Form Energy has validated a new class of iron-air batteries capable of providing 100 hours of energy storage at a fraction of the cost of lithium-ion. This technology utilizes the reversible oxidation of iron to stabilize renewable energy grids during extended periods of low wind or sun.
TLDR: Researchers at Form Energy have developed an iron-air battery that stores electricity for four days, addressing the intermittency of renewable power. By utilizing the natural process of rusting, the system offers a low-cost, scalable alternative to lithium-ion for long-duration grid stabilization and decarbonization efforts.
The global transition toward renewable energy faces a persistent challenge: the intermittency of wind and solar power. While lithium-ion batteries have become the standard for short-term storage, they remain prohibitively expensive for durations exceeding a few hours. Researchers at Form Energy, a private-sector technology firm, have recently validated a multi-day storage solution using iron-air battery chemistry. This technology leverages the basic chemical process of rusting to store and discharge electricity at a cost estimated to be less than one-tenth that of lithium-ion systems.
The fundamental mechanism of an iron-air battery involves the reversible oxidation of iron. During the discharge cycle, the battery breathes in oxygen from the air and converts iron metal into iron oxide, commonly known as rust. This chemical reaction releases electrons that flow through an external circuit to power the grid. When the battery is charged, an electrical current converts the rust back into metallic iron, releasing oxygen back into the atmosphere. This cycle can be repeated thousands of times without significant degradation of the active materials.
One of the primary advantages of this system is the abundance and safety of its components. Iron is one of the most plentiful elements on Earth, and the electrolyte used is a non-flammable, water-based solution. This eliminates the fire risks associated with lithium-ion batteries and simplifies the supply chain, as it does not rely on rare or geopolitically sensitive minerals like cobalt or nickel. The modular design allows for scaling to meet the needs of large-scale utility projects, with individual units grouped together to form massive storage blocks.
Laboratory testing and pilot programs have demonstrated that these batteries can provide continuous power for up to 100 hours. This duration is critical for maintaining grid reliability during extended periods of low wind and solar output that can last several days. By bridging these gaps, iron-air technology enables a higher penetration of renewable energy without the need for backup natural gas plants. The validation of this technology marks a shift from experimental chemistry to industrial-scale application.
The company has moved beyond the laboratory phase, breaking ground on a major manufacturing facility in West Virginia. This site, located on the grounds of a former steel mill, symbolizes the shift from traditional heavy industry to clean energy manufacturing. The facility is designed to produce hundreds of megawatts of storage capacity annually, targeting the specific needs of utility companies looking to decarbonize their portfolios. Initial deployments are focused on replacing aging coal and gas infrastructure with clean, long-duration alternatives.
The integration of these systems into existing electrical infrastructure requires sophisticated power electronics to manage the conversion between direct current and alternating current. Unlike the rapid response times of lithium-ion, which are ideal for frequency regulation, iron-air batteries are optimized for steady, long-term output. This makes them a complementary technology rather than a direct competitor. While lithium-ion handles the minute-to-minute fluctuations, iron-air provides the foundational energy reserve needed for seasonal or weather-related shifts in production.
Future research is now directed toward optimizing the efficiency of the oxygen-reduction reaction and extending the cycle life of the iron electrodes. Engineers are also exploring ways to integrate advanced sensors and machine learning algorithms to monitor the health of the cells in real-time. As the first commercial-scale projects prepare to come online in 2025, the success of iron-air technology could redefine the economics of the global power grid. This advancement provides a tangible pathway for achieving 100% renewable energy systems by solving the long-duration storage puzzle.
Mark Davis serves as the Senior Correspondent for Energy, Climate, and Resource Economics at Just Right News. In an era where the conversation around the environment is often dominated by alarmism and top-down mandates, Mark provides a vital, market-oriented perspective on the complex forces shaping our world. As the lead voice behind the acclaimed feature series “Power and the Planet,” he explores the intersection of environmental policy, global energy markets, and the fundamental economic principles that sustain modern civilization.
Mark’s pragmatic approach to resource management was forged in the high desert of his hometown, Albuquerque, New Mexico. Growing up in a region defined by both its breathtaking natural beauty and its rugged, resource-dependent landscape, he developed an early appreciation for the delicate balance between conservation and utilization. New Mexico’s unique position as a hub for both traditional energy production and cutting-edge scientific research provided Mark with a front-row seat to the evolution of the American energy sector. This upbringing instilled in him a deep-seated belief that true environmental stewardship is inseparable from economic prosperity and technological innovation.
Now based in Boulder, Colorado, Mark operates from the heart of the nation’s climate research community. While Boulder is often seen as a bastion of environmental idealism, Mark utilizes his post to provide a necessary counterweight, grounded in the realities of resource economics. He understands that energy policy does not exist in a vacuum; it has tangible consequences for the American taxpayer, the stability of the national power grid, and the strength of the domestic manufacturing sector. By reporting from the front lines of the climate debate, he is able to challenge prevailing narratives with hard data and a commitment to the principles of the free market.
Throughout his tenure at Just Right News, Mark has distinguished himself by focusing on the “Resource Economics” aspect of his beat. He frequently highlights the hidden costs of rapid energy transitions and advocates for an “all-of-the-above” energy strategy that prioritizes American energy independence. His work often shines a light on the geopolitical implications of resource scarcity, arguing that a secure nation must first be an energy-secure nation. Whether he is analyzing the impact of federal land-use regulations or investigating the supply chains required for new technologies, Mark remains focused on how policy decisions affect the lives and livelihoods of everyday citizens.
In “Power and the Planet,” Mark continues to bridge the gap between complex scientific concepts and the economic realities facing the country. He rejects the false choice between a healthy environment and a thriving economy, instead seeking out solutions that leverage American ingenuity and private-sector competition. For Mark, reporting on the climate is not about following the latest trends, but about ensuring that the conversation remains tethered to the foundational values of liberty, property rights, and fiscal responsibility. His contributions ensure that Just Right News readers receive a comprehensive, clear-eyed view of the challenges and opportunities defining the future of our planet.