In a new study, published in Science Advances, scientists have shown that iron can be used in ion batteries.

“We have transformed the reactivity of metallic iron, the cheapest metal,” says study leader Xiulei Ji in a statement.

“Our electrode can offer a higher energy density than state-of-the-art cathode materials used in electric vehicles. And since we use iron, the cost of our batteries is much lower,” adds Ji.

Iron could be key to less expensive, greener lithium-ion batteries, research finds
CORVALLIS, Ore. – What if a common element rather than scarce, expensive ones was a key component in electric car batteries? A collaboration co-led by an Oregon State University chemistry researcher is hoping to spark a green battery revolution by showing that iron instead of cobalt and nickel can be used as a cathode material in lithium-ion batteries. The findings, published today in Science Advances, are important for multiple reasons, Oregon State’s Xiulei “David” Ji notes. “We’ve transformed the reactivity of iron metal, the cheapest metal commodity,” he said.
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According to interesting engineering, the cathode currently represents 50% of the cost of manufacturing a lithium-ion battery cell. In addition to the economic aspect, iron-based cathodes would allow for greater safety and sustainability.

As more lithium-ion batteries are manufactured to electrify the transportation sector, the global demand for nickel and cobalt has increased. In a few decades' time, the predicted shortage of nickel and cobalt will put the brakes on battery production as it is today.

Iron makes lithium batteries cheap, safe, sustainable, says study
The new iron-based batteries were crafted by enhancing the reactivity of the metal via a specially designed chemical environment.
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The energy density of these elements is already being pushed to its maximum limit, which means that the oxygen released during charging can cause the batteries to catch fire.

In addition, cobalt is highly toxic and can contaminate ecosystems and water sources if it is leached from landfills.

“Our iron-based cathode is not limited by resource scarcity,” says Ji, explaining that iron, as well as being the most common element on Earth, measured by mass, is the fourth most abundant element in the earth's crust.

“We will only run out of iron when the Sun turns into a red giant,” concludes the researcher.

Even so, there is a need to improve storage efficiency, as not all the electricity introduced into the battery during charging is available for use after discharge.

When these improvements are introduced, the result will be a battery that works much better than the ones currently used, while being cheaper and more environmentally friendly.