Advances in lithium-sulfur batteries for commercialization

Lithium-sulfur batteries have emerged as a promising candidate for next-generation rechargeable energy storage systems, offering several advantages such as theoretically higher energy density, lower-cost active materials, and environmental benefits due to the absence of critical metals like nickel, cobalt, and manganese. However, despite considerable research and development efforts from both academia and industry, the commercialization of lithium-sulfur batteries remains hindered by a number of significant challenges. These include issues such as the insulating nature of the sulfur cathode, the detrimental polysulfide shuttle effect in organic ether-based electrolytes, and dendritic growth on the lithium anode. A notable discrepancy exists between the progress made in laboratory-scale (coin cell) lithium-sulfur batteries and that achieved in larger industrial-scale (pouch cell) systems. To address this gap, it is essential for researchers to focus on scaling up production processes, enhancing material stability, and optimizing battery designs to meet the stringent requirements of industrial applications. This review aims to highlight the critical technical and material-related challenges that currently impede the practical deployment of lithium-sulfur batteries, while also providing an overview of the latest advancements in lithium-sulfur pouch cell technology and the ongoing industrial efforts toward its commercialization.