Form Energy to Utilize New Iron-Air Battery Technology That Is Easy to Build, Maintain, and Recycle at End of Life.
Form Energy, based in Somerville, Massachusetts, is planning to transform an old paper mill in Lincoln, Maine, into the site of the largest battery installation in the world, capable of providing 85 MW to the power grid. While other energy storage solutions, such as pumped hydroelectric storage, have much higher capacity, this will be the first project of its kind using only battery technology, as reported by Interesting Engineering on August 16.
Design of the iron-air battery system by Form Energy. (Photo: Form Energy).
As the world shifts towards clean energy with increasingly popular wind and solar power plants, the demand for large-scale renewable energy storage solutions has become urgent. Although pumped hydroelectric storage can provide substantial capacity, this solution requires complex construction processes and is not feasible at every location.
Lithium-ion batteries are currently the only flexible energy storage solution available. However, this technology is quite expensive, limited in duration, and comes with risks, especially in high-temperature areas. Form Energy employs iron-air battery technology, which is cost-effective at one-tenth the price of lithium-ion batteries, can provide energy for 100 hours, is non-flammable, and easier to recycle.
Iron-air batteries use simple materials including iron, water, and air. They rely on the phenomenon of rusting and a non-flammable aqueous electrolyte. When the battery discharges, it uses oxygen from the air to convert metallic iron into iron oxide or rust. During charging, iron oxide is converted back to iron, releasing oxygen.
A large iron-air battery module is roughly the size of a washing machine. It contains about 50 cells, each approximately one meter tall, submerged in the electrolyte. Multiple modules are then stacked into a cage for protection, forming a megawatt-scale battery cluster. Form Energy will use these clusters to store 85 MW of electricity for 100 hours, making it the largest battery in the world.
To date, Form Energy’s completed projects include battery systems with several MW of capacity, primarily built for electric utility companies. In Lincoln, Maine, the company is undertaking an independent project. In addition to setting a record, the project aims to address the energy scarcity issues that the states in the region are facing. The area has a limited supply of fossil fuels due to environmental regulations prohibiting the construction of new pipelines. Therefore, the entire region relies on liquefied natural gas to meet the increasing electricity demand.
Form Energy’s battery system will help store renewable energy from wind and solar farms, ensuring the power grid meets demand when production capacity is low. The U.S. Department of Energy (DOE) has allocated $147 million in funding for the project, which is expected to be operational by 2028.
