Charging Ahead: Adapting to Emerging Battery Chemistries

Batteries have long been at the core of advancements in electronics, electric vehicles (EVs), and renewable energy storage. Yet as battery technologies evolve, so too must the charging solutions that support them.

As part of The Future of Electrification 2025 conference, Matthew Moore, Application Engineer at ZIVAN, presented the session "Charging Ahead: Adapting to Emerging Battery Chemistries," and examined this dual evolution of battery chemistry and charging, providing critical insights for OEMs navigating electrification.

Watch the full session here:

Overview: Top Three Takeaways

From legacy battery designs to next-generation chemistries, Moore’s observations serve as a valuable guide for OEMs, delivering essential context regarding which battery technologies best align with modern electrification strategies. Consider some of these takeaways as discussed in the session.

#1. The Evolution of Battery Chemistry

Since their inception, batteries have continuously evolved to meet the growing energy demands of industrial and commercial applications. 

Today, two chemistries dominate electric power solutions:

• Lead-acid –Of the oldest and most widely used battery technologies, lead-acid remains a staple in automobiles, forklifts, and backup power systems. Durability, recyclability, and widespread availability make it a reliable choice. However, its weight, low energy density, and slow charge times may indicate that the chemistry already achieved its full potential.
• Lithium-ion – The industry standard for consumer electronics and EVs, lithium-ion batteries offer high energy density, lightweight construction, and rapid charging capabilities. Widespread adoption nonetheless remains constrained by thermal runaway risks, supply chain concerns, and sustainability considerations.

Beyond the dominant players, Moore highlighted additional chemistries that introduce trade-offs in cost, energy density, and sustainability, including:

• Nickel-based batteries – Deliver high durability and energy output, yet suffer from a “memory effect” that lowers their capacity over time. Nickel’s natural toxicity further raises environmental concerns. 
• Absorbent glass mat (AGM) – An evolution of the sealed lead-acid battery offering spill-proof, maintenance-free operations, yet suffer from many of the same drawbacks as traditional lead-acid.
• Gel batteries – Another sealed lead-acid variant, gel electrolytes immobilize the acid to enhance safety and performance. They require a slower charge to avoid damage, and are more expensive than AGM.

#2. Emerging Chemistries: Overcoming Limitations

While current-generation batteries serve as today’s standard, the development of emerging chemistries seeks to overcome existing limitations and expand the possibilities for electrified applications.

Moore scrutinized several promising chemistries currently in experimental use:

• Zinc-air – Used in low-power devices such as hearing aids and sensors, zinc-air offers high energy density while simplifying supply chain logistics. Even so, short lifecycles and limited power output restrict viability for larger applications.
• Sodium & calcium ion – Positioned as cost-effective, sustainable alternatives to lithium-ion, these chemistries are inexpensive to produce and environmentally friendly. However, low energy density and electrolyte limitations prevent them from competing in high-power applications.
• Solid-state batteries – Regarded as the “next frontier” in battery technology, solid-state batteries challenge the lithium-ion standard with higher energy density, greater safety, and extended lifespans. Yet high production costs and recycling challenges continue to limit large-scale adoption.

#3. Charger Integration: Chemistry’s Role in Charging Efficiency

While battery chemistry is a key consideration for OEMs, Moore noted that charger integration is equally critical to electrification success.

Different battery chemistries require unique charging profiles—a factor often overlooked in early design stages. To ensure optimal performance and safety, charging systems must be engineered to support the specific needs of each chemistry.

Battery management systems (BMS) play a vital role in bridging this gap between chemistry and charging by: 

• Maintaining proper cell balancing by ensuring each cell charges and discharges evenly, extending overall battery life.
• Managing and regulating battery temperatures to prevent thermal runaway, system failure, and fire risks, allowing for safe charging across any chemistry. 
• Monitoring battery state-of-charge and state-of-health, dynamically adjusting current and voltage levels in line with chemistry requirements.

As Moore asserted, advancements in BMS technology remain essential to wider electric adoption—particularly in off-road and industrial applications.

ZAPI GROUP: Charging Innovation and Collaboration

Concluding the session, Moore’s powerful call to action reminded us that collaboration remains the most critical factor in advancing battery and charging technology.

As emerging chemistries and hybrid solutions gain traction, OEMs must maintain close partnerships with battery manufacturers, charging solution providers, and R&D teams to drive innovation and supply chain resiliency.

ZIVAN, a ZAPI GROUP company, continues to lead by example with proprietary solutions, off-board charging technologies, and chemistry-specific charging algorithms—along with the expertise OEMs need to power the next generation of electrified equipment.

To explore these innovations more thoroughly, watch the video, or contact Matthew Moore for consultation on your electrification strategy.

Matthew Moore e-mail​: matthew.moore@zapiinc.com  ​

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Violetta Fulchiati | Marketing & Communication Specialist 
Phone: +39 0522 960593
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