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In situ regeneration engineering enables low-cost and high-rate Na2+2xFe2−x(SO4)3 cathodes from industrial byproducts
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DOI：10.1016/j.ensm.2026.105452.png)
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Abstract
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Alluaudite-type Na2+2xFe2−x(SO4)3 is considered as a promising cathode for large-scale energy storage due to its high structural stability and cost-effectiveness. However, due to low theoretical specific capacity, NFS still exhibits insufficient overall cost competitiveness, and it also suffers from low intrinsic electrical conductivity. Here, we propose a direct regeneration strategy based on industrial byproducts to prepare a low-cost and high-conductivity Na2.56Fe1.65Mg0.05Mn0.014Al0.006(SO4)3 cathode. Compared to traditional synthetic routes for pure compounds, the direct degeneration of industrial byproducts can reduce iron source costs by approximately 83%. In addition, Mg, Mn, and Al impurities from industrial byproducts are in situ doped into the polyionic framework, achieving functionalized utilization. Mg/Mn/Al co-doping not only induces strong interactions with oxygen to stabilize the crystal structure, but also decreases Na+ migration energy barriers and enhances the electrical conductivity. Na2.56Fe1.65Mg0.05Mn0.014Al0.006(SO4)3 exhibit low lattice strain and uniform ion concentration distribution during electrochemical processes, demonstrating excellent rate capability and cycling stability. It shows 100% capacity retention after 1,500 cycles at 3 C, and delivers a high discharge capacity of 50.16 mAh g−1 at 30 C. This study provides a scalable route for the valorization of industrial waste and the development of low-cost, high-performance polyanionic cathodes for sodium-ion batteries.
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