Comprehensive review for zinc powder anodes: Significance, optimizing design, and industrial feasibility in zinc-ion batteries

Abstract

Rechargeable aqueous zinc-ion batteries (AZIBs) have emerged as promising candidates for sustainable energy storage systems, due to their low cost, enhanced safety, and high-power density. Nevertheless, practical applications are still hampered by inherent challenges related to the zinc (Zn) foil anode, including dendrite formation and interfacial parasitic reactions. As an alternative, Zn powder (Zn-p) presents significant potential, owing to its cost-efficiency, large-scale processability, versatility, and industrial applicability. Notably, the amount of Zn-p can be accurately regulated, enhancing Zn anodes utilization efficiency and facilitating industrial applications. Nevertheless, the unique spherical microstructure of Zn-p introduces specific challenges, such as complex ion pathways, uneven Zn deposition, and a complicated electrode manufacturing process, which directly impact the battery performance, safety, and lifespan. In pursuit of a deeply comprehensive relationship between electrode structure and electrochemical performance for Zn-p-based anodes, this review provides a detailed examination of the working mechanisms of Zn-p-based anodes, while also identifying both the opportunities they present and the unique challenges they face. Moreover, the latest research progress is summarized, with a focus on innovative design strategies for optimizing Zn-p-based anodes. The relationship between these structural aspects and the resulting electrochemical performance, including safety, cycle life, and capacity, is thoroughly examined to provide a deeper understanding of how to achieve optimal battery system design and performance. Meanwhile, the fabrication processes and potential for practical flexible applications of Zn-p-based batteries were detailed. Finally, prospects for achieving high performance and practical utilization of Zn-p-based anodes are offered, providing scientific guidance for their practical application.