The growing demand for large-scale energy storage has boosted the development of batteries that prioritize safety, low environmental impact, and cost-effectiveness1-3. On account of abundant sodium and the compatibility with commercial industrial systems4, aqueous sodium-ion batteries (ASIBs) are practically promising for affordable, sustainable, and safe large-scale energy storage. However, their energy density and cycling stability are limited due to the narrow electrochemical stability window of 1.23 V for water. Additionally, the accumulation of flammable hydrogen (H2) from water decomposition during cycling compromises battery safety and restricts the development of ASIBs. One common strategy for improving the performance of aqueous batteries is to use expensive fluorine-containing salts to create a solid-electrolyte interphase (SEI)5 that can suppress the hydrogen evolution reaction (HER) and increase the electrochemical window of the electrolyte. However, the high solubility of SEI components such as LiF, NaF, and Na2CO3 limits its durability6. Moreover, the high cost of fluorine-containing salts significantly compromises the cost-effectiveness of aqueous batteries. Another approach involves using co-solvents7, including polymers, to improve the water stability of the electrolyte. Unfortunately, these strategies significantly increase the viscosity of the electrolyte, making it challenging to match with high loading electrodes for commercial applications. The organic co-solvents' potential flammability also compromises the safety of aqueous batteries. Therefore, developing alternative strategies to enhance the water stability of aqueous batteries while maintaining their cost-effectiveness and safety is a critical research priority.
Compared to conventional aqueous electrolytes with a pH close to 7, alkaline electrolytes offer thermodynamic suppression of HER on the anode based on the Pourbaix diagram for water8. Whereas shifting the electrolyte from near neutrality to alkalinity aggravates the oxygen evolution reaction (OER) on the cathode9. Furthermore, the high concentration of OH− in electrolytes limits the choice of cathodes as it interacts with transition metal-based electrodes, leading to the deterioration of electrode structures, especially for Prussian blue analogues (PBAs) cathodes10. As the commonly used Mn-based PBAs, they have been widely studied in traditional aqueous batteries benefiting from advantages of non-toxicity, low cost, and high energy density5-7. Nevertheless, their potential use in alkaline electrolytes is constrained due to the strong Jahn-Teller effects in the redox couples of Mn2+/Mn3+ as well as the dissolution of Fe11. Consequently, PBA-based alkaline ASIBs have not been reported to date.
Here, we report a hydrogen-free alkaline ASIB based on a Mn-based PBA cathode (Na2MnFe(CN)6, NMF), NaTi2(PO4)3 (NTP) anode, and an affordable alkaline electrolyte of fluorine-free sodium perchlorate (NaClO4) whose price is much cheaper than commonly-used sodium triflate and sodium bis(trifluoromethylsulfonyl)imide in highly concentrated electrolytes. As illustrated in Fig. 1a, the alkaline electrolyte effectively suppresses HER at the anode. Moreover, by coating a commercially available nickel/carbon (Ni/C) nanoparticle-based layer on the NMF cathode, a H3O+-rich local environment forms near the cathode surface. This H3O+-rich local environment results from the irreversible formation of Ni(OH)2 and reversible Ni(OH)2/NiOOH redox (confirmed by in-situ Attenuated Total Reflectance Infrared (ATR-IR), Raman and Operando synchrotron X-ray powder diffraction, XRPD), which significantly reduces OER and electrode dissolution. Additionally, partial Ni atoms in the coating are in-situ embedded in the cathode to stabilize the NMF structure in alkaline media, as confirmed by operando Raman and high-angle annular dark-field scanning transmission electron microscopy (HAADF-STEM).
Electrochemical performance of alkaline NMF/NTP coin cells
At first, the prepared NMF, NTP, and the commercial Ni/C powders were studied by X-ray diffraction (XRD, Supplementary Figs. 1-3), indicating their good crystallinity for further applications in batteries. Then, the impact of salt concentration in electrolytes on HER was investigated by in-situ differential electrochemical mass spectrometry (DEMS) in NaClO4 electrolytes with selected salt concentrations. Results show that, without forming a reliable SEI, increasing the electrolyte concentration cannot change the onset potential of HER (Supplementary Fig. 4).
Notably, increasing the alkalinity of electrolyte suppresses HER (Supplementary Figs. 5a-c), which contributes to a better cycling stability of NTP anode (Supplementary Figs. 6a-c). However, the increased alkalinity of electrolyte propels OER (Supplementary Fig. 5d) and also increases the dissolution rate of Fe and Mn elements12 of the NMF cathode, leading to the poor cycling stability even at a water-stable voltage range of 0-1.0 V (Supplementary Figs. 6d-e and h). In comparison, after coating Ni/C layer on the NMF electrode (thickness: ca. 1 µm, Supplementary Fig. 7), its cycling stability is significantly enhanced (Supplementary Figs. 6f), as confirmed by the unchanged electrolyte colour (Supplementary Figs. 6i) as well as the suppressed Fe dissolving concentration in the electrolyte verified by results of inductively coupled plasma mass spectrometry (ICP-MS) (Supplementary Fig. 8).
The performance of NMF/NTP full cells using neutral electrolyte or alkaline electrolyte with/without Ni/C coating, was evaluated in a wide charging voltage range of 0.5 to 2.2 V. The NMF/NTP full cell with Ni/C coating exhibits a highly boosted rate performance and higher average discharge voltage than those without Ni/C coating, contributing to the fast-charge ability and high energy density of the battery (Supplementary Figs. 9a-b). Fig. 1b compares the cycling performance of NMF/NTP batteries under three different conditions at 1 C. Batteries without Ni/C coating in both neutral and alkaline electrolytes show a rapid capacity decay with capacity retention of < 60% following 200 cycles, whereas the alkaline-based battery with Ni/C coating exhibits a higher retention of ~ 100%. Furthermore, the electrolyte exhibits a lower freezing point in comparison to previously reported highly concentrated electrolytes5, 11,, allowing the battery to function effectively at low temperatures. (Supplementary Fig. 10). Consequently, the battery with Ni/C coating displays a capacity retention of 91.3% after 200 cycles at 0.5 C under −30 °C (Fig. 1c). Importantly, this full cell features a record lifespan of > 13,000 cycles with a high capacity retention of 74.3% at 10 C (Fig. 1d), surpassing mostly previously reported aqueous batteries13.
Pouch cell’s performance and comparison
To meet commercial requirements for large-scale energy storage, a Ni/C coated NMF//alkaline electrolyte//NTP pouch cell was assembled with the electrode loading of ca. 20 mg cm−2. This pouch cell exhibits a high capacity retention of 85% following 1,000 cycles at 500 mA g−1 (Fig. 2a). Additionally, the mass loading of single electrode can be further increased to the industry level of > 30 mg cm−2 benefiting from the low viscosity of the alkaline electrolyte (6.0 mPa s, Supplementary Table 1). Under such high loading, NMF/NTP pouch cell shows stable cycling life with a capacity retention of ~ 100% within 200 cycles at 300 mA g−1 (Fig. 2b). This large-size pouch cell also exhibits an ultra-high stability under ‘harsh’ conditions of cutting and immersion in water (Supplementary Videos 1-2, Supplementary Figs. 11a-c and Fig. 2c). In addition, the cut pouch cell can continuously power a humidity clock in water for > 20 h (Supplementary Video 3 and Fig. 2d). This confirms that the battery is resistant to electrolyte leakage and can withstand significant damage in high-humidity environments. As a result, the battery offers high safety for practical applications in energy storage and underwater electrical equipment.
Significantly, in addition to high safety, our battery design reduces the cost of manufacture and fabrication via hiring low-cost fluorine-free salt. Compared to other electrolytes for reported aqueous Li/Na/K ion batteries with an energy density of > 80 Wh kg−1 (based on total mass of anode and cathode), our electrolyte has a significantly lower unit-cost (the detailed comparison displays in Supplementary Fig. 12 and Supplementary Table 2), which guarantees the actual application of alkaline-based batteries. Furthermore, our batteries can achieve a high cycling stability and discharge capacity under ultra-low positive/negative capacity ratio of 1.06. Under such a low capacity ratio and 0.5 C charging rate, a greatest energy density amongst ASIBs (90 Wh kg−1) can be obtained (Fig. 2e and Supplementary Table 3). Compared to reported electrochemical battery storage devices, our battery system possesses significant advantages including, use of abundant elements (such as Fe, Mn, and Ti), high safety (high toleration to high humidity environment), environment friendliness (non-poisonous electrolyte), and a record lifespan (Fig. 2f and Supplementary Table 4). Although its energy density is slightly lower than that of Li-ion and nickel-metal-hydride (Ni-MH) batteries, its cost-efficacy and safety, namely key requirements for large-scale energy storage, are superior.
The origin of H3O+-rich local environment
To determine underlying factors for the high performance of the alkaline ASIB, the interface structure with Ni/C coating was assessed viain-situ ATR-IR spectroscopy. The carbon coating was taken as a ‘control’ to eliminate any influences of carbon support. For the electrode modified by pure carbon, the spectra exhibit no apparent change even after being charged to 1.3 V (vs. Ag/AgCl), evidencing that the carbon and binder do not change microenvironment of the cathode surface (Fig. 3a, the function of carbon in Ni/C coating is discussed in Supplementary Text S1 and Supplementary Fig. 13). In contrast, with Ni/C modification, new peaks at 1,798 and 2,032 cm−1 appear when the potential is > 0.6 V, attributed to two
(Supplementary Fig. 14a). Operando DEMS was employed to determine the water decomposition in this alkaline battery system during battery cycling. The battery without Ni/C coating exhibits HER and OER concurrently at a low positive/negative capacity ratio in the neutral electrolyte (Supplementary Fig. 14b). However, after coating Ni/C on the NMF cathode in alkaline electrolyte, both HER and OER become inconspicuous, except for trace O2 at the first cycle before activating the surface coating (Fig. 3b). It can be concluded that the H3O+-rich local environment induced by Ni/C protective layer suppresses the deteriorative OER in the alkaline electrolyte, while the alkaline electrolyte effectively retards HER.
The H+ accumulation mechanism on the electrode surface with Ni/C is illustrated in Fig. 3c. The H3O+ comes from water dissociation, inequivalent adsorption ability of H+ and OH− on Ni, together with a reversible transformation between Ni(OH)2 and NiOOH. Ni nanoparticles promote water dissociation, resulting in the production of H+ and OH− around this coating16. The OH− from bulk alkaline electrolyte and water dissociation on the surface of Ni can be confined due to the strong interaction between Ni and OH−, as evidenced by density functional theory (DFT) simulations (Supplementary Table 5). As the applied potential on Ni increases, the interaction between Ni and H+ becomes weaker whilst the interaction between Ni and OH− remains stable, evidencing that H3O+ is more likely to be generated at high voltages, which is confirmed by ATR-IR and Raman spectra mentioned before. Moreover, Ni is oxidized to Ni(OH)2 at higher voltages to bond with OH−. Additional H+ is generated when Ni(OH)2 is oxidized to NiOOH, as confirmed by XRPD and soft X-ray absorption spectra (XAS, Supplementary Figs. 15-16 and Supplementary discussion Text S2). Thereby, H+ bonds with nearby water molecules rather than Ni nanoparticles to form H3O+. These H3O+ ions exposed to bulk alkaline electrolyte are readily neutralized by excess OH−. In contrast, because of physical blocking of the coating, abundant H3O+ ions underneath the coating accumulate, leading to a H3O+-rich local environment on the cathode surface that suppresses OER during battery operation.
Ni-substituted process
Besides the increased OER, the improved alkalinity of electrolyte also compromises the cycling stability of PBA-based cathode material (without Ni/C coating). During charging/discharging process, the lattice constants of NMF changes in limited ranges accompanied by redox reactions of Mn, which causes collapse of Fe–CN–Mn bridges and vacancy generation17, as confirmed by gradually missing of the first discharge plateau (Figs. 4a-b). The dissolution of NMF is aggravated in alkaline electrolyte (Supplementary Figs. 17-18), which further decreases the stability of NMF cathode12. In contrast, the first discharge plateau for NMF/NTP cell and the structure of NMF cathode exhibit ultra-high stability after Ni/C coating even after 80 cycles (Fig. 4c). The stable discharge plateau for NMF/NTP after coating is mainly due to the in-situ substitution of Ni atoms to balance ‘tiny’ structural disturbances caused by redox reactions in Mn sites10, 18, 19 (Fig. 4d).
This hypothesis is confirmed by operando Raman spectra of Ni/C coated NMF cathodes cycled in the alkaline electrolyte (Fig. 4e). Peaks in the range of 2,050 to 2,200 cm−1 are assigned to cyano (CN) groups, evidencing that CN− groups bond with transition-metal ions with diverse valence states. Prior to cycling, two peaks at 2,089 and 2,124 cm−1 are visible, corresponding to Fe2+−CN−Mn2+ and Fe2+−CN−Mn3+ vibrations, respectively20. After charging to 1.89 V, both peaks disappear, evidencing transformation of Fe2+ to Fe3+ and Mn2+ to Mn3+. More importantly, after charging to 2.2 V, a new ‘weak’ peak appears at 2,195 cm−1 corresponding to Fe3+−CN−Ni2+ 21. This finding confirms the introduction of Ni atom in NMF particle following transformation of Mn2+ to Mn3+. After discharging to 0.5 V, peaks for Fe2+−CN−Mn2+ and Fe2+−CN−Mn3+ shift to 2,092 and 2128 cm−1 and a new peak appears at 2,164 cm−1 that is assigned to Fe2+−CN−Ni2+ 21. The introduction of Ni is also proved by the HAADF-STEM and energy-dispersive spectroscopy (EDS) mapping (Fig. 4f). Additionally, the EDS line-scan spectra for a single NMF particle confirms that Ni atoms are introduced into the edge of particles to suppress dissolution of inner Mn atoms (Fig. 4g). The EDS mappings for NMF cathode with Ni/C coating following 1st, 5th and 20th cycles (Supplementary Table 6 and Supplementary Fig. 19) evidence that the content of Ni in NMF particles is stable after the first cycle, confirming that the introduction of Ni into NMF cathode reaches an equilibrium in the first cycle to guarantee a long-term stability of the cathode.
This structure stability of NMF cathode achieved by the introduction of ‘inert’ Ni atoms in alkaline electrolyte is confirmed via XRPD patterns during charge/discharge. The structural evolutions of NMF structure happened at a high voltage range over 1.7 V, ascribing to the Mn2+ to Mn3+ (Fig. 5a). Fig. 5b shows the 2D contour map of NMF reflection. The highly reversible structure evolution during charge and discharge process can be easily observed. Further, the Rietveld refinements of NMF with/without Ni/C coating after 1st cycle show that both electrodes exhibit cubic phases with Fm-3m space group and a = b = c (Figs. 5c-d and Supplementary Table 7), however, the lattice parameters for Ni/C coated NMF (5.28161 Å) are greater than that for uncoated NMF (5.26358 Å). This finding is attributed to the introduction of Ni in Ni/C coated NMF upon cycling. An increased a (b, c) contributes to a boosted rate performance for the cathode, which is consistent with our results (Supplementary Fig. 9a). Importantly, compared to the deteriorated structure of uncoated NMF after 1st and 3rd cycle (Fig. 5e), the overlapping patterns for Ni/C coated NMF following 1st and 3rd cycle confirm the excellent stability of NMF and that Ni introduction occurs at 1st cycle, because otherwise, continuous Ni introduction will change the XRPD pattern (Fig. 5f).
To assess the possible universality of the new electrode modification strategy in alkaline batteries, the Co/C nanoparticle was employed to build the cathode coating as well. Similar to Ni nanoparticle, Co can be oxidized to Co(OH)2 in alkaline media and, it possesses reversible redox pair of Co(OH)2/CoOOH, together with ability to in-situ substitute the Mn atom. As a result, the good stability of battery with Co/C coating is achieved (Supplementary Fig. 20). This discovery provides evidence for the universality of creating H3O+-rich cathode surfaces and in-situ optimizing the NMF structure by building metal nanoparticle coating to enhance the performance of alkaline ASIBs.