Redox flow battery design for enhanced reactant distribution

In this thesis, the impact of cell design on reactant distribution is thoroughly examined using a combination of experimental evaluation and coupled electrochemical/computational fluid dynamics modelling. Fused-deposition-modelling 3D-printing has been used to develop a platform facilitating the production of fully customisable laboratory-scale flow cells. Printing parameters have been refined, reducing void formation, and resulting in more robust test cells.

To obtain statistically significant data from experiments that compare cell geometries, refinements to existing flow battery testing protocols have been made. Key shortcomings in these protocols have been identified yielding recommendations that detail the importance of replicate testing, the calibration of fluidics, and the proper processing and handling of electrode and membrane materials. The development of a 3D full-cell transient model is detailed and improved parameters have been implemented.

The model has been validated against experimental results and subsequently used to evaluate several cell designs through simulation of charge-discharge cycling and polarisation curve analysis. The efficacy of different performance metrics found in literature are discussed along with modelling limitations and proposed future developments. The approaches developed in this thesis provide potential improvements to the processes of flow battery cell design, manufacture, testing and simulation.</p><p></p>