R&D
World’s first high-power aluminum-ion battery system for energy storage
For the first time, a complete aluminum-graphite-dual-ion battery system has been built and tested, showing that lithium-free, high-power batteries can deliver stability, fast response, and recyclability for next-generation grid applications.
By
Marija Maisch
Dec 05, 2025
R&D
Technologies
Aluminum-graphite-dual-ion battery system consisting of pouch cells, battery module, battery management system and quantum sensor. | Image: Andreas Scheunert / Fraunhofer IISB
In a milestone for lithium-free battery technology, the collaborative R&D project INNOBATT, led by the Fraunhofer Institute for Integrated Systems and Device Technology (IISB), has completed a battery system demonstrator based on aluminum-graphite-dual-ion batteries (AGDIB). The demonstrator confirms the stability of this new cell chemistry not only in laboratory conditions but also under realistic operational scenarios.
The rechargeable aluminum-ion battery is a cost-effective, non-flammable energy storage technology that uses easily obtainable active materials – aluminum and graphite. With natural graphite as the cathode material, AGDIB cells can achieve energy densities of 160 Wh/kg and power densities exceeding 9 kW/kg. As a high-power storage device, the aluminium ion batteries can be charged and discharged rapidly at high C-rates, enabling fast-response applications.
According to Fraunhofer IISB, the reversible chemistry allows over 10,000 cycles at 100% depth of discharge (DoD) in laboratory test cells, with nearly 100% Coulombic efficiency and energy efficiency above 85%. The corrosion-resistant multi-layer pouch cells developed for aluminium ion batteries have capacities of up to 200mAh, achieving more than 1,000 cycles for 4-layer 200mAh cells at 6C and over 7,000 cycles for single-layer 30mAh cells at 30C.
With such capabilities, aluminium-ion batteries show great potential for stationary and hybrid mobile applications, particularly as USP systems and high-performance storage devices for dynamic grid stabilization, where frequent low-energy micro-cycles demand high power rather than high energy density.
While many new lithium-free battery technologies remain at the lab scale, system-level demonstrators are rare. Within the INNOBATT project, a full battery system demonstrator has now been established after prior scaling of AGDIB technology to small-size pouch cells, Fraunhofer IISB reported in late November. Development focused on the entire value chain: sustainable lithium-free cell chemistry, integration of a wireless battery management system (BMS), bidirectional quantum-based current sensing, and recyclability.
In a realistic test case, the demonstrator integrates eight AGDIB pouch cells with a wireless BMS based on the open-source foxBMS® platform, featuring secure RF communication and a diamond-based quantum sensor for high-resolution current measurement.
Active materials and cell design were optimized to improve stability, reliability, and reproducibility. The battery module was assembled in a 4s2p configuration, with a BMS-Slave communicating wirelessly with the BMS-Master. The quantum sensor, based on NV centers in diamond, measures currents over five orders of magnitude, capturing both small and large dynamic currents with high precision.
This system successfully validates the high-power capabilities of AGDIB chemistry for grid stabilization, Fraunhofer IISB said. Results previously observed at the cell level were confirmed at the module level using real-frequency data to emulate instantaneous reserve applications. The system maintained stable performance under dynamic high-current loads at 10C, demonstrating AGDIB’s scalability through successful cell manufacturing, interconnection, and system integration. Unlike many conventional battery systems, AGDIB supports very high charge and discharge rates, making it well-suited for applications like providing virtual inertia to the grid.
Recyclability was a core consideration throughout development. Cell materials can be separated physically without toxic chemicals, enabling closed material cycles. The module design follows a design-for-recycling strategy, exceeding current EU regulatory requirements for battery recycling efficiency and showcasing a sustainable, future-ready energy storage system.
While many new Li-free battery technologies are examined on lab-size cell level, battery system demonstrators employing new cell chemistries remain rare. However, such a battery system demonstrator based on AGDIB has now been set up within the INNOBATT project after scaling the technology to small-size pouch cells in previous research projects first, Frauenhofer IISB, the INNOBATT project consortium leader, said in late November. The development of this innovative battery system focuses on the whole value chain, from a sustainable Li-free cell chemistry over integration of wireless battery management system (BMS) and bidirectional quantum-based current sensor technologies to recyclability considerations.
In a realistic test case, the INNOBATT demonstrator proves the stability of the new type battery cells. Integrating eight AGDIB pouch cells with a wireless BMS based on the open source BMS platform foxBMS® from Fraunhofer IISB with secure radio frequency based (RF) communication, the prototype also features a novel diamond-based quantum sensor for high-resolution current measurement.
AGDIB active materials and cell design were improved to increase stability and reliability of the cells and ensure reproducible performance metrics. This allowed for a proper cell matching despite the manual manufacturing technology. The battery module was assembled in 4s2p configuration, employing a BMS-Slave with a safe wireless RF communication to the BMS-Master. The quantum sensor is based on NV-centers in diamond. In comparison to conventional current sensors, the measuring range covers five orders of magnitudes. Consequently, both small and large dynamical currents can be measured with a very high resolution.
This battery system successfully validates the Al-ion based cell chemistry and its high-power capabilities for grid stabilization applications. Previously obtained results on cell level could be verified within the whole battery module by emulating instantaneous reserve applications based on real frequency data. The system proves stable performance with dynamic high current loads at 10C over long time periods and therefore demonstrates AGDIB’s ability for upscaling via successful cell manufacturing, cell interconnection and system integration. A major advantage of AGDIB is that it allows for very high discharge rates and, unlike many established battery systems, also high charging rates, as required for grid applications (e.g. providing virtual inertia).
The recyclability of the cells and modules was carefully considered during development. Cell recyclability was assessed through a physical separation process that eliminates the use of toxic chemicals, thereby facilitating the establishment of closed material cycles. The module design followed a design-for-recycling strategy, surpassing current EU regulatory requirements for battery recycling efficiencies and leading to the advancement and demonstration of this sustainable energy storage system.
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