Design and Characterization of Porous Electrodes for Redox Flow Batteries

The commercialization of redox flow batteries as large-scale energy storage systems depends on lowering the capital and operating costs which depend on achieving maximum power density. Optimizing electrode design parameters and flow field-electrode combinations is critical to minimize losses and maximize active material utilization. Modeling the current drawn from an electrode offers a means to interpret electrode structure based on the electrolyte distribution driven by internal design. However, direct imaging methods (such as in-situ fluorescence microscopy and X-ray tomography) and numerical methods for current to potential prediction (3D Lattice Boltzmann modeling) are specific to individual electrode structures and possess limited predictable value to obtain an ideal electrode design. In this work, we present an electrode impedance spectroscopy (EIS)-based approach for determining electrode design parameters and devise a general method for determination of effective diffusion layer thickness. Using COMSOL modeling we verified the development of slug flow behavior in highly randomized porous electrode systems, indicating that the mass transport properties are dictated by inter-fiber distance. An analytical model to predict current as a function of applied overpotential is presented which allows us to vary structural parameters of the porous electrodes to study the influence of surface area, inter-fiber distances and diffusion layer thickness on the RFB performance. This model is a highly flexible tool applicable to any electrochemical system using a porous electrode and identifies critical variables affecting electrode design to characterize optimal electrode structure to minimize mass transport losses and optimize operational parameters.