Empire State Review Contributor 
In a significant leap forward for energy technology, researchers from the University of Adelaide announced on June 22, 2025, the development of a new dry-process zinc-iodine battery that promises to enhance the safety, lifespan, and scalability of energy storage systems. The innovation offers a viable alternative to lithium-ion batteries and aims to resolve long-standing limitations in aqueous battery design.
Unlike conventional wet electrolyte batteries, which often suffer from issues like fluid leakage, short-circuiting, and high manufacturing costs, this dry-process approach features a novel solid-state electrode architecture. The key breakthrough lies in fabricating the battery’s iodine-based cathode without the use of liquid slurries. Instead, researchers used a dry mix of iodine and binder materials, which they rolled into ultra-thick, freestanding cathodes capable of supporting high mass loadings—up to 100 milligrams per square centimeter.
This dense architecture allows the battery to achieve a significantly higher areal capacity—around 15.8 mAh/cm²—than earlier aqueous or even some lithium-ion cathodes. More importantly, it eliminates the polyiodide “shuttle effect” and iodine sublimation that typically plague iodine-based systems. By reducing these side reactions, the dry electrode design dramatically improves both performance and stability over long usage periods.
To address another chronic issue—zinc dendrite formation, which can lead to dangerous short-circuits—the team added a small amount of 1,3,5-trioxane to the aqueous electrolyte. During the charging cycle, this compound forms a thin polymer layer on the zinc anode. The result is a more uniform zinc deposition process, which suppresses dendrite growth and improves the overall safety of the battery.
In terms of performance, the battery has shown impressive results in laboratory tests. Coin cell prototypes retained nearly 99.8% of their initial capacity after 500 cycles, while pouch cells maintained 88.6% after 750 cycles. These numbers point to a highly durable design that could compete favorably with current-generation lithium-ion batteries in both longevity and efficiency.
The design is also well-suited for scalable manufacturing. Its compatibility with roll-to-roll electrode production techniques makes it an attractive option for mass production, significantly reducing fabrication costs and time. Researchers believe this dry-process method could be applied to other halogen-based systems, such as zinc-bromine, further expanding the scope of aqueous battery technology.
The implications of this development are far-reaching. For grid-scale energy storage—a critical component of integrating renewable energy sources like solar and wind—these batteries could offer a safer, more affordable solution. The non-toxic and abundant nature of zinc and iodine makes the battery more environmentally sustainable compared to lithium-based options, which rely on scarce and often geopolitically sensitive materials.
Applications could also extend to electric vehicles (EVs) and portable electronics. While the current prototype offers an energy density of around 45 Wh/kg, researchers are optimistic that refinements in design—such as lighter current collectors and electrolyte adjustments—could boost that figure to approximately 90 Wh/kg. If successful, this would bring the technology closer to competing directly with EV-grade lithium-ion batteries, opening doors for more sustainable electric transportation.
Industry response has been swift. Clean energy firms and venture capital investors are already in discussions with the University of Adelaide to explore commercialization paths. If pilot-scale production proves successful, the first commercially available dry-process zinc-iodine batteries could hit the market as early as 2026.
The project’s lead researchers emphasize that this battery is not just a lab experiment but a promising platform for future scalable, green energy solutions. With governments and industries worldwide pushing for safer and more sustainable battery technologies, innovations like this could become foundational in the next generation of energy infrastructure.
