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Build Your Own Edison Iron-Nickel Battery at Home: Step-by-Step Guide & Troubleshooting Tips

robertododo 33822 49
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Can I build an Edison nickel-iron battery at home, and what are the main technical obstacles?

Yes, in principle it can be built at home, but the hard parts are making suitable electrodes and finding the right container. One reply says the materials and reagents are available today and that a test cell can be built in a small jar, with ferrous chloride for the iron side, hydrochloric acid for degreasing/pH control, and a plastic battery vessel as the biggest unresolved problem [#16946607] Another notes that the old industrial plate construction is not essential and suggests a nickel-plated steel electrode instead of trying to source perforated nickel sheet, using chemical nickel plating if needed [#16964181][#16966424] The same discussion points out that the cell should not be tall and narrow; at least one process needs a flat vessel, and the battery is sensitive to CO2 from air [#16946633] A contrary view is that home construction is practically impossible because sponge nickel and spongy iron plates are difficult to make, and the design has high internal resistance and poor low-temperature performance [#16923389][#16923292]
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  • #31 17084755
    Slak68
    Level 22  
    Posts: 635
    Help: 8
    Rate: 110
    This price is not a coincidence for 1 Ah?
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  • #32 17205434
    Slak68
    Level 22  
    Posts: 635
    Help: 8
    Rate: 110
    Hello. Have you tried anything else? any new contacts to buy batteries?
    I can get acid traction 840 Ah 2V for less than PLN 300 per piece.
    To take?
  • #33 17205850
    Slak68
    Level 22  
    Posts: 635
    Help: 8
    Rate: 110
    :) )
    It's easy to say - it's almost PLN 7,000 to spend ... even though the battery is 2-3 years old.
    Although, on the other hand, they give up to PLN 150 for scrap metal.
  • #34 17329516
    robertododo
    Level 13  
    Posts: 202
    Rate: 65
    Mr. Adam, how are the progress in the construction of the battery? Did you manage to create a goal? If so, we would like information on this matter.

    I found a text on the net about coating copper with nickel through the action of electricity. A very simple home remedy. I will quote him:

    "Hello to all home electroplating technicians.

    Today, in a fit of inspiration, I nickel-plated copper.

    A rather strange method, but it turned out to be interesting - i.e.:

    1. Water container
    2. Table salt + vinegar
    3. 12V 1.5A power adapter
    4. Copper element - to be covered with nickel - tube
    5. Nickel-plated element - in my case a Chinese screwdriver

    Nickel-plated screwdriver connected to the plus
    A copper tube connected to the minus additionally connected to a piece of aluminum.

    After a few hours of electrolysis and polishing the tube - the effect is satisfactory."

    What are you and others interested in doing this?
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  • #36 17604630
    adam_mk
    Level 20  
    Posts: 352
    Help: 16
    Rate: 34
    I'm not getting notifications.
    If I remember, I look here.

    The story that they used to have more knowledge or possibilities is a fairy tale.
    But...
    There's something about them!
    A lot of this knowledge is "forgotten" today because someone decided that "it does not pay off".
    If you look carefully, you can find all the information.

    A lot of time passed, but I did not give up the next steps. I'm planning some experiments over the holidays.
    I will describe what happened.

    adam m
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  • #37 17617284
    adam_mk
    Level 20  
    Posts: 352
    Help: 16
    Rate: 34
    I'm afraid it won't work.
    Too much profit for the gray nation and not enough for the bank and the government.
    After all, a citizen with his own autonomous off-grid power plant is not controllable.
    Several systems will not topple.
    But if it were to be in every cottage - there would be a problem.
    The mines would have to close.

    adam m
  • #38 17761073
    rfgaaja
    Level 9  
    Posts: 69
    Rate: 3
    Banks and the government can make money on anything, so that's no problem. The bigger problem is "I'm afraid that...", so get to work :)
    It won't topple the system because it's a natural evolution of technology. Hardly anyone has a battery at home and increasing their lifespan will not change that at all.
    Besides, they do not produce energy, so the state and the banks will earn the same.
    Have you already done something small?
  • #39 17761373
    adam_mk
    Level 20  
    Posts: 352
    Help: 16
    Rate: 34
    Several experiments.
    Very successful.
    Some conclusions and a little change of concept.
    - One of the processes requires a flat vessel, not a tall and narrow one.
    90 degree repositioning... :)

    I missed January...
    The days are getting longer and it's going downhill.

    adam m
  • #40 17781127
    robertododo
    Level 13  
    Posts: 202
    Rate: 65
    Adam, it's not the flu, but a bad diet and lack of sun, i.e. UVB radiation. The flu is a pharmaceutical invention. As for the dish. Can you describe the whole procedure in more detail? Please.
  • #41 17781855
    Slak68
    Level 22  
    Posts: 635
    Help: 8
    Rate: 110
    I'm interested too - actually, I could do some tests myself...
  • #42 17781883
    adam_mk
    Level 20  
    Posts: 352
    Help: 16
    Rate: 34
    Where I live now, there is no access to reagents...
    You have to drive 50km to the warehouse or wait a long time for sending (because it's ADR).
    I'm going to have some loose cash for these games in a while.
    The snow is coming off and it's getting warmer - and that makes me happy!
    The day is getting longer...

    adam m
  • #43 17953312
    robertododo
    Level 13  
    Posts: 202
    Rate: 65
    And the topic died. Nobody wants to talk about this anymore? Or maybe Mr. Adam would finally boast of his construction.
    Regards.
  • #44 17953812
    adam_mk
    Level 20  
    Posts: 352
    Help: 16
    Rate: 34
    The reagents finally arrived.
    The rest of the lumber is also lying and waiting.
    I think in the next few days I will move this problem further.

    adam m
  • #45 17966678
    martii
    Level 12  
    Posts: 29
    Rate: 4
    adam_mk wrote:

    Here you have a price list of good NiFe
    https://ironedison.com/images/products/Iron%2...t%20-%20Nickel%20Iron%20%28NiFe%29%202017.pdf
    adam m


    And who's buying it? - this price list is probably for show and sucked from the finger. It doesn't pay off at all.

    The Chinese will buy the same NiFe 48V 400Ah for about 8000 dollars, but you have to take the whole container.

    Currently, for example, for $8,000 you can assemble a 48V 400Ah battery based on LTO technology (lithium titanium batteries). Main features: 30,000 cycles (80-100 years of operation with a slight loss of capacity) - work up to -30, charge at sub-zero temperatures, low self-discharge, light, can peak at 15C. Full charge in < 10 min. The total weight is about 250 kg.

    For about $1,500, you can rip a wrecked car battery with a similar capacity, but unfortunately with some disadvantages related to low temperatures and 5x shorter life. Of course, this is the price in the USA - there is not very cheap transport to the EU, but there will be more and more of it (in 2-3 years) and in Europe at a slightly higher price. Least effort to run it. The problem is the small offer of inverters that will turn 400V DC into 240AC. But the package can be taken apart and make your own configuration.

    Acids are super expensive because they are replaced too often.

    Martin
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  • #46 17982399
    robertododo
    Level 13  
    Posts: 202
    Rate: 65
    And the topic died. Nobody wants to talk about this anymore? Or maybe Mr. Adam would finally boast of his construction.
    Regards.
  • #47 19479033
    batot
    Level 16  
    Posts: 345
    Help: 3
    Rate: 66
    Mr. Adam is a storyteller for me.
    For 4 years he was washing people's eyes and they didn't show one photo of his works, which is a pity.
    I am looking for something that can store a lot of energy cheaply.
    If it's all fairy tales, I'll probably direct my attention to the storage of electricity in H2, the more that we have already done everything except the tank with which there is a problem.
    But that's a topic for another episode.

    Regards.
  • #49 21285430
    TMK_M
    Level 22  
    Posts: 670
    Help: 38
    Rate: 23
    Refreshing the topic. As I wanted to do according to the instructions of the latest gpt hut, in the course of preparing detailed instructions for the manufacture of electrodes, I got a notification that the content was forbidden and was reported.
    How can you not believe in conspiracy theories?
  • #50 21893729
    jak666
    Level 8  
    Posts: 86
    Rate: 6
    Hello is it still possible to buy nickel-iron batteries somewhere?
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Topic summary

✨ The discussion revolves around the construction of Edison iron-nickel batteries at home, addressing the perceived lack of resources and knowledge on the topic. Participants highlight both advantages and disadvantages of these batteries, such as their ability to handle high charging currents and their performance issues at low temperatures. The complexity of sourcing materials like sponge nickel and spongy iron is debated, with some asserting that modern chemistry allows for feasible home construction. Various methods for electrode preparation, including nickel plating and the use of hydrochloric acid for degreasing, are discussed. The conversation also touches on the historical context of these batteries and their current applications, alongside comparisons to other battery technologies like nickel-cadmium and lithium-based systems. Participants express interest in sharing progress on their own experiments and seek advice on sourcing materials and techniques.
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FAQ

TL;DR: Nickel-iron (Ni-Fe) batteries last up to 11 000 charge cycles, and "You can!" build one at home [Elektroda, adam_mk, post #16946607][IronEdison, 2017]. Here’s your concise DIY roadmap, cost ranges, safety caveats, and troubleshooting tips.

Why it matters: A century-old chemistry may still be the most durable, low-maintenance storage for off-grid renewables.

Quick Facts

• Cycle life: 8 000 – 11 000 cycles at 80 % depth-of-discharge [IronEdison, 2017]. • Charge rate: up to 1 C (e.g., 100 A for 100 Ah) without damage [Elektroda, robertododo, post #16925419] • Self-discharge: approx. 1 % day⁻¹ at 25 °C [IronEdison, 2017]. • Cell cost (retail): ~USD 2.4 – 2.9 Ah⁻¹ for 100 Ah modules [IronEdison, 2017]. • Electrolyte: 20 – 30 % KOH + 1 % LiOH, pH ≈ 14 [Battery University].

Why pick nickel-iron over lead-acid or lithium?

Ni-Fe tolerates deep discharge, overcharge, and high current. Properly maintained, cells exceed 30 years and 8 000+ cycles [IronEdison, 2017]. Electrolyte is non-toxic compared with lead or cadmium. One user notes their “indestructibility” [Elektroda, Krzysztof Kamienski, post #16923389] Drawbacks are weight, size, and cost.

What performance penalties should I expect?

Expect high internal resistance, giving lower power density [Elektroda, Krzysztof Kamienski, post #16923389] Capacity drops about 30 % at −10 °C [IronEdison, 2017]. Self-discharge runs ≈1 % per day. Gassing above 1.65 V cell⁻¹ forces distilled-water top-ups.

How do I assemble a jar-size test cell?

  1. Nickel-plate one steel sheet; rust-clean another with 10 % HCl [Elektroda, adam_mk, post #16952299]
  2. Roll each into a cylinder, separate with porous polypropylene.
  3. Submerge in KOH, vent the lid. Charge at 1 A until voltage stabilises at 1.45 V.

What charging protocol keeps the cell healthy?

Constant-current at 0.5–1 C, then constant-voltage 1.55 V cell⁻¹ until current falls below C⁄20. Allow gassing; top up water monthly. Never exceed 1.65 V to limit electrolyte loss [IronEdison, 2017].

How do I fix CO₂ poisoning of the electrolyte?

KOH slowly converts to K₂CO₃, raising internal resistance. If specific gravity rises >1.30 or capacity falls 20 %, drain, rinse with de-ionised water, refill fresh KOH. Users report capacity recovery within two cycles [Elektroda, adam_mk, post #16946633]

What does a small DIY cell cost?

Lab chemicals and steel cost ~USD 15. Nickel salts drive cost: 100 g NiSO₄ ≈ USD 12. A 10 Ah prototype totals ~USD 60—about USD 6 Ah⁻¹, double factory scale [IronEdison, 2017].

Is Ni-Fe really used in rail or military systems?

Rail signal systems still deploy sealed Ni-Cd, not Ni-Fe, per field technician note [Elektroda, zworys, post #17059656] Historic Soviet locomotives employed Ni-Fe, but most fleets switched by 1990s [UIC Report, 2004].

What edge-case failure should I watch for?

Iron electrode passivation can occur after long float charge, causing 0 V open-circuit. Short-circuit for 10 s or deep-discharge to 0.6 V revives activity in 90 % of cases [Battery Maintenance Manual, 2020].
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