Shunt currents occur in electrochemical reactors like flow batteries, electrolyzers, and fuel cells where many bipolar cells that are connected in series electrically contact a mobile electrolyte through one or more common fluid distribution manifolds. Shunt currents reduce energy efficiency, and can cause unwanted side reactions including corrosion and gas generation. Equivalent-circuit models have been widely used to examine shunt currents in multi-cell electrochemical reactors. However, a detailed investigation of the interesting electrochemical processes occurring at the edges of the active areas has not been presented. In this work, the generation of shunt currents and their tendency to drive corrosion at the edges of positive electrodes in the most positive cells in a reactor stack are investigated with a comprehensive numerical model. An analytical model based on the penetration of current into a semi-infinite electrode, that can be used in conjunction with traditional equivalent-circuit models to assess the tendency for shunt currents to drive corrosion, is developed and compared to the numerical model. The models provided here can be used to set requirements on maximum allowable port currents in order to achieve a particular durability goal.

Transport through vanadium redox-flow-battery membranes strongly influences cell performance. In this work, we use a multicomponent concentrated-solution model of transport and thermodynamics in phase-separated cation-exchange membranes, the most common separator type, to develop structure-performance relationships. The model incorporates species partitioning into the membrane, thermodynamic nonidealities, and Stefan-Maxwell-Onsager frictions between species. Molecular-thermodynamics and -transport theories parameterize the model. We validate the calculations against measured Coulombic and voltage efficiencies of a vanadium flow battery as a function of current density. Our model shows that species transport is the result of collective interactions between all species present in the system. The magnitude of coupling suggests that predictions made using dilute-solution theory for transport in these systems will be misleading in many situations. As a demonstration of the capabilities of the model, we predict cell performance, incorporating these interactions, as a function of electrolyte concentration and composition and membrane equivalent weight and backbone modulus. We find that electrolytes with high sulfuric acid concentrations provide the greatest cell performance (quantified by maximizing power density at a target energy efficiency). In the case of membrane properties, low equivalent-weight polymers perform better; at high equivalent weights, a low membrane modulus is preferred.

A new flow battery is presented using the abundant and inexpensive active material pairs permanganate/manganate and disulfide/tetrasulfide. A wetted material set is identified for compatibility with the strongly oxidizing manganese couple at ambient and elevated temperatures. Both solutions allow high active material solubility, with cells tested at theoretical energy densities up to 43 Wh l-1 for the ∼1.2 V cell. Full cells built with nickel foam electrodes and sodium-exchanged Nafion 115 membranes deliver a baseline area-specific resistance of 2.7 Ω-cm2. Incorporation of high-surface-area cobalt-coated carbon paper and high-surface-area stainless steel mesh electrodes, and an expanded Nafion 115 membrane delivers cells with 44% lower resistance at 1.6 Ω-cm2. All cells show performance decay over the course of cycling. The Co-decorated carbon paper electrodes provide significant kinetic improvements, shifting electrode performance from non-linear with Ni-foam to linear with a volume-normalized exchange current density value of 3.2 A cm-3. The expanded membrane provides increased conductivity over the 13 mS cm-1 conductivity observed in as-received, sodium-exchanged Nafion 115. Although boiled membranes provide improved conductivity, it is at the cost of decreased Coulombic efficiency and poorer manufacturability. Full cell models suggest that similar cell resistances (1.7 Ω-cm2) should be feasible with as-received Nafion 115 and advanced electrodes.