Synchrotron X-ray Radiography and Tomography of Vanadium Redox Flow Batteries-Cell Design, Electrolyte Flow Geometry, and Gas Bubble Formation

Investigating Bubble Formation and Evolution in Vanadium Redox Flow Batteries via Synchrotron X-Ray Imaging

The parasitic hydrogen evolution reaction (HER) hinders electrolyte transport. It reduces the effective electrochemical surface area in the negative half-cell of vanadium redox flow batteries (VRFBs), resulting in substantial efficiency losses. This study investigates the formation and evolution of hydrogen bubbles within VRFB electrodes through comprehensive experimental characterization and a detailed analysis of the resolved bubbles. The electrode is imaged using synchrotron X-ray tomography, and gas bubbles in the images are identified and characterized using a deep learning model combined with a morphological analysis tool. The HER intensity increases at more negative working electrode potentials, causing residual bubbles to grow and fuse in the electrode central region. In contrast, independent bubbles predominantly form at the electrode edges. Furthermore, bubble growth leads to the gradual development of irregular shapes. These observations provide insights into bubble formation and evolution rules, contributing to a better understanding of the system.

Quantifying concentration distributions in redox flow batteries with neutron radiography

The continued advancement of electrochemical technologies requires an increasingly detailed understanding of the microscopic processes that control their performance, inspiring the development of new multi-modal diagnostic techniques. Here, we introduce a neutron imaging approach to enable the quantification of spatial and temporal variations in species concentrations within an operating redox flow cell. Specifically, we leverage the high attenuation of redox-active organic materials (high hydrogen content) and supporting electrolytes (boron-containing) in solution and perform subtractive neutron imaging of active species and supporting electrolyte. To resolve the concentration profiles across the electrodes, we employ an in-plane imaging configuration and correlate the concentration profiles to cell performance with polarization experiments under different operating conditions. Finally, we use time-of-flight neutron imaging to deconvolute concentrations of active species and supporting electrolyte during operation. Using this approach, we evaluate the influence of cell polarity, voltage bias and flow rate on the concentration distribution within the flow cell and correlate these with the macroscopic performance, thus obtaining an unprecedented level of insight into reactive mass transport. Ultimately, this diagnostic technique can be applied to a range of (electro)chemical technologies and may accelerate the development of new materials and reactor designs.

Investigating the Influence of Treatments on Carbon Felts for Vanadium Redox Flow Batteries

Vanadium redox flow battery (VRFB) electrodes face challenges related to their long-term operation. We investigated different electrode treatments mimicking the aging processes during operation, including thermal activation, aging, soaking, and storing. Several characterization techniques were used to deepen the understanding of the treatment of carbon felts. Synchrotron X-ray imaging, electrochemical impedance spectroscopy (EIS) with the distribution of relaxation times analysis, and dynamic vapor sorption (DVS) revealed differences between the wettability of felts. The bulk saturation after electrolyte injection into the carbon felts significantly differed from 8 % to 96 %. DVS revealed differences in the sorption/desorption behavior of carbon felt ranging from a slight change of 0.8 wt % to over 100 wt %. Additionally, the interactions between the water vapor and the sample change from type V to type H2. After treatment, morphology changes were observed by atomic force microscopy and scanning electron microscopy. Cyclic voltammetry and EIS were used to probe the electrochemical performance, revealing different catalytic activities and transport-related impedances for the treated samples. These investigations are crucial for understanding the effects of treatments on the performance and optimizing materials for long-term operation.

Revealing the Multifaceted Impacts of Electrode Modifications for Vanadium Redox Flow Battery Electrodes

Carbon electrodes are one of the key components of vanadium redox flow batteries (VRFBs), and their wetting behavior, electrochemical performance, and tendency to side reactions are crucial for cell efficiency. Herein, we demonstrate three different types of electrode modifications: poly(o-toluidine) (POT), Vulcan XC 72R, and an iron-doped carbon-nitrogen base material (Fe-N-C + carbon nanotube (CNT)). By combining synchrotron X-ray imaging with traditional characterization approaches, we give thorough insights into changes caused by each modification in terms of the electrochemical performance in both half-cell reactions, wettability and permeability, and tendency toward the hydrogen evolution side reaction. The limiting performance of POT and Vulcan XC 72R could mainly be ascribed to hindered electrolyte transport through the electrode. Fe-N-C + CNT displayed promising potential in the positive half-cell with improved electrochemical performance and wetting behavior but catalyzed the hydrogen evolution side reaction in the negative half-cell.

Dead-zone-compensated design as general method of flow field optimization for redox flow batteries

One essential element of redox flow batteries (RFBs) is the flow field. Certain dead zones that cause local overpotentials and side effects are present in all conventional designs. To lessen the detrimental effects, a dead-zone-compensated design of flow field optimization is proposed. The proposed architecture allows for the detection of dead zones and their compensation on existing flow fields. Higher reactant concentrations and uniformity factors can be revealed in the 3D multiphysical simulation. The experiments also demonstrate that at an energy efficiency (EE) of 80%, the maximum current density of the novel flow field is 205 mA cm-2, which is much higher than the values for the previous ones (165 mA cm-2) and typical serpentine flow field (153 mA cm-2). Extensions of the design have successfully increased system EE (2.7 to 4.3%) for a variety of flow patterns. As a result, the proposed design is demonstrated to be a general method to support the functionality and application of RFBs.

X-ray Tomography Applied to Electrochemical Devices and Electrocatalysis

X-ray computed tomography (CT) is a nondestructive three-dimensional (3D) imaging technique used for studying morphological properties of porous and nonporous materials. In the field of electrocatalysis, X-ray CT is mainly used to quantify the morphology of electrodes and extract information such as porosity, tortuosity, pore-size distribution, and other relevant properties. For electrochemical systems such as fuel cells, electrolyzers, and redox flow batteries, X-ray CT gives the ability to study evolution of critical features of interest in ex situ, in situ, and operando environments. These include catalyst degradation, interface evolution under real conditions, formation of new phases (water and oxygen), and dynamics of transport processes. These studies enable more efficient device and electrode designs that will ultimately contribute to widespread decarbonization efforts.

Applications and Development of X-ray Inspection Techniques in Battery Cell Production

Demand for lithium-ion battery cells (LIB) for electromobility has risen sharply in recent years. In order to continue to serve this growing market, large-scale production capacities require further expansion and the overall effectiveness of processes must be increased. Effectiveness can be significantly optimized through innovative manufacturing technology and by identifying scrap early in the production chain. To enable these two approaches, it is imperative to quantify safety- and function-critical product features in critical manufacturing steps through appropriate measurement techniques. The overview in this paper on quality control in LIB production illustrates the necessity for improved inspection techniques with X-rays to realize a fast, online measurement of inner features in large-scale cell assembly with short cycle times and to visualize inner product-process interactions for the optimization in electrolyte filling. Therefore, two new inspection techniques are presented that contribute to overcoming the aforementioned challenges through the targeted use of X-rays. First, based on the results of previous experiments in which the X-ray beam directions were deliberately varied, a online coordinate measurement of anode-cathode (AC) overhang was developed using a line detector. Second, a new concept and the results of a continuous 2D visualization of the electrolyte filling process are presented, which can be used in the future to optimize this time-critical process step. By using a X-ray-permeable and portable vacuum chamber it is possible to quantify the influence of process parameters on the distribution of the electrolyte in the LIB.