To fabricate a full-scale pilot model of the cost-effective Na-(Ni,Fe)Cl 2 cell, a Na-beta-alumina solid electrolyte (BASE) was developed by applying a one-step synthesis cum sintering process as an alternative to the conventional solid-state reaction process. Also, Fe metal powder, which is cheaper than Ni, was mixed with Ni metal powder, and was used for cathode material to reduce the cost of raw material. As a result, we then developed a prototype Na-(Ni,Fe)Cl 2 cell. Consequently, the Ni content in the Na-(Ni,Fe)Cl 2 cell is decreased to approximately (20 to 50) wt.%. The #1 prototype cell (dimensions: 34 mm × 34 mm × 235 mm) showed a cell capacity of 15.9 Ah, and 160.3 mAh g -1 (per the Ni-Fe composite), while the #2 prototype cell (dimensions: 50 mm × 50 mm × 335 mm) showed a cell capacity of 49.4 Ah, and 153.2 mAh g -1 at the 2 n d cycle.
Sodium metal chloride batteries have become a substantial focus area in the research on prospective alternatives for battery energy storage systems (BESSs) since they are more stable than lithium ion batteries. This study demonstrates the effects of the cathode microstructure on the electrochemical properties of sodium metal chloride cells. The cathode powder is manufactured in the form of granules composed of a metal active material and NaCl, and the ionic conductivity is attained by filling the interiors of the granules with a second electrolyte (NaAlCl4). Thus, the microstructure of the cathode powder had to be optimized to ensure that the second electrolyte effectively penetrated the cathode granules. The microstructure was modified by selecting the NaCl size and density of the cathode granules, and the resulting Na/(Ni,Fe)Cl2 cell showed a high capacity of 224 mAh g−1 at the 100th cycle owing to microstructural improvements. These findings demonstrate that control of the cathode microstructure is essential when cathode powders are used to manufacture sodium metal chloride batteries.
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