An example of a lab-scale prototype of the system called a flow cell. Credit: Gretchen Ertl
A New Dawn for Electric Aviation
In a groundbreaking development, researchers at the Massachusetts Institute of Technology (MIT) have unveiled a sodium-air fuel cell that could revolutionize electric aviation. This innovative technology not only offers a significant boost in energy density compared to traditional lithium-ion batteries but also actively captures carbon dioxide (CO₂) from the atmosphere during operation.
The Science Behind the Innovation
Traditional lithium-ion batteries have long been the cornerstone of electric vehicles, but their energy density limitations have hindered their application in aviation. MIT’s new fuel cell addresses this challenge by utilizing liquid sodium metal as fuel, which reacts with oxygen from the air to generate electricity. A solid ceramic electrolyte facilitates the movement of sodium ions, while a porous air electrode enables the electrochemical reaction. This design achieves an energy density of over 1,500 watt-hours per kilogram at the component level, surpassing the 1,000 Wh/kg threshold deemed necessary for practical electric flight.
The research team, from left to right: Saahir Ganti-Agrawal , Karen Sugano, Sunil Mair, and Yet-Ming Chang. Credit: Gretchen Ertl
Environmental Benefits: Capturing CO₂ Mid-Flight
Beyond its impressive energy performance, the sodium-air fuel cell offers a unique environmental advantage. As the fuel cell operates, it produces sodium oxide as a byproduct, which naturally reacts with moisture in the air to form sodium hydroxide. This compound then binds with atmospheric CO₂, resulting in the formation of sodium carbonate and eventually sodium bicarbonate—commonly known as baking soda. This sequence effectively removes CO₂ from the atmosphere, offering a passive carbon capture mechanism during flight.
Safety and Scalability Considerations
While sodium metal is highly reactive and requires careful handling, the design of the fuel cell mitigates safety risks by separating the reactive components. Unlike batteries that store all reactants together, the fuel cell’s configuration reduces the likelihood of runaway reactions. Additionally, the system is designed for scalability, with the potential for modular fuel packs that can be easily replaced or refueled, similar to changing cartridges.
Looking Ahead: From Drones to Regional Flights
The MIT team has already developed laboratory-scale prototypes and established a startup, Propel Aero, to further develop the technology. Their initial goal is to create a brick-sized fuel cell capable of powering large drones, with future aspirations to scale up for regional electric aviation. Given that regional flights account for a significant portion of domestic air travel and associated emissions, this technology could play a pivotal role in reducing the aviation industry’s carbon footprint.
Reference: “Sodium-air fuel cell for high energy density and low-cost electric power” by Karen Sugano, Sunil Mair, Saahir Ganti-Agrawal, Alden S. Friesen, Kailash Raman, William H. Woodford, Shashank Sripad, Venkatasubramanian Viswanathan and Yet-Ming Chiang, 27 May 2025, Joule.
DOI: 10.1016/j.joule.2025.101962
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