Rechargeability and economic aspects of alkaline zinc–manganese dioxide cells for electrical storage and load leveling

• Zn–MnO2 battery was cycled at shallow DOD for more than 3000 cycles.
• Relatively low delivered cost of less than $150 per kWh.
• Mathematical model developed to understand the capacity fade mechanisms.
• Resistive film formation on the surface of MnO2 particle during cycling.
• Change in SOC during cycling was used to measure capacity loss.

Batteries based on manganese dioxide (MnO2) cathodes are good candidates for grid-scale electrical energy storage, as MnO2 is low-cost, relatively energy dense, safe, water-compatible, and non-toxic. Alkaline Zn–MnO2 cells, if cycled at reduced depth of discharge (DOD), have been found to achieve substantial cycle life with battery costs projected to be in the range of $100 to 150 per kWh (delivered). Commercialization of rechargeable Zn–MnO2 batteries has in the past been hampered due to poor cycle life. In view of this, the work reported here focuses on the long-term rechargeability of prismatic MnO2 cathodes at reduced DOD when exposed to the effects of Zn anodes and with no additives or specialty materials. Over 3000 cycles is shown to be obtainable at 10% DOD with energy efficiency >80%. The causes of capacity fade during long-term cycling are also investigated and appear to be mainly due to the formation of irreversible manganese oxides in the cathode. Analysis of the data indicates that capacity loss is rapid in the first 250 cycles, followed by a regime of stability that can last for thousands of cycles. A model has been developed that captures the behavior of the cells investigated using measured state of charge (SOC) data as input. An approximate economic analysis is also presented to evaluate the economic viability of Zn–MnO2 batteries based on the experiments reported here.