Enabling sustainable sodium-ion batteries, from materials to cell development

Several emerging battery technologies are currently considered to take the share of the
dominant position taken by lithium-ion batteries (LIBs). Sodium-ion batteries (SIBs) are
among the most promising alternatives, offering significant advantages such as greater
sustainability, lower projected material costs, compatibility with existing LIB manufacturing
facilities, and enhanced safety features like 0V storage capability.
The recent industrial investments reflect the accelerated progress toward commercial
viability. However, SIBs still face challenges, particularly their lower energy density
compared to LIBs. While several cathode materials have been proposed, hard carbon (HC)
has become the preferred anode for SIBs.
This presentation highlights the development of 1Ah sodium-ion pouch cells using Prussian
White (PW) cathodes and biomass-derived HC anodes. Both electrodes are processed in
water, aligning with goals of low toxicity, cost, and environmental impact. However, the
inherently low density of PW and HC limits the cells' volumetric energy density. To overcome
this, alloying-type anodes like tin (Sn) are being investigated for their high capacity,
conductivity, and density. Despite challenges like volume expansion during cycling, our
research shows that micrometric Sn can form a stable, porous “coral-like” network that
resists structural degradation—even at high Sn content. This morphology enables improved
volumetric energy density and paves the way for more commercially competitive SIBs.