismuth (III) oxide (Bi 2 O 3 ), bismuth (III) sulfide (Bi 2 S 3 ), barium oxide (BaO), barium sulfate (BaSO 4 ), barium hydroxide (Ba(OH) 2 ), calcium oxide (CaO), calcium sulfate (CaSO 4 ), calcium hydroxide (Ca(OH) 2 ), magnesium oxide (MgO), magnesium hydroxide (Mg(OH) 2 ), carbon nanotubes, carbon nanofibers, graphene, nitrogen-doped carbon nanotubes, nitrogen-doped carbon nanofibers, nitrogen-doped graphene, or combinations thereof.

18 . The battery of claim 1 , wherein a separator material is used between the first electrode and the second electrode.

19 . The battery of claim 1 , wherein the iron comprises concentrate.

20 . The battery of claim 1 , wherein the iron comprises at least one form of iron selected from the group consisting of pellets, BF grade pellets, DR grade pellets, hematite, magnetite, wustite, martite, goethite, limonite, siderite, pyrite, ilmenite, or spinel manganese ferrite.

21 . The battery of claim 1 , wherein the iron comprises iron ore.

22 . The battery of claim 21 , wherein the iron ore comprises at least 0.1% SiO 2 by mass.

23 . The battery of claim 21 , wherein the iron ore comprises at least 0.1% CaO by mass.

24 . The battery of claim 1 , wherein the iron comprises atomized iron powder.

25 . The battery of claim 1 , wherein the iron comprises iron agglomerates.

26 . The battery of claim 25 , wherein the iron agglomerates have an average length ranging from about 50 um to about 50 mm.

27 . The battery of claim 25 , wherein the iron agglomerates have an average internal porosity ranging from about 10% to about 90% by volume.

28 . The battery of claim 25 , wherein the iron agglomerates have an average specific surface area ranging from about 0.1 m 2 /g to about 25 m 2 /g.

29 . The battery of claim 25 , wherein the electrolyte comprises a molybdate anion and a sulfide anion.

30 . A bulk energy storage system, comprising:
a stack of one or more batteries, wherein at least one of the one or more batteries comprises:
a first electrode, comprising a manganese oxide;
an electrolyte; and
a second electrode, comprising iron.

31 . The bulk energy storage system of claim 30 , wherein the bulk energy storage system is a long duration energy storage (LODES) system.

32 . The bulk energy storage system of claim 31 , wherein the iron comprises direct reduced iron (DRI).

33 . The bulk energy storage system of claim 31 , wherein the electrolyte is a liquid electrolyte.

34 . The bulk energy storage system of claim 33 , wherein the electrolyte comprises an alkali metal hydroxide comprising lithium hydroxide (LiOH), sodium hydroxide (NaOH), potassium hydroxide (KOH), cesium hydroxide (CsOH), or mixtures thereof.

35 . The bulk energy storage system of claim 34 , wherein the electrolyte comprises alkali metal sulfide or polysulfide comprising lithium sulfide (Li 2 S) or polysulfide (Li 2 S x , x=2 to 6), sodium sulfide (Na 2 S) or polysulfide (Na 2 S x , x=2 to 6), potassium sulfide (K 2 S) or polysulfide (K 2 S x , x=2 to 6), cesium sulfide (Cs 2 S) or polysulfide (Cs 2 S x , x=2 to 6), or mixtures thereof.

36 . The bulk energy storage system of claim 31 , wherein the second electrode is pelletized and comprises a multimodal distribution.

37 . The bulk energy storage system of claim 31 , wherein the manganese oxide comprises manganese (IV) oxide (MnO 2 ), manganese (III) oxide (Mn 2 O 3 ), manganese (III) oxyhydroxide (MnOOH), manganese (II) oxide (MnO), manganese (II) hydroxide (Mn(OH) 2 ), or mixtures thereof.

38 . The bulk energy storage system of claim 31 , wherein the second electrode further comprises iron oxides, hydroxides, sulfides or mixtures thereof.

39 . The bulk energy storage system of claim 31 , wherein the second electrode further comprises one or more secondary phases including silica (SiO 2 ) or silicates, calcium oxide (CaO), magnesium oxide (MgO) or mixtures thereof.

40 . The bulk energy storage system of claim 31 , wherein the second electrode further comprises an inert conductive matrix comprising carbon black

Assignees

• Form Energy Inc

Inventors

• Su Liang
• Milshtein Jarrod David
• Woodford William Henry
• Chiang Yet-Ming
• Whitacre Jay
• Cohen Lucas
• Chakraborty Rupak
• Liotta Andrew Haynes
• Mckay Ian Salmon
• Conry Thomas
• Gibson Michael Andrew
• Newhouse Jocelyn Marie
• Kharey Amelie Nina
• Thompson Annelise Christine
• Smith Weston
• Pantano Joseph Anthony
• Caruso Isabella
• Hultman Benjamin Thomas
• Chu Max Rae
• Perkins Nicholas
• Wehner Florian
• Eisenach Rebecca
• Westwood Mitchell Terrance
• Gilbert Tristan
• Mumma Rachel Elizabeth
• Uber Brandon
• Weber Eric
• Smith Danielle Cassidy
• Wojeski Brooke

Classifications

• H01M4/521 Primary

  of iron for aqueous cells · CPC title

• H01M2300/0014

  Alkaline electrolytes · CPC title

• H01M2220/10

  Batteries in stationary systems, e.g. emergency power source in plant · CPC title

• H01M2004/021

  Physical characteristics, e.g. porosity, surface area · CPC title

• H01M12/08 Primary

  composed of a half-cell of a fuel-cell type and a half-cell of the secondary-cell type · CPC title