Indian Scientists Break Supercapacitor Voltage Barrier, Boost EV Range

Traditional supercapacitors are constrained by electrolyte instability at higher voltages, often leading to decomposition and safety risks such as flammability.

Indian researchers have developed a high-voltage supercapacitor electrode that overcomes long-standing safety and performance limits, paving the way for more efficient solar systems, faster-charging electric vehicles, and compact energy-storage modules.

Scientists at the International Advanced Research Centre for Powder Metallurgy and New Materials (ARCI)—an autonomous institute under the Department of Science and Technology (DST)—have created a dual-functional porous graphene carbon nanocomposite (PGCN) electrode that enables supercapacitors to operate at 3.4 volts, well beyond the 2.5–3.0 V ceiling of conventional devices.

Solving the voltage and safety bottleneck

Traditional supercapacitors are constrained by electrolyte instability at higher voltages, often leading to decomposition and safety risks such as flammability. The new PGCN-based design overcomes the 3.0 V limit, while significantly improving energy storage and long-term stability.

The breakthrough delivers 33% higher energy storage, doubles energy density compared with many existing designs, and supports higher power output, translating into greater driving range and faster acceleration for electric vehicles. The higher operating voltage also reduces the need to stack multiple low-voltage cells, simplifying module design and improving overall efficiency.

Why the material works

The performance leap comes from the engineered surface chemistry of the PGCN electrode, which is both:

• Water-repellent, suppressing water-induced degradation

• Highly compatible with organic electrolytes, enabling rapid infiltration into its porous structure

This dual functionality enhances ion transport and electrochemical efficiency, delivering power densities of up to 17,000 W/kg alongside excellent durability.

In testing, the PGCN-based supercapacitor retained 96% of its performance after 15,000 charge–discharge cycles, marking it as a strong candidate for demanding applications such as EVs, grid-scale storage, and portable electronics.

Green, scalable manufacturing

The electrodes are produced using an eco-friendly hydrothermal carbonization process, with 1,2-propanediol as the precursor. Conducted at 300°C for 25 hours in a sealed vessel, the method:

• Avoids harsh chemicals and external gases

• Minimises environmental impact

• Achieves yields above 20%

• Is scalable from lab to industrial production

The resulting micro- and mesoporous architecture supports fast ion movement and consistent performance, outperforming commercial carbon electrodes such as YP-50F in both operating voltage and power output.

Strategic boost for India’s clean energy ambitions

The research, published in the Chemical Engineering Journal (Elsevier) and supported by DST under the Technical Research Centre (TRC) initiative, strengthens India’s domestic capabilities in advanced energy storage.

By enabling higher-voltage, longer-lasting supercapacitors, the innovation aligns with Aatma Nirbhar Bharat and India’s clean energy goals—supporting electrification, renewable integration and next-generation mobility.