The membrane is a crucial component of Zn slurry–air flow battery since it provides ionic conductivity between the electrodes while avoiding the mixing of the two compartments. Herein, six commercial membranes (Cellophane™ 350PØØ, Zirfon®, Fumatech® PBI, Celgard® 3501, 3401 and 5550) were first characterized in terms of electrolyte uptake, ion conductivity and zincate ion crossover, and tested in Zn slurry–air flow battery. The peak power density of the battery employing the membranes was found to depend on the in-situ cell resistance. Among them, the cell using Celgard® 3501 membrane, with in-situ area resistance of 2 Ω cm2 at room temperature displayed the highest peak power density (90 mW cm−2). However, due to the porous nature of most of these membranes, a significant crossover of zincate ions was observed. To address this issue, an ion-selective ionomer containing modified poly(phenylene oxide) (PPO) and N-spirocyclic quaternary ammonium monomer was coated on a Celgard® 3501 membrane and crosslinked via UV irradiation (PPO-3.45 + 3501). Moreover, commercial FAA-3 solutions (FAA, Fumatech) were coated for comparison purpose. The successful impregnation of the membrane with the anion-exchange polymers was confirmed by SEM, FTIR and Hg porosimetry. The PPO-3.45 + 3501 membrane exhibited 18 times lower zincate ions crossover compared to that of the pristine membrane (5.2 × 10−13 vs. 9.2 × 10−12 m2 s−1). With low zincate ions crossover and a peak power density of 66 mW cm−2, the prepared membrane is a suitable candidate for rechargeable Zn slurry–air flow batteries.

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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.