This review article summarizes the development of flow fields and stacks, and design considerations for next-generation flow batteries.

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Flow batteries show promise for very large scale stationary energy storage such as needed for the grid and renewable energy implementation. In recent years, researchers and developers of redox flow batteries (RFBs) have found that electrode and flow field designs of PEM fuel cell (PEMFC) technology can increase the power density and consequently push down the cost of flow battery stacks. In this paper we present a macroscopic model of a typical PEMFC-like RFB electrode-flow field design. The model is a layered system comprised of a single passage of a serpentine flow channel and a parallel underlying porous electrode (or porous layer). The effects of the inlet volumetric flow rate, permeability of the porous layer, thickness of the porous layer and thickness of the flow channel on the flow penetration into the porous layer are investigated. The maximum current density corresponding to stoichiometry is estimated to be 377 mA cm-2 and 724 mA cm-2, which compares favorably with experiments of ~400 mA cm-2 and ~750 mA cm-2, for a single layer and three layers of the carbon fiber paper, respectively.

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A methodology for the design and construction of simple foil thrust bearings intended for parametric performance testing and low marginal costs is presented. Features drawn from a review of the open literature are discussed as they relate to bearing performance. The design of fixtures and tooling required to fabricate foil thrust bearings is presented, using conventional machining processes where possible. A prototype bearing with dimensions drawn from literature is constructed, with all fabrication steps described. A load-deflection curve for the bearing is presented to illustrate structural stiffness characteristics. Start-stop cycles are performed on the bearing at a temperature of 425°C to demonstrate early-life wear patterns. A test of bearing load capacity demonstrates useful performance when compared with data obtained from the open literature.