Abstract: Various embodiments relate to several processes that may recover commodity chemicals from an alkaline metal-air battery. In various embodiments, while the cell is operating, various side products and waste streams may be collected and processed to regain use or additional value. Various embodiments also include processes to be performed after the cell has been disassembled, and each of its electrodes have been separated such as not to be an electrical hazard. The alkaline metal battery recycling processes described herein may provide multiple forms of commodity iron, high purity transition metal ores, fluoropolymer dispersions, various carbons, commodity chemicals, and catalyst dispersions.

Abstract: Systems and methods of the various embodiments may provide a battery including a rolling diaphragm configured to move to accommodate an internal volume change of one or more components of the battery. Systems and methods of the various embodiments may provide a battery housing including a rolling diaphragm seal disposed between an interior volume of the battery and an electrode assembly within the battery. Various embodiments may provide an air electrode assembly including an air electrode supported on a buoyant platform such that the air electrode is above a surface of a volume of electrolyte when the buoyant platform is floating in the electrolyte.

Abstract: Various embodiments provide a battery, a bulk energy storage system including the battery, and/or a method of operating the bulk energy storage system including the battery. In various embodiment, the battery may include a first electrode, an electrolyte, and a second electrode, wherein one or both of the first electrode and the second electrode comprises direct reduced iron (“DRI”). In various embodiments, the DRI may be in the form of pellets. In various embodiments, the pellets may comprise at least about 60 wt % iron by elemental mass, based on the total mass of the pellets. In various embodiments, one or both of the first electrode and the second electrode comprises from about 60% to about 90% iron and from about 1% to about 40% of a component comprising one or more of the materials selected from the group of SiO2, Al2O3, MgO, CaO, and TiO2.

Abstract: Various embodiments provide a battery, a bulk energy storage system including the battery, and/or a method of operating the bulk energy storage system including the battery. In various embodiment, the battery may include a first electrode, an electrolyte, and a second electrode, wherein one or both of the first electrode and the second electrode comprises direct reduced iron (“DRI”). In various embodiments, the DRI may be in the form of pellets. In various embodiments, the pellets may comprise at least about 60 wt % iron by elemental mass, based on the total mass of the pellets. In various embodiments, one or both of the first electrode and the second electrode comprises from about 60% to about 90% iron and from about 1% to about 40% of a component comprising one or more of the materials selected from the group of SiO2, Al2O3, MgO, CaO, and TiO2.

Abstract: Various embodiments provide a battery, a bulk energy storage system including the battery, and/or a method of operating the bulk energy storage system including the battery. In various embodiment, the battery may include a first electrode, an electrolyte, and a second electrode, wherein one or both of the first electrode and the second electrode comprises direct reduced iron (“DRI”). In various embodiments, the DRI may be in the form of pellets. In various embodiments, the pellets may comprise at least about 60 wt % iron by elemental mass, based on the total mass of the pellets. In various embodiments, one or both of the first electrode and the second electrode comprises from about 60% to about 90% iron and from about 1% to about 40% of a component comprising one or more of the materials selected from the group of SiO2, Al2O3, MgO, CaO, and TiO2.

Abstract: Various embodiments may include a battery electrode, comprising: an iron electrode body comprising iron active material and a zinc sulfide additive, wherein the zinc sulfide additive comprises crystalline cubic zinc sulfide. Various embodiments may include a battery electrode, comprising: an iron electrode body comprising iron active material and a manganese sulfide additive, wherein the manganese sulfide additive comprises crystalline cubic manganese sulfide. Various embodiments may include an iron electrode battery, comprising: an iron electrode; and a sulfide reservoir separate from the iron electrode, the sulfide reservoir comprising crystalline cubic zinc sulfide. Various embodiments may include an iron electrode battery, comprising: an iron electrode and a sulfide reservoir separate from the iron electrode, the sulfide reservoir comprising crystalline cubic manganese sulfide.

Abstract: Iron electrode materials, iron electrodes, and methods for fabricating said iron electrode materials and iron electrodes via elevated temperature thermomechanical processing of porous particulate iron materials are described. For example, as part of iron electrode manufacture, a particulate iron material into an apparatus may be provided. In addition, pressure and/or heat may be applied to the particulate iron material in the apparatus for a time period to form an electrode having therein conductive connections between particles of the particulate iron material.

Abstract: Various embodiments relate to several processes that may recover commodity chemicals from an alkaline metal-air battery. In various embodiments, while the cell is operating, various side products and waste streams may be collected and processed to regain use or additional value. Various embodiments also include processes to be performed after the cell has been disassembled, and each of its electrodes have been separated such as not to be an electrical hazard. The alkaline metal battery recycling processes described herein may provide multiple forms of commodity iron, high purity transition metal ores, fluoropolymer dispersions, various carbons, commodity chemicals, and catalyst dispersions.

Abstract: Materials, designs, and methods of fabrication for iron-manganese oxide electrochemical cells are disclosed. In various embodiments, the negative electrode is comprised of pelletized, briquetted, or pressed iron-bearing components, including metallic iron or iron-based compounds (oxides, hydroxides, sulfides, or combinations thereof), collectively called “iron negative electrode.” In various embodiments, the positive electrode is comprised of pelletized, briquetted, or pressed manganese-bearing components, including manganese (IV) oxide (MnO2), manganese (III) oxide (Mn2O3), manganese (III) oxyhydroxide (MnOOH), manganese (II) oxide (MnO), manganese (II) hydroxide (Mn(OH)2), or combinations thereof, collectively called “manganese oxide positive electrode.” In various embodiments, electrolyte is comprised of aqueous alkali metal hydroxide including lithium hydroxide (LiOH), sodium hydroxide (NaOH), potassium hydroxide (KOH), cesium hydroxide (CsOH), or combinations thereof.

Abstract: Systems and methods of the various embodiments may provide metal electrodes for electrochemical cells. In various embodiments, the electrodes may comprise iron. Various methods may enable achieving high surface area with low cost for production of metal electrodes, such as iron electrodes.

Abstract: Systems and methods of the various embodiments may provide low cost bifunctional air electrodes. Various embodiments may provide a bifunctional air electrode, including a metal substrate and particles of metal and/or metal oxide catalyst and/or metal nitride catalyst coated on the metal substrate. Various embodiments may provide a bifunctional air electrode, including a first portion configured to engage an oxygen reduction reaction (ORR) in a discharge mode and a second portion configured to engage an oxygen evolution reaction (OER) in a charge mode. Various embodiments may provide a method for making an air electrode including coating a metal substrate with particles of metal and/or metal oxide catalyst and/or metal nitride catalyst. Various embodiments may provide batteries including air electrodes.

Abstract: Systems and methods of the various embodiments may provide device architectures for batteries. In various embodiments, these may be primary or secondary batteries. In various embodiments these devices may be useful for energy storage. Various embodiments may provide a battery including an Oxygen Reduction Reaction (ORR) electrode, an Oxygen Evolution Reaction (OER) electrode, a metal electrode; and an electrolyte separating the ORR electrode and the OER electrode from the metal electrode.

Abstract: Various embodiments provide a battery, a bulk energy storage system including the battery, and/or a method of operating the bulk energy storage system including the battery. In various embodiment, the battery may include a first electrode, an electrolyte, and a second electrode, wherein one or both of the first electrode and the second electrode comprises direct reduced iron (“DRI”). In various embodiments, the DRI may be in the form of pellets. In various embodiments, the pellets may comprise at least about 60 wt % iron by elemental mass, based on the total mass of the pellets. In various embodiments, one or both of the first electrode and the second electrode comprises from about 60% to about 90% iron and from about 1% to about 40% of a component comprising one or more of the materials selected from the group of SiO2, Al2O3, MgO, CaO, and TiO2.

Abstract: Systems and methods of the various embodiments may provide a battery including a rolling diaphragm configured to move to accommodate an internal volume change of one or more components of the battery. Systems and methods of the various embodiments may provide a battery housing including a rolling diaphragm seal disposed between an interior volume of the battery and an electrode assembly within the battery. Various embodiments may provide an air electrode assembly including an air electrode supported on a buoyant platform such that the air electrode is above a surface of a volume of electrolyte when the buoyant platform is floating in the electrolyte.