The "all-iron flow battery" technology was developed by a research team from the Institute of Metal Research under the Chinese Academy of Sciences, and their findings were published earlier this month in the journal Advanced Energy Materials.

Unlike the lithium-ion batteries commonly used today, all-iron flow batteries rely on iron, which is far cheaper and more widely available, with lithium currently trading at more than 80 times the cost of iron.

The large price gap makes iron-based batteries a possible solution to supply constraints slowing the global shift to green energy, according to Interesting Engineering.

The main challenge for iron flow batteries has been their short lifespan. Over time, the battery’s active materials can break down or leak through internal membranes, reducing efficiency and shortening operational life.

To solve this, the Chinese team designed a new iron compound that acts like a protective shield. It helps prevent damage to the battery’s core materials and stops them from leaking across the membrane, as reported by the South China Morning Post.

Battery packs. Illustration photo by Pexels

According to the academy, the battery remained stable after more than 6,000 cycles, equivalent to more than 16 years of daily use, with no precipitation or buildup of harmful by-products.

It also achieved a 99.4% leak-proof efficiency, meaning very little energy was lost during operation. Even at high power output, it retained 78.5% of its energy efficiency, showing the design is both reliable and durable.

The battery also uses a water-based electrolyte, making it less likely to catch fire than lithium batteries.

"It offers a low-cost, long-life solution for large-scale energy storage," CAS said in a press release on April 16.

They said the design could set a new standard for future iron battery development and help lower the long-term cost of clean energy storage, including electricity generated by solar panels and wind farms.