Hi all, I'm Kirk, I've been collaborating with Daniel on this battery project. We set up a website
https://fbrc.dev/ and just got a small
grant to continue the work. I'll be working on mostly the engineering of the stack design.
I see groups are experimenting with prussian blue and prussian white
For flow batteries? Or for Na-ion?
You can make your own lifepo4 battery with materials purchased from 1688 for ~30$/kwh not including shipping and tax.
Yes, LFP is cheap, and benefits massively from economies of scale right now. Beyond just up-front cost, I think it's important to consider safety, cycle life, and the sustainability of the materials needed to make the battery, as well as how easy it is to recycle them at the end of life. Also, the cost of clean/dry rooms, solvent handling, calendaring equipment, etc. to produce nonaqueous intercalation batteries like Li and Na-ion means the upfront capital investment to build a factory is massive - which is why we see so many "gigafactories" being announced - the capital expenditures must be huge to get to the scale where one can profitably make Li-ion batteries. And even then, the profit margins are not that large. Recycling for Li-ion is coming around, but unmixing a slurry electrode is a big battle with entropy.
In contrast, flow batteries are safer to produce and use (aqueous, no risk of fire/explosion), have fewer degradation pathways and longer cycle life, tolerate wide SOC ranges, can be made from more sustainable materials (ie. Zn, I, Mn, Fe... I'm not counting V) and as far as manufacturing them... well, we can test and assemble small-scale ones in our apartments. The same cannot be said for Li-ion, where you would have to handle anhydrous propylene carbonate solvent and fluorinated salts. This general barrier of having expensive equipment (like a glovebox, Karl-Fisher titrator, etc) scales up to the manufacturing line in terms of the strictness and purity required. Flow batteries, on the other hand, are more similar to building a small chemical reactor, and water is always easier to work with than hazardous solvents. There are still plenty of challenges, of course...
These are some reasons why I think it's still interesting to work on flow batteries even though Li-ion has come down a lot in price. I think it's possible to eventually get to something cheaper than Li-ion or lead-acid, with longer cycle life, safe, and more sustainable - the main downside being less energy density.