Nickel-Iron Battery/Research Development: Difference between revisions

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=Overview=
=Review=
Research pertaining to [[Battery]] Research.
*''The nickel/iron battery is a rechargeable electrochemical power source with certain special advantages. It has good scope for traction applications. The present state-of-art advantages, limitations, and uses of the nickel/iron battery, along with its electrochemical characteristics, are outlined in this review. Various methods available for fabricating both the negative iron and the positive nickel oxy-hydroxide (NiO·OH) electrodes, as well as the electrochemical characteristics of these electrodes, are discussed.'' - study this for manufacturing techniques - [https://www.sciencedirect.com/science/article/abs/pii/037877539180002F]


See also [[Batteries]] for a comparison of different chemistries.
==Research==
Patent Review whitepaper - [[File:nifepatents.zip]]
 
 
===Battery Chemistries===


'''Battery Chemistries'''
*[[Nickel-Iron Battery]]
*[[Nickel-Iron Battery]]
**[[Edison Battery]]
**[[Edison Battery]]
*[[Lead Acid Battery]]
*[[Lead Acid Battery]]
*[[Aluminum-Air Battery]]
*[[Aluminum-Air Battery]]
*[[Zinc bromine battery]]
*[[Zinc bromine battery]]
*[https://wiki.opensourceecology.de/Zn/O-Brennstoffzelle OSE Germany's Zinc/Oxygen (from the air) battery]
*[[Other Batteries]]
*[[Other Batteries]]


'''Research'''
*[[Battery Research Gregor]]
*[[Battery Chemistry]]


'''Additional Research'''
 
*[[NiFe Sourcing]]
===Research===
 
*[[Battery Research Gregor]] Unedited library research notes.
 
*[[Nickel-Iron Battery/Chemistry|Battery chemistry]]
 
*[[Battery Chemistry Comparison]] Comparison between potential battery chemistries to see if there might be something better than nickel iron for OSE purposes.  Summary: Zinc bromine may well be better, see zinc bromine pages for details.
 
 
 
===Additional Research===
 
*[[Nickel-Iron Battery/Sourcing|Nickel-Iron Battery Sourcing]]
 
*[[Battery Patents]]
*[[Battery Patents]]
*[[Battery Papers]]
*[[Battery Papers]]


'''Nickle Iron'''
 
 
===Nickel Iron===
 
*[[Nickel-Iron SLI battery]]
*[[Nickel-Iron SLI battery]]
*[[Battery Concept]]
*[[Battery Concept]]
*[[Nickel-Iron_Battery/Prototype]]
*[[Battery Spec]]


==Projects==
===Ideas===


'''Ed's Workshop'''
*[[NiFe Vehicles]]


The Yahoo Group contains current efforts including a photo deck of his current battery. He also includes lots of other DIY projects that fit the theme here: DC motor control, Induction Furnace, Metal Casting, Electro-forming ...
*[http://www.nickel-iron-battery.com hydrogen use]


* Yahoo Group: http://tech.groups.yahoo.com/group/edsworkshp/
*[[Nickel-Iron_Battery/Research_Development/Ideas/3D_Printed|3D Printed]]
* YouTube Channel: http://www.youtube.com/user/edsworkshop#p/u/14/CBGcdtAzzUE


Suggested Source:
* Nickel Carbonate (Baily Pottery) approx $28/lb or less (depending on size of order)


http://www.baileypottery.com/clay/clays-chemicals.htm


'''noonco'''
===Collaboration===


* Edison Battery Construction Nickel Iron‏ - YouTube: http://www.youtube.com/watch?v=K84PywMwjZg 
*[[Battery Projects]]
* Edison Battery Page: http://www.noonco.com/edison/


=Note on efficiency measures=
*[[Battery Collaboration]]
The charge/discharge (also called round trip and overall) efficiency is the performance parameter that we care about, of course.  Hypothetically it should be equal to the charge efficiency multiplied by the discharge efficiency.  In this case the efficiency is energy efficiency.


The charge efficiency is often quoted in absence of the discharge or overall efficiency, which is very annoying as it makes it harder to compare different battery designs that are mentioned in the literature.  In marketing materials it is probably used in the hope the customer will erroneously assume it is equivalent to overall efficiency, since it is always higher than overall.
=Basic Material Cost Calculations=
*$4550 for 4kwhr storage, 750 lb -[https://ironedison.com/nickel-iron-ni-fe-battery]
*Nickel iron batteries are made from nickel and iron.
*Nickel $8/lb. $18k usd/2200lb - [https://tradingeconomics.com/commodity/nickel]. Scrap costs $4/lb. [https://www.scrapregister.com/metal-price/nickel-alloy-scrap/34]
*Iron costs 10 cents/lb at commodity price - [https://iscrapapp.com/prices/]
*Weight of a 4kWhr system is 750 lb [https://ironedison.com/images/Spec%20Sheets/2.%20Nickel%20Iron%20battery%20info/Iron%20Edison%20-%20Nickel%20Iron%20Data%20Sheet%202018.pdf]
*Nickel oxide costs $25/lb [https://www.alibaba.com/showroom/nickel-oxide-price.html]
*Nickel oxide hydroxide [https://en.wikipedia.org/wiki/Nickel_oxide_hydroxide] is used in batteries. It is prepared from nickel(II) hydroxide - [https://en.wikipedia.org/wiki/Nickel(II)_hydroxide] which is in turn prepared from nickel II salts with sodium hydroxide. [https://en.wikipedia.org/wiki/Nickel(II)_chloride#Other_uses]. Nickel chloride is a common salt - $8/lb. [https://www.alibaba.com/product-detail/nickel-chloride-hexahydrate-nickel-chloride-price_1600216717236.html?spm=a2700.7724857.normal_offer.d_title.313bceeeXyuQnC]. Nasty chem appears to be involved.
*Iron oxide is 50 cents/lb [https://www.alibaba.com/showroom/iron%252b%2528iii%2529%252boxide.html]
*Graphite powder is 50 cents/lb [https://www.alibaba.com/showroom/graphite+powder.html?fsb=y&IndexArea=product_en&CatId=&SearchText=graphite+powder&isGalleryList=G]


The discharge efficiency is rarely referred to in isolation for some reason, probably because it usually more or less commensurate with charge efficiency and can be computed easily from the overall and charge efficiency. Commensurate does not mean equal though.
'''Problem Statement:''' Say the battery is 20% nickel [https://www.solarpaneltalk.com/forum/off-grid-solar/batteries-energy-storage/ni/7052-how-much-nickel-is-really-in-a-nickel-iron-ni-fe-battery]. Then 150 lb of nickel would be $600 for baseline cost at scrap nickel prices. Except the process relies on Nickel Oxide Hydroxide - not the same thing. So we need to trace the manufacturing process down to nickel oxide hydroxide sourcing. As well as how much nickel oxide hydroxide is actually used per battery.


Not energy efficiency:
About 2M tons of nickel are produced per year. This determines the number of batteries that can be produced.


Faradaic and coloumbic efficiency: see wikipedia article.  Unfortunately it is apparent in patents and other documents it is apparently that this is in fact often, either due to ignorance or more likely sloppiness, used to mean charge efficiency or overall efficiency so watch out for this.
=Design=


Polarization of the electrodes, see wikipedia.
==Variables and Formulas==


Overpotential, see wikipedia.
http://en.wikipedia.org/wiki/Ampere-hour


=Non-chemical factors affecting performance=
==Design Proposals==
At low temperatures with some iron electrode designs sulfur can accumulate on the iron electrode and increase internal resistance (designs which incorporate elemental sulfur, patents indicate this can be rectified by using a sulfide salt of low solubility like iron sulfide FeS).


The conductivity of the electrolyte goes up as the temp goes up.  This is desirable but other undesirable reactions increase in rate at higher temps so there is a compromise there.  Also this is one of the main mechanisms that can lead to thermal runaway during constant voltage charging as it can form a positive feedback loop.  The solution is to just not use constant voltage charging, which is easy.
===10 cell with flat plates===


The factors like the energy to weight ratio and power to weight will of course tend to be affected by any non-reactant materials used to e.g. reduce cost etc, but fortunately those are of relatively little importance in the context of OSE for off grid electricity and farm equipment, although they may be important for the electric car.  Basically we want to produce something that can replace lead acid which is cheaper, easier to work with and make and maintain, more durable with abuse and longer lasting, and not as bad for the environment.  Ideally both for starting lighting ignition (SLI) batteries and also storage.  Batteries described in documents can handle 6C and more without seriously hard to manufacture materials and additives so SLI is definitely an option.  See related pages section.  None of these require high energy density or power to weight ratio although they are always nice.
https://drive.google.com/folderview?id=0BwxMMqGvwTM-Wm5maHJVMVExRTg&usp=sharing 10 cell 3d printed


The fraction of active material that actually is utilized if low will reduce power and energy to weight and volume ratio. Can be affected by particle size, additives and also any particles of active material that are not in reasonable electrical contact with the current collector for whatever reason will remain unused.
::<html><img src="https://docs.google.com/drawings/d/1JaxzGdN-nkb_fk_Cq_IGbGAbIGHFxetyJZsGELH6DB8/pub?w=251&amp;h=107"></html>


The level of the electrolyte can if not maintained in a non-sealed battery, drop below the level of the plates, and the uncovered portion of the plate may remain unused, decreasing capacity until the electrolyte is replenished.
https://github.com/dorkmo/ose-battery


There is always some distance that the current needs to travel to get from the reaction area to the current collector, and to do this is has to pass along the active material. Therefore the conductivity of the active material is an issue which significantly affects internal ohmic  resistance (the term internal resistance is often used to refer in a catch all way to the current draw vs. voltage output relationship even though this is due to many factors besides ohmic resistance). See wikipedia for polarization for more information that relates to the voltaic efficiency.  
=Cost=
*Quoted $200 each on 2/5/18 for 400A, 1.2V battery from ZhuHai CIYI Battery Co.,Ltd, battery model CYNF400. Price FOB Shenzhen. But just look at the discharge cycles - 62 years at 50% DoD if daily discharge. $400/kWh. Price for 10 batteries will be + $280 for shipping to Kansas City.


For a vehicle:
[[Image:CYNF400.jpg|900px]]
Power to weight ratio is affected strongly by the surface are to weight ratio of the electrodes.
*Another quote from Seawill Technology Co. is TN800 - 1.2V -800Ah - 57.5kg - $349 each, so 40 are a $13960 total, $710 shipping to KC


The pressure the casing needs to stand increases as the internal pressure dose of course, see sealed battery section, if sealed it will need to stand significant pressure and therefore be relatively heavy.
=Archives=
Due to people's attempts to edit things on the wiki that were started but never finished, some valuable information has been lost from the nickel iron project in recent revisions of some wiki pages.  In particular, if you are interested in the nickel iron project, I have a collection of high quality documents from the peer reviewed literature that will be quite helpful.  Email me at Gregorfolouk@hotmail.com and I will send you the documents though.  Edit: here is the file you can download with all the docs http://kiwi6.com/file/7u7r1fm2ys  The service is supposed to host it in perpetuity but we'll see.


=Nickel iron for electric vehicles=
Here is a list of the document titles, and other information from the last intact copy of the page I had built for the nickel iron project before it was torn up, for more information [http://opensourceecology.org/w/index.php?title=Nickel-Iron_Battery&diff=prev&oldid=32539#library search the titles on google scholar].
There is some interest in using nickel iron in electric vehicles as it can produce major long term cost savings compared with some types of lithium.  Also, as discussed on the battery comparison page there are only enough known lithium reserves to make roughly 3 million electric car batteries, nowhere near enough. So clearly some other battery technology will be needed, it is just a matter of which.


In contrast to photovoltaic system, obviously power to weight ratio and energy to weight ratio (specific energy) are paramount.  Power to weight ratio for bursts during acceleration can always be improved using an ultracapacitor or other storage system in parallel however, but specific energy is a fundamental limitation.


As discussed above, the theoretical limitations of the chemistry for specific energy is 182.5 Wh/kg.


The practical weight is increased by a variety of factors mentioned in the non chemical factors that decrease performance section.


Wikipedia indicates around 50 Wh per kg for flooded cells, but those cells are not designed for low weight so that could be improved upon quite substantially.


Changhong uses nife pocket plate cells for starting batteries (SLI) so obviously they are capable of high rates though it is not clear how high.  The starved electrolyte, sealed battery document mentions 6C at substantial efficiency loss.  The ultimate electrode for both these ratios is the microfiber metal plaque, essentially nickel fibers around 2 microns wide assembled into a sheet with 95% porosity or so but that may not be needed.
=See Also=


One issue may be the relatively large amount of heat produced during charging, which may be twice or more that of lithium ion, therefore limiting the charge rate, but probably not a major issue.
* [[Batteries]]
* [[Electricity]]
* [[Nickel-Iron SLI battery]]
* [[Impact of battery characteristics on off grid system_cost]]
* [http://www.youtube.com/watch?v=K84PywMwjZg&feature=youtube_gdata_player video]


There are quite a number of papers I have come across whose abstracts describe nife batteries being used to power electric vehicles for city fleets etc. and development projects of various sorts to develop nife batteries suitable for vehicles.  It certainly works, it's jut a matter of achieving competitive performance. Zinc bromine may be more suitable for vehicle use, for a variety of reasons.
=Ongoing Research=
*Westinghouse , 500 cycles, 80%DOD tests with new designs - [https://worldwidescience.org/topicpages/n/nickel+iron+battery.html]


The discharge efficiency matters relatively more here as overall energy efficiency is less important that for photovoltaic systems probably. The lower it is, all other things being equal, the battery will weight more as the amount of energy stored is lower than what gets to the load, so you'd need a bigger battery.
=Useful Links=
*Y-Combinator discussion - [https://news.ycombinator.com/item?id=15618494]
*Walk-through of '''Edison's battery factory including how the batteries are made''' - [[Nickel-Iron_Battery/Manufacturing_Instructions]]
* [http://en.wikipedia.org/wiki/Battery_(electricity) Wikipedia: Battery]


=See Also=
* [http://en.wikipedia.org/wiki/Nickel_iron_battery Wikipedia: Nickel iron Battery]
 
*Comparison of Lithium Ion to Nickel Iron batteries from Tesla Motors - [https://forums.tesla.com/forum/forums/nickeliron-batteries]. Copied to OSE Wiki for archival purposes - [[Nickel Iron vs Lithium Ion Battery from Tesla Motors]].
 
*Example of DIY build - [https://www.youtube.com/watch?v=K84PywMwjZg]
 
*Website [https://www.noonco.com/edison/improvements.htm] contains useful materials - [[File:NiFepaper1.pdf]], [[File:NiFepaper2.pdf]]
 
*Stanford fast NiFe battery - [https://newatlas.com/scientists-give-new-life-to-thomas-edisons-nickel-iron-battery/23102/]. It's useful to contact the researchers


* [[Batteries]]
* Nuts and Volts article on the NiFe Battery - [http://nutsvolts.texterity.com/nutsvolts/201202/?folio=38#pg38]
* [[Nickel-Iron_Battery/Research]]
* [[Nickel-Iron_Battery/Prototype]]
* [[Nickel-Iron_Battery collaboration and correspondence]]
* [[Battery chemistry comparison]]
* [[Nickel-Iron SLI battery]]
* [[Nickel-Iron Off grid battery]]


* [[Edison Battery]]
* Edison Battery improvements - [http://www.noonco.com/edison/improvements.htm]
* [[Impact of battery characteristics on off grid system cost]]


* [[Impact of battery efficiency on cost]]
* Patent - nickel oxide hydroxide electrodes - [http://www.google.com/patents/US4462875]
* [[Zinc_bromine_battery]]


* http://en.wikipedia.org/wiki/Nickel_iron_battery
* Good discussion on OSE Workshops FB page - [https://www.facebook.com/OpenSourceEcology/posts/10153603267576562]


* Battery University: [https://batteryuniversity.com/]


[[Category: Research]]
[[Category: Research]]


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Latest revision as of 19:39, 23 June 2021


Nickel-Iron Battery
   Home  |  Research & Development  |  Bill of Materials  |  Manufacturing Instructions  |  User's Manual  |  User Reviews    Nickel-Iron Battery.png

Review

  • The nickel/iron battery is a rechargeable electrochemical power source with certain special advantages. It has good scope for traction applications. The present state-of-art advantages, limitations, and uses of the nickel/iron battery, along with its electrochemical characteristics, are outlined in this review. Various methods available for fabricating both the negative iron and the positive nickel oxy-hydroxide (NiO·OH) electrodes, as well as the electrochemical characteristics of these electrodes, are discussed. - study this for manufacturing techniques - [1]

Research

Patent Review whitepaper - File:Nifepatents.zip


Battery Chemistries


Research

  • Battery Chemistry Comparison Comparison between potential battery chemistries to see if there might be something better than nickel iron for OSE purposes. Summary: Zinc bromine may well be better, see zinc bromine pages for details.


Additional Research


Nickel Iron

Ideas


Collaboration

Basic Material Cost Calculations

  • $4550 for 4kwhr storage, 750 lb -[2]
  • Nickel iron batteries are made from nickel and iron.
  • Nickel $8/lb. $18k usd/2200lb - [3]. Scrap costs $4/lb. [4]
  • Iron costs 10 cents/lb at commodity price - [5]
  • Weight of a 4kWhr system is 750 lb [6]
  • Nickel oxide costs $25/lb [7]
  • Nickel oxide hydroxide [8] is used in batteries. It is prepared from nickel(II) hydroxide - [9] which is in turn prepared from nickel II salts with sodium hydroxide. [10]. Nickel chloride is a common salt - $8/lb. [11]. Nasty chem appears to be involved.
  • Iron oxide is 50 cents/lb [12]
  • Graphite powder is 50 cents/lb [13]

Problem Statement: Say the battery is 20% nickel [14]. Then 150 lb of nickel would be $600 for baseline cost at scrap nickel prices. Except the process relies on Nickel Oxide Hydroxide - not the same thing. So we need to trace the manufacturing process down to nickel oxide hydroxide sourcing. As well as how much nickel oxide hydroxide is actually used per battery.

About 2M tons of nickel are produced per year. This determines the number of batteries that can be produced.

Design

Variables and Formulas

http://en.wikipedia.org/wiki/Ampere-hour

Design Proposals

10 cell with flat plates

https://drive.google.com/folderview?id=0BwxMMqGvwTM-Wm5maHJVMVExRTg&usp=sharing 10 cell 3d printed

https://github.com/dorkmo/ose-battery

Cost

  • Quoted $200 each on 2/5/18 for 400A, 1.2V battery from ZhuHai CIYI Battery Co.,Ltd, battery model CYNF400. Price FOB Shenzhen. But just look at the discharge cycles - 62 years at 50% DoD if daily discharge. $400/kWh. Price for 10 batteries will be + $280 for shipping to Kansas City.

CYNF400.jpg

  • Another quote from Seawill Technology Co. is TN800 - 1.2V -800Ah - 57.5kg - $349 each, so 40 are a $13960 total, $710 shipping to KC

Archives

Due to people's attempts to edit things on the wiki that were started but never finished, some valuable information has been lost from the nickel iron project in recent revisions of some wiki pages. In particular, if you are interested in the nickel iron project, I have a collection of high quality documents from the peer reviewed literature that will be quite helpful. Email me at Gregorfolouk@hotmail.com and I will send you the documents though. Edit: here is the file you can download with all the docs http://kiwi6.com/file/7u7r1fm2ys The service is supposed to host it in perpetuity but we'll see.

Here is a list of the document titles, and other information from the last intact copy of the page I had built for the nickel iron project before it was torn up, for more information search the titles on google scholar.



See Also

Ongoing Research

  • Westinghouse , 500 cycles, 80%DOD tests with new designs - [15]

Useful Links

  • Example of DIY build - [18]
  • Stanford fast NiFe battery - [20]. It's useful to contact the researchers
  • Nuts and Volts article on the NiFe Battery - [21]
  • Edison Battery improvements - [22]
  • Patent - nickel oxide hydroxide electrodes - [23]
  • Good discussion on OSE Workshops FB page - [24]
  • Battery University: [25]


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