The global implementation of secondary lithium ion (Li-ion) batteries continues to expand rapidly, finding clear utility in portable electronics and vehicle electrification. For large format, grid-scale energy storage however, concerns over the safety, reliability, cost, and lifetime of these batteries has motivated the drive to find alternatives to Li-ion systems. Here we describe the materials-driven development of a low temperature molten sodium-halide battery for grid-scale applications. Molten sodium batteries, such as sodium sulfur (NaS) and sodium nickel chloride (Na-NiCl2or ZEBRA) batteries, continue to show promise for grid-scale applications, valued for their use of earth abundant chemistries, scalability, and the absence of volatile, potentially hazardous organic electrolytes. Widespread implementation of these batteries has been limited, however, by relatively high operating temperatures (~300°C). Potentially impacting both cost and lifetime of these batteries, lowering the battery operating temperature would reduce material degradation, enable the use of lower cost battery components, and facilitate simplified, more cost effective heat management and operating strategies. The promising low temperature system described here comprises a molten sodium anode, a solid state ion-conducting separator, and a sodium iodide (NaI)-based molten salt catholyte. This NaI-based system avoids the hazards of volatile organic electrolytes, employing a fully molten catholyte designed to enable long cycle life while still offering a higher voltage (>3V) than traditional molten sodium batteries. Here, we will describe promising demonstrations of prototype battery cycling at drastically reduced operating temperatures near 100°C. In addition, we will address new materials challenges unique to operating a molten sodium battery at these reduced temperatures. In particular, we will focus on the complex goal of increasing lower temperature separator conductance in mechanically robust solid state electrolytes while minimizing resistances at interfaces between these separators and the molten anode and catholyte. Tuning separator materials chemistry and microstructure, both in the bulk and at separator interfaces, can significantly impact electrolyte wetting, reduce cell resistance, and improve battery cycling performance. Continued development of these emerging molten Na-NaI batteries promises a new route to the type of safe, cost-effective, long-lifetime batteries needed for grid-scale energy storage. Sandia National Laboratories is a multi-mission laboratory managed and operated by National Technology and Engineering Solutions of Sandia, LLC., a wholly owned subsidiary of Honeywell International, Inc., for the U.S. Department of Energy’s National Nuclear Security Administration under contract DE-NA0003525.
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