Zinc
alkaline anodes command significant share of consumer battery
markets and are a key technology for the emerging grid-scale battery
market. Improved understanding of this electrode is required for long-cycle
deployments at kWh and MWh scale due to strict requirements on performance,
cost, and safety. Here we give a modern literature survey of zinc
alkaline anodes with levelized performance metrics and also present
an experimental assessment of leading formulations. Long-cycle materials
characterization, performance metrics, and failure analysis are reported
for over 25 unique anode formulations with up to 1500 cycles and ∼1.5
years of shelf life per test. Statistical repeatability of these measurements
is made for a baseline design (fewest additives) via 15 duplicates.
Baseline design capacity density is 38 mAh per mL of anode volume,
and lifetime throughput is 72 Ah per mL of anode volume. We then report
identical measurements for anodes with improved material properties
via additives and other perturbations, some of which achieve capacity
density over 192 mAh per mL of anode volume and lifetime throughput
of 190 Ah per mL of anode volume. Novel in operando X-ray microscopy
of a cycling zinc paste anode reveals the formation of a nanoscale
zinc material that cycles electrochemically and replaces the original
anode structure over long-cycle life. Ex situ elemental mapping and
other materials characterization suggest that the key physical processes
are hydrogen evolution reaction (HER), growth of zinc oxide nanoscale
material, concentration deficits of OH– and ZnOH4
2–, and
electrodeposition of Zn growths outside and through separator membranes.