Engineering Lung-Inspired Flow Field Geometries for Electrochemical Flow Cells with Stereolithography 3D Printing.

Electrochemical flow reactors are increasingly relevant platforms in emerging sustainable energy conversion and storage technologies. As a prominent example, redox flow batteries, a well-suited technology for large energy storage if the costs can be significantly reduced, leverage electrochemical reactors as power converting units. Within the reactor, the flow field geometry determines the electrolyte pumping power required, mass transport rates, and overall cell performance. However, current designs are inspired by fuel cell technologies but have not been engineered for redox flow battery applications, where liquid-phase electrochemistry is sustained. Here, we leverage stereolithography 3D printing to manufacture lung-inspired flow field geometries and compare their performance to conventional flow field designs. A versatile two-step process based on stereolithography 3D printing followed by a coating procedure to form a conductive structure is developed to manufacture lung-inspired flow field geometries. We employ a suite of fluid dynamics, electrochemical diagnostics, and finite element simulations to correlate the flow field geometry with performance in symmetric flow cells. We find that the lung-inspired structural pattern homogenizes the reactant distribution throughout the porous electrode and improves the electrolyte accessibility to the electrode reaction area. In addition, the results reveal that these novel flow field geometries can outperform conventional interdigitated flow field designs, as these patterns exhibit a more favorable balance of electrical and pumping power, achieving superior current densities at lower pressure loss. Although at its nascent stage, additive manufacturing offers a versatile design space for manufacturing engineered flow field geometries for advanced flow reactors in emerging electrochemical energy storage technologies.

Taurine Electrografting onto Porous Electrodes Improves Redox Flow Battery Performance.

The surface properties of porous carbonaceous electrodes govern the performance, durability, and ultimately the cost of redox flow batteries (RFBs). State-of-the-art carbon fiber-based electrode interfaces suffer from limited kinetic activity and incomplete wettability, fundamentally limiting the performance. Surface treatments for electrodes such as thermal and acid activation are a common practice to make them more suitable for aqueous RFBs; however, these treatments offer limited control over the desired functional properties. Here, we propose, for the first time, electrografting as a facile, rapid, and versatile technique to enable task-specific functionalization of porous carbonaceous electrodes for use in RFBs. Electrografting allows covalent attachment of organic molecules on conductive substrates upon application of an electrochemical driving force, and the vast library of available organic molecules can unlock a broad range of desired functional properties. To showcase the potential of electrografting for RFBs, we elect to investigate taurine, an amine with a highly hydrophilic sulfonic acid tail. Oxidative electrografting with cyclic voltammetry allows covalent attachment of taurine through the amine group to the fiber surface, resulting in taurine-functionalized carbon cloth electrodes. In situ polarization and impedance spectroscopy in single-electrolyte flow cells reveal that taurine-treated cloth electrodes result in 40% lower charge transfer and 25% lower mass transfer resistances than off-the-shelf cloth electrodes. We find that taurine-treated electrode interfaces promote faster Fe3+ reduction reaction kinetics as the electrochemical surface area normalized current densities are 2-fold and 4-fold higher than oxidized and untreated glassy carbon surfaces, respectively. Improved mass transfer of taurine-treated electrodes is attributed to their superior wettability, as revealed by operando neutron radiography within a flow cell setup. Through demonstrating promising results for aqueous systems with the model molecule taurine, this work aims to bring forth electrografting as a facile technique to tailor electrode surfaces for other RFB chemistries and electrochemical technologies.

Narrow Pressure Stability Window of Gas Diffusion Electrodes Limits the Scale-Up of CO2 Electrolyzers.

Electrochemical CO2 reduction is a promising process to store intermittent renewable energy in the form of chemical bonds and to meet the demand for hydrocarbon chemicals without relying on fossil fuels. Researchers in the field have used gas diffusion electrodes (GDEs) to supply CO2 to the catalyst layer from the gas phase. This approach allows us to bypass mass transfer limitations imposed by the limited solubility and diffusion of CO2 in the liquid phase at a laboratory scale. However, at a larger scale, pressure differences across the porous gas diffusion layer can occur. This can lead to flooding and electrolyte breakthrough, which can decrease performance. The aim of this study is to understand the effects of the GDE structure on flooding behavior and CO2 reduction performance. We approach the problem by preparing GDEs from commercial substrates with a range of structural parameters (carbon fiber structure, thickness, and cracks). We then determined the liquid breakthrough pressure and measured the Faradaic efficiency for CO at an industrially relevant current density. We found that there is a trade-off between flooding resistance and mass transfer capabilities that limits the maximum GDE height of a flow-by electrolyzer. This trade-off depends strongly on the thickness and the structure of the carbon fiber substrate. We propose a design strategy for a hierarchically structured GDE, which might offer a pathway to an industrial scale by avoiding the trade-off between flooding resistance and CO2 reduction performance.

When Flooding Is Not Catastrophic-Woven Gas Diffusion Electrodes Enable Stable CO2 Electrolysis.

Electrochemical CO2 reduction has the potential to use excess renewable electricity to produce hydrocarbon chemicals and fuels. Gas diffusion electrodes (GDEs) allow overcoming the limitations of CO2 mass transfer but are sensitive to flooding from (hydrostatic) pressure differences, which inhibits upscaling. We investigate the effect of the flooding behavior on the CO2 reduction performance. Our study includes six commercial gas diffusion layer materials with different microstructures (carbon cloth and carbon paper) and thicknesses coated with a Ag catalyst and exposed to differential pressures corresponding to different flow regimes (gas breakthrough, flow-by, and liquid breakthrough). We show that physical electrowetting further limits the flow-by regime at commercially relevant current densities (≥200 mA cm-2), which reduces the Faradaic efficiency for CO (FECO) for most carbon papers. However, the carbon cloth GDE maintains its high CO2 reduction performance despite being flooded with the electrolyte due to its bimodal pore structure. Exposed to pressure differences equivalent to 100 cm height, the carbon cloth is able to sustain an average FECO of 69% at 200 mA cm-2 even when the liquid continuously breaks through. CO2 electrolyzers with carbon cloth GDEs are therefore promising for scale-up because they enable high CO2 reduction efficiency while tolerating a broad range of flow regimes.

Non-Solvent Induced Phase Separation Enables Designer Redox Flow Battery Electrodes.

Porous carbonaceous electrodes are performance-defining components in redox flow batteries (RFBs), where their properties impact the efficiency, cost, and durability of the system. The overarching challenge is to simultaneously fulfill multiple seemingly contradictory requirements-i.e., high surface area, low pressure drop, and facile mass transport-without sacrificing scalability or manufacturability. Here, non-solvent induced phase separation (NIPS) is proposed as a versatile method to synthesize tunable porous structures suitable for use as RFB electrodes. The variation of the relative concentration of scaffold-forming polyacrylonitrile to pore-forming poly(vinylpyrrolidone) is demonstrated to result in electrodes with distinct microstructure and porosity. Tomographic microscopy, porosimetry, and spectroscopy are used to characterize the 3D structure and surface chemistry. Flow cell studies with two common redox species (i.e., all-vanadium and Fe2+/3+ ) reveal that the novel electrodes can outperform traditional carbon fiber electrodes. It is posited that the bimodal porous structure, with interconnected large (>50 µm) macrovoids in the through-plane direction and smaller (<5 µm) pores throughout, provides a favorable balance between offsetting traits. Although nascent, the NIPS synthesis approach has the potential to serve as a technology platform for the development of porous electrodes specifically designed to enable electrochemical flow technologies.

Investigating Electrode Flooding in a Flowing Electrolyte, Gas-Fed Carbon Dioxide Electrolyzer.

Managing the gas-liquid interface within gas-diffusion electrodes (GDEs) is key to maintaining high product selectivities in carbon dioxide electroreduction. By screening silver-catalyzed GDEs over a range of applied current densities, an inverse correlation was observed between carbon monoxide selectivity and the electrochemical double-layer capacitance, a proxy for wetted electrode area. Plotting current-dependent performance as a function of cumulative charge led to data collapse onto a single sigmoidal curve indicating that the passage of faradaic current accelerates flooding. It was hypothesized that high cathode alkalinity, driven by both initial electrolyte conditions and cathode half-reactions, promotes carbonate formation and precipitation which, in turn, facilitates electrolyte permeation. This mechanism was reinforced by the observations that post-test GDEs retain less hydrophobicity than pristine materials and that water-rinsing and drying electrodes temporarily recovers peak selectivity. This knowledge offers an opportunity to design electrodes with greater carbonation tolerance to improve device longevity.

Elucidating the Nuanced Effects of Thermal Pretreatment on Carbon Paper Electrodes for Vanadium Redox Flow Batteries.

Sluggish vanadium reaction rates on the porous carbon electrodes typically used in redox flow batteries have prompted research into pretreatment strategies, most notably thermal oxidation, to improve performance. While effective, these approaches have nuanced and complex effects on electrode characteristics hampering the development of explicit structure-function relations that enable quantitative correlation between specific properties and overall electrochemical performance. Here, we seek to resolve these relationships through rigorous analysis of thermally pretreated SGL 29AA carbon paper electrodes using a suite of electrochemical, microscopic, and spectroscopic techniques and culminating in full cell testing. We systematically vary pretreatment temperature, from 400 to 500 °C, while holding pretreatment time constant at 30 h, and evaluate changes in the physical, chemical, and electrochemical properties of the electrodes. We find that several different parameters contribute to observed performance, including hydrophilicity, microstructure, electrochemical surface area, and surface chemistry, and it is important to note that not all of these properties improve with increasing pretreatment temperature. Consequently, while the best overall performance is achieved with a 475 °C pretreatment, this enhancement is achieved from a balance, rather than a maximization, of critical properties. A deeper understanding of the role each property plays in battery performance is the first step toward developing targeted pretreatment strategies that may enable transformative performance improvements.

Performance-Enhancing Asymmetric Separator for Lithium-Sulfur Batteries.

Asymmetric separators with polysulfide barrier properties consisting of porous polypropylene grafted with styrenesulfonate (PP-g-PLiSS) were characterized in lithium-sulfur cells to assess their practical applicability. Galvanostatic cycling at different C-rates with and without an electrolyte additive and cyclic voltammetry were used to probe the electrochemical performance of the cells with the PP-g-PLiSS separators and to compare it with the performance of the cells utilizing state-of-the-art separator, Celgard 2400. Overall, it was found that regardless of the applied cycling rate, the use of the grafted separators greatly enhances the Coulombic efficiency of the cell. An appropriate Li-exchange-site (-SO3(-)) concentration at and near the surface of the separator was found to be essential to effectively suppress the polysulfide shuttle without sacrificing the Li-ion mobility through the separator and to improve the practical specific charge of the cell.

Engineered Water Highways in Fuel Cells: Radiation Grafting of Gas Diffusion Layers.

A novel method to produce gas diffusion layers with patterned wettability for fuel cells is presented. The local irradiation and subsequent grafting permits full design flexibility and wettability tuning, while modifying throughout the whole material thickness. These water highways have improved operando performance due to an optimized water management inside the cells.