A techno-economic model was developed to investigate the influence of components on the system costs of redox flow batteries. Sensitivity analyses were carried out based on an example of a 10 kW/120 kWh vanadium redox flow battery system, and the costs of the individual components were analyzed. Particular consideration was given to the influence of the material costs and resistances of bipolar plates and energy storage media as well as voltages and electric currents. Based on the developed model, it was possible to formulate statements about the targeted optimization of a developed non-commercial vanadium redox flow battery system and general aspects for future developments of redox flow batteries.

In this study, 1.6 M vanadium electrolytes in the oxidation forms V(III) and V(V) were prepared from V(IV) in sulfuric (4.7 M total sulphate), V(IV) in hydrochloric (6.1 M total chloride) acids, as well as from 1:1 mol mixture of V(III) and V(IV) (denoted as V^3.5+) in hydrochloric (7.6 M total chloride) acid. These electrolyte solutions were investigated in terms of performance in vanadium redox flow battery (VRFB). The half-wave potentials of the V(III)/V(II) and V(V)/V(IV) couples, determined by cyclic voltammetry, and the electronic spectra of V(III) and V(IV) electrolyte samples, are discussed to reveal the effect of electrolyte matrix on charge-discharge behavior of a 40 cm² cell operated with 1.6 M V^3.5+ electrolytes in sulfuric and hydrochloric acids. Provided that the total vanadium concentration and the conductivity of electrolytes are comparable for both acids, respective energy efficiencies of 77% and 72–75% were attained at a current density of 50 mA∙cm⁻². All electrolytes in the oxidation state V(V) were examined for chemical stability at room temperature and +45 °C by titrimetric determination of the molar ratio V(V):V(IV) and total vanadium concentration.

The flow field design and material composition of the electrode plays an important role in the performance of redox flow batteries, especially when using highly viscous liquids. To enhance the discharge power density of zinc slurry air flow batteries, an optimum slurry distribution in the cell is key. Hence, several types of flow fields (serpentine, parallel, plastic flow frames) were tested in this study to improve the discharge power density of the battery. The serpentine flow field delivered a power density of 55 mW∙cm⁻², while parallel and flow frame resulted in 30 mW∙cm⁻² and 10 mW∙cm⁻², respectively. Moreover, when the anode bipolar plate material was changed from graphite to copper, the power density of the flow frame increased to 65 mW∙cm⁻², and further improvement was attained when the bipolar plate material was further changed to copper–nickel. These results show the potential to increase the power density of slurry-based flow batteries by flow field optimization and design of bipolar plate materials.

A techno-economic model was developed to investigate the influence of components on the system costs of redox flow batteries. Sensitivity analyses were carried out based on a example of a 10 kW/120 kWh vanadium redox flow battery system and the costs of the individual components were analyzed. Particular consideration was given to the influence of material costs and resistances of bipolar plates and energy storage media as well as voltages and electric currents. Based on the developed model it was possible to formulate statements about the targeted optimization of existing battery systems and general aspects for future developments of redox flow batteries.

The performance of redox flow batteries is notably influenced by the electrolyte, especially in slurry-based flow batteries, as it serves as both an ionic conductive electrolyte and a flowing electrode. In this study, carbon additives were introduced to achieve a rechargeable zinc slurry flow battery by minimizing the zinc plating on the bipolar plate that occurs during charging. When no carbon additive was present in the zinc slurry, the discharge current density was 24 mA∙cm⁻² at 0.6 V, while the use of carbon additives increased it to up to 38 mA∙cm⁻². The maximum power density was also increased from 16 mW∙cm⁻² to 23 mW∙cm⁻². Moreover, the amount of zinc plated on the bipolar plate during charging decreased with increasing carbon content in the slurry. Rheological investigation revealed that the elastic modulus and yield stress are directly proportional to the carbon content in the slurry, which is beneficial for redox flow battery applications, but comes at the expense of an increase in viscosity (two-fold increase at 100 s⁻¹). These results show how the use of conductive additives can enhance the energy density of slurry-based flow batteries.