1. Introduction
The current ever-growing energy demand, along with the environmental pollution caused by fossil fuels, makes necessary a shift towards cleaner and sustainable energy sources. However, the associated intermittency of renewable energies requires the utilization of energy storage devices, with rechargeable batteries, specifically lithium-ion batteries (LIBs), being one of the most popular choices [
1,
2]. Besides large-scale applications, such as grid-scale, LIBs dominate the market of portable electronic devices due to their high energy density and long cycle life, and also power EVs (electric vehicles), which globally accounted for nearly 14 million sales in 2023 [
3]. Nonetheless, this successful technology presents certain limitations. LIB production is limited by the scarce, costly, and unevenly distributed lithium resources [
4,
5,
6], and the prospects for their recycling [
7] are not yet encouraging enough. Emerging alternatives to LIBs based on abundant (hence, more economical) and worldwide available alkali metals, now under exhaustive research, are sodium-ion batteries (NIBs) [
8,
9,
10,
11,
12,
13,
14,
15,
16,
17,
18,
19] and potassium-ion batteries (KIBs) [
20,
21,
22,
23,
24,
25,
26,
27,
28,
29,
30]. Sodium (2.4 wt.%) and potassium (2.1 wt.%) are, respectively, the sixth and the eighth most abundant elements on the Earth´s crust, after oxygen (46.1 wt.%), silicon (28.2 wt.%), aluminum (8.23 wt.%), iron (5.63 wt.%) and calcium (4.15 wt.%) [
31]. Both NIBs and KIBs follow the same working principle as LIBs, where the corresponding alkali ions “rock” back and forth between the electrodes that build up the battery [
32]. In addition, as a result of their similar physicochemical properties, most of the knowledge acquired over the years, the kind of electrode materials and electrolytes used in LIBs, as well as manufacturing processes, could be, in principle, transferred to NIBs and KIBs, being a drop-in technology [
26,
33]. Regrettably, this is not so straightforward since sodium and potassium have larger ionic radii than lithium (see
Table 1), and hence, host electrodes in NIBs and KIBs must provide big enough sites to accommodate them within their structure. On the other hand, unlike LIBs, NIBs, and KIBs can benefit from using aluminum foil as the current collector in the anode since Na and K do not alloy with aluminum at low voltages. The replacement of copper with aluminum not only translates into battery cost [
20] and weight reductions, opening the possibility to bipolar-stacking [
23], but also into safety improvement, as the batteries can be transported and stored fully discharged [
34]. Nonetheless, despite the aforementioned similarities, KIBs possess three valuable advantages over NIBs (please see
Table 1):
1) K
+ has the smallest Stokes (or solvated) radius compared to Li
+ and Na
+ due to its weaker Lewis acidity, resulting in faster K
+ diffusion either in aqueous or non-aqueous electrolyte and, hence, would enable enhanced power capability, which is extremely beneficial for the quick charge and discharge requirement that the market demands lately [
24,
34].
2) The K
+/K standard reduction potential (vs. SHE) is lower than that of Na
+/Na and closer to the Li
+/Li one, thus guaranteeing a higher cell operating voltage and, therefore, theoretically overcoming the constrained energy density of NIBs [
20,
21,
23]. Indeed, K
+/K exhibits a lower potential than that of Li
+/Li in PC (propylene carbonate) [
35] and EC: DEC (ethylene carbonate: diethyl carbonate), encouraging the possibility that KIBs may achieve even higher cell voltages than LIBs, as long as the cathodes in KIBs displayed the same voltages as their LIBs analogues [
20].
3) Besides, K
+ intercalates into commercially available graphite anode electrodes conversely to Na
+, as we will further detail in the subsequent paragraphs. This represents a step forward towards the potential industrial production of KIBs, being truly a “drop-in technology”, which can be quickly transferred to standard LIB production [
26].
Table 1.
Comparison of some physicochemical, electrochemical, and economic properties of Li, Na, and K.
Table 1.
Comparison of some physicochemical, electrochemical, and economic properties of Li, Na, and K.
Properties |
Li |
Na |
K |
Atomic mass, u |
6.941 |
22.989 |
39.098 |
Melting point, ⁰C |
180.5 |
97.7 |
63.4 |
Atomic radius, pm |
145 |
180 |
220 |
Ionic radius, Å [36] |
0.76 |
1.02 |
1.38 |
Stokes radius in water, Å [37] |
2.38 |
1.84 |
1.25 |
Stokes radius in PC, Å [38] |
4.8 |
4.6 |
3.6 |
Voltage (A+/A) vs. SHE, 1 V [39] |
-3.04 |
-2.71 |
-2.93 |
Voltage (A+/A) vs. Li+/Li in PC, V [39] |
0 |
0.23 |
-0.09 |
Voltage (A+/A) vs. Li+/Li in EC: DEC, V [40] |
0 |
- |
-0.15 |
Theoretical capacity of graphite, mAh g-1 [41] |
372 |
111.72
|
279 |
Crust abundance, mass % [31] |
0.0017 |
2.4 |
2.1 |
Distribution [27] |
70% S. Am.3
|
Global |
Global |
Cost of carbonate [42], 4 US$ ton-1
|
13860 |
350 |
1540 |
Nonetheless, KIBs also present some disadvantages with respect to NIBs (as reflected in
Table 1), such as i) a low melting point of K metal, reducing the maximum operating temperature of the cell to 60 ⁰C (in case the anode is K metal), ii) a bigger K ionic radius, requiring cathode and anode materials with larger cavities to diffuse the K
+ and not hinder its kinetics, and iii) a higher cost of K-based carbonate (typically used as a precursor in the synthesis of K-based materials), whilst still much lower than the Li one.
Although KIBs are mainly envisaged for large-scale applications, a recent techno-economic analysis based on Hurlbutt
et al.´s model, carried out by Pasta
et al., [
26] also suggested that this technology could rival/compete with commercial LiFePO
4/graphite LIBs,
i.e., cobalt-free LIBs, for low-range EVs applications, both in terms of cost and specific energy. In fact, efforts are being performed in this regard; for example, the Group1 US company announced in 2024 their 1
st 18650 KIB production, composed of graphite anode and Prussian White cathode [
43]. However, KIBs still face several challenges that must be overcome before entering the real market, such as limited energy and power density, low K ion diffusion in solid electrodes, poor rate performance, large volume variations upon potassiation/depotassiation, and battery safety hazards [
24]. With the common goal of pursuing KIBs reaching the same destination as LIBs,
i.e., a real application, research, particularly in electrode materials, has been hectic since 2015. So far, the main classes of cathodes under investigation are layered transition metal oxides, Prussian blue analogues, polyanionic compounds, and organic materials [
44,
45,
46,
47]. In this review, we will explore the anode materials, focusing on the different types of intercalation materials, which are the most promising ones until today. We will provide a compilation of an updated bibliography, highlighting the most promising candidates based on the most recent advances. In addition, the shortcomings and key issues of this technology will be addressed, along with the possible strategies and future directions to follow.
6. Conclusions and Perspectives
This review emphasizes the potential of KIBs for several applications, such as EVs and large-scale stationary applications. The abundance and global distribution of potassium, as well as the lack of critical raw materials on their electrode components, conversely to LIBs, make KIBs as sustainable and low-cost as NIBs. Advantageously, KIBs are more appealing for high-power applications than NIBs due to the faster K+ diffusion in liquid electrolytes. In addition, if the K+ diffusion obstacle in solids is overcome, and an optimal electrode composition and electrode-electrolyte configuration are designed, high energy density and long-term KIBs could be reached, which will be competitive with LIBs - due to the proximity in their standard reduction potentials -. Nevertheless, KIBs are still in their infancy, and further investigations should be carried out to understand how their electrochemical performances could be boosted to make their commercialization a reality.
The main challenges are related to the electrochemical properties of the anode materials, and their reactivity and compatibility with a liquid electrolyte. Although great achievements have been made in the development of anode materials for KIBs, overcoming some of their issues (e.g., improving the ICE, specific capacity, long-term stability, and so on) is still necessary before moving from lab scale to the prototype or industrial level. Particularly, this work has comprehensively reviewed the recently reported intercalation anode materials for KIBs, such as carbon-based species and titanium- and vanadium-based oxides, with the aim of opening new avenues of research and developing competitive anode materials and, in turn, competitive KIBs.
Carbon-based materials are the best candidates as anode electrodes for KIBs - as are graphite and hard carbon, respectively, for LIBs and NIBs - mainly due to their low voltage of potassiation, easy synthetic route and flexibility to tune physicochemical and electrochemical properties during their fabrication. Among them, graphite seems to stand as the potential winning horse, but this remains to be proven. Therefore, graphite, soft- and hard-carbon materials are primarily the only viable option for KIBs. However, they still exhibit a great variety of challenges and issues, and are far from being the perfect anode materials.
Regarding the synthesis, the manufacture of carbon materials, such as graphite and soft carbon, requires high temperatures (
> 2500 ⁰C) and low heating rates (0.1-5 K min
-1), increasing significantly the energy consumption and, consequently, the production cost [
26,
112,
171]. The hard carbon could represent a better choice since they could be obtained at lower temperatures (< 1200 ⁰C). However, its synthetic yield is usually lower than 30% and, although the use of bio-waste as a precursor could reduce the market price, its chemical properties have a direct influence on the hard carbon final electrochemical properties [
172]. Therefore, new and cost-effective fabrication methods should be designed to make the carbon-based anode materials good candidates in terms of cost production.
As just mentioned, another important aspect is that the final properties of the soft- and hard carbon anode materials depend on a large variety of parameters, such as the precursor’s source and properties, pre-and post-treatment steps, annealing conditions (temperature, time, heating rate, inter atmosphere and its flux, and so on), etc. In other words, there is no standard synthesis protocol for soft- and hard-carbon anode materials.
In addition, the K+ storage mechanism is still controversial. In fact, several mechanisms have been proposed for graphite and hard carbon anodes in the last years, making it difficult to understand which properties are crucial for enhancing K+ storage, although again these are related to the fact that each investigation uses carbon anode with intrinsically different properties. Hence, it is not possible to extrapolate the results obtained on one type of carbon to other carbon-based materials, making synthetic production protocol standardization difficult.
Moreover, the techniques for characterizing carbon microstructure, pore properties, and K-storage mechanism are still limited, further complicating the standardization of carbon manufacturing. Therefore, not only should studies be performed on the material level to understand the process better, but additional techniques or new measurement protocols should be developed to understand and characterize the carbon-based material well.
The challenges related to the electrochemical properties of graphite, soft- and hard-carbon anode materials, in general, are their low ICE, limited specific capacity, poor rate capability and cycling stability, and large volume expansion upon (de)potassiation. Although multiple strategies have been reported in the last years, with excellent results, they are still insufficient to achieve performances similar to graphite or hard carbon in LIBs and NIBs, respectively. The main approaches are related to the engineering of electrodes and electrolytes, such as heteroatom doping, control of particle size and shape, surface modifications, and adjustment of the chemistry and/or formulation of the electrode and/or electrolytes.
For instance, heteroatom-doping is commonly used to enhance the K
+ storage capacity, enlarging the interlayer distance of graphite or creating absorption sites on the surface of the carbon anode and so enhancing its electronic conductivity. Nonetheless, as mentioned in the review, the impact of the doping positions and the cooperative effects of doping with multiple heteroatoms on the K ion storage performance should be examined in detail. Indeed, the addition of heteroatom(s) usually induces a large specific surface area on the carbon anode, significantly increasing the side reactions between the active material and the electrolyte, thus drastically reducing its reversibility (and affecting its ICE) [
172]. Therefore, in the heteroatom-doping strategy, an equilibrated balance between doping and the specific surface area formed is critical.
Another possible strategy to boost the specific capacity, as well as the rate performance and cycle stability, is the use of 1D (CNTs, CNCs, CNFs, etc.) and 2D (graphene) carbon-based materials. However, these materials are not an alternative for real applications due to their very low bulk density (even lower than hard carbon), which leads to poor volumetric energy densities. In our opinion, these 1D and 2D carbon-based materials would be best used in electrode composites, which could be beneficial, for instance, to increase the electronic conductivity or behave as a matrix to limit and retain the volume expansion upon cycling.
The benefits of using 1D and 2D carbon-based materials for composites with titanium- and vanadium-based oxides have been reported as well. Titanium-based compounds (vanadium-based materials are less attractive in terms of sustainability and toxicity) are often coated and/or composed with 1D/2D carbons to enhance their poor electronic conductivity. Although their applications in KIBs are currently limited due to their low conductivity and restricted K+ diffusion, these non-carbonaceous intercalation anode materials should be seriously considered in the near future since they show excellent chemical and thermal stability, non-toxicity, abundance, and exhibit higher average operating voltage than carbon-based anode, making them safer anodes.
On the other hand, despite alloy- and conversion-type materials (not addressed in this review) could be considered second-generation anode electrodes due to their higher theoretical specific capacities, the reality is that they exhibit significant capacity fading upon cycling caused by i) a large volume expansion, resulting in aggregation and pulverization of the active material, and ii) formation of an unstable SEI, newly exposing its surface to additional decomposition reactions (during the charge/discharge processes). Considering the larger ionic radius of K ion, these types of anode materials are not an option (at least at this stage) for KIBs. Nonetheless, like in LIBs, their composites with graphite (the latter in a dominant proportion) could be an attractive solution.
Moving back to the most promising anode materials, graphite, soft- and hard carbon, their ICE, reversible capacity, and cycle stability can be controlled by electrode and electrolyte engineering.
On the one hand, electrode composition and surface engineering are crucial because they could block the degradation of the electrode surface resulting from contact with the electrolyte. The binder, which is typically considered an inert component of the electrodes, contributes to the SEI formation and, in turn, to the first reversibility (i.e., ICE). It is not clear yet, but aqueous binders, such as CMC, could participate in the formation of the SEI due to their decomposition upon reduction, protecting the carbon-based electrode surface from the first cycle, in addition to being beneficial in terms of sustainability in the electrode production. Another approach to improve the ICE, and consequently reversible capacity and long-term stability, could be the creation of some protective surface coating and/or resort to an artificial SEI that could prevent the electrode degradation and tune the electrolyte decomposition reaction with the electrode and, in turn, the SEI formation.
On the other hand, the electrolyte selection is another critical parameter, as already demonstrated for LIBs and NIBs. In the case of LIBs, the addition of EC co-solvent, which prevents the exfoliation of graphite upon cycling and helps form a stable SEI, was crucial for its commercialization in 1991 [
173]. In NIBs, although carbonate-based electrolytes are mainly used, it has been reported that non-carbonate-based electrolytes are better candidates because they do not form carbonate species on the SEI, which are highly soluble in the electrolyte, providing higher stability upon cycling [
174,
175]. In the case of KIBs, the presence of carbonate-based species, either as solvent or additives, such as FEC, lead to not so favorable or even detrimental electrochemical performance. Besides, the standard KPF
6 salt is not the best choice since, as already mentioned in this review, it does not form enough inorganic species upon reduction to stabilize the K-based SEI. Ether-based and KFSI-salt-based electrolytes are one possible solution. However, it is known that they exhibit poor oxidation stability, also causing Al current collector corrosion at high potential, not being, in general, compatible with high-voltage cathodes, and hindering the development of high energy density KIBs. Although highly concentrated KFSI-based electrolytes ameliorate the stability against aluminum corrosion, this comes at a price (literally, it increases cost), and do not solve its oxidation stability problem. This clearly reveals the need to continue developing new salts and electrolytes for KIBs. The recently reported results on the use of non-flammable and fire-retardant electrolytes,
i.e., TEP or TMP, should be the way forward in the search for safe KIBs.
Therefore, it is paramount that upcoming studies focus on the overall electrode composition as well as on the compatibility between electrode-electrolytes, emphasizing the need to develop new materials and not directly transfer the acquired knowledge from LIBs and NIBs.
To identify which electrode composition and electrolyte chemistry are best for achieving carbon-based anode materials (e.g., graphite, soft- and had-carbon) with high ICE and capacity, the following analysis has been carried out. Graphite: PVDF electrode composition tested in 0.8 M KPF
6 in EC: DEC electrolyte (see
Table 2) [
41] i.e., the parameters most identical to those used for commercial LIB technology, have been taken as reference values. The ICE and capacity are then compared, where only one parameter (i.e., binder, electrolyte salt and solvent, or active material properties) has been modified and the exhibited ICE or capacity is higher than that of the reference system. Exceptionally, 0.8 M KFSI in EC: DEC can be considered as a second reference value for graphite (
Figure 4a). Nevertheless, it should be mentioned that it is impossible to accurately contrast the reported work on graphite, soft- and hard carbon-based anode materials to understand their optimum properties and find the best electrode-electrolyte configuration because there is no standardized material, electrode composition, electrolyte chemistry, formulation, electrochemical cycling protocol, etc.
Figure 4 and
Figure 5 illustrate some critical properties to enhance the ICE and capacity of graphite and soft- and hard-carbon electrodes, respectively.
For the particular case of graphite, the ICE (
Figure 4a) is upgraded by tuning the electrode and/or electrolyte chemistry. Indeed, higher reversibility in the 1
st cycle could be attained by controlling the particle size of graphite (BM graphite) or replacing KFP
6 with KFSI - due to the formation of inorganic-rich SEI -, as mentioned above. However, these results suggest that the most critical parameters to obtain a high ICE (> 80%) correspond to the binder election and/or electrolyte solvent(s), both of which participate in the SEI formation. The best results (
Figure 4a) have been achieved with aqueous-based CMC binder, KFSI salt and EC: DEC carbonate solvents, or with PVDF in a non-carbonate and non-flammable based TEP solvent.
Regarding the capacity after 50-100 cycles (
Figure 4b), similar behavior is observed,
i.e., the binder and electrolyte chemistry are decisive. The comparison indicates that the most critical component is again a good combination between the binder and electrolyte. Indeed, the highest capacity (after 100 cycles) reported for the graphite is achieved by using CMC: SBR binder, TMP solvent and DTD additive. Unfortunately, there is no direct correlation between high ICE and high capacity. For example, the graphite: CMC electrodes tested in 1M KFSI in EC: DEC exhibit the highest ICE (89%); however, the capacity they deliver (not included in
Figure 4b) is only of 230 mAh g
-1. For its part, the graphite: CMC: SBR electrodes tested in 1M KFSI in TMP + 6wt.% DTD exhibits a slightly lower ICE of 86.6%, but the highest capacity retention. The combination of these results reveals that the optimum electrode and electrolyte chemistry should be based on aqueous binders (CMC, SBR) with KFIS and non-flammable electrolytes (TMP, or probably TEP). Additionally, the use of non-carbonate-based additives, such as DTD seems to be crucial, where its concentration might be optimized. Hence, further studies should be carried out to explore the possibility of developing superior graphite anode electrodes for KIBs.
A similar analysis has been performed with soft- and hard-carbon electrodes (values from
Table 5), the other promising carbon-based anode materials. In terms of ICE (
Figure 5a), there is not enough reported work to draw an accurate conclusion. However, the soft carbon material exhibits a higher ICE in comparable systems, e.g., electrodes based on PVDF binder and tested in 0.8M KPF
6 in EC: DEC electrolyte. More findings could be found in terms of delivered capacities (
Figure 5b). Both soft- and hard-carbon anode electrodes deliver higher capacities than graphite – easily explained by the adsorption phenomenon they experience in addition to the intercalation mechanism -, which could be further increased by engineering the active material, such as changing the carbon precursor or resorting to heteroatom doping. In fact, heteroatom doping is one of the most promising strategies for enhancing the specific capacity and long-term stability of hard carbon [
176].
In summary, this analysis demonstrates the superior performance - regarding certain electrochemical properties (such as ICE and capacity) here evaluated - of soft- and hard-carbon anodes relative to graphite for KIBs. Besides, it should be considered that soft- and hard-carbon anode electrodes were mainly tested with carbonate-based electrolytes, and as shown for graphite, the alternative chemistries, such as KFSI, glymes or non-flammable electrolytes, could even lead to superior performances and be the path to follow.
Finally, although this review has focused on anode intercalation materials for the practical application of KIBs, the current performance evaluation is still insufficient and mainly based on material-level and half-cell testing. Thus, paying more attention to full cell testing protocols from lab to device level is necessary, avoiding using K metal as a counter electrode, which could alter the results. In addition, it is advisable to go one step further, focusing on the cathode-anode degradation mechanism of the full cell, as well as moving to cell device configuration.