Redox flow battery system for distributed energy storage

• US 7,820,321 B2
• Filed: 07/06/2009
• Issued: 10/26/2010
• Est. Priority Date: 07/07/2008
• Status: Expired due to Fees

• Current Assignee: EnerVault Corporation
• Original Assignee: EnerVault Corporation
• Inventors: Horne, Craig R., Hickey, Darren B., Kinoshita, Kim
• Primary Examiner(s): Yuan, Dah-Wei D
• Assistant Examiner(s): Arciero, Adam A
• Application Number:
  US12/498,103
• Publication Number:
  US 20100003545A1
• Time in Patent Office: 477 Days
• Field of Search: None
• US Class Current: 429/149
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 53/302 Cooling of charging equipment
• CPC Class Codes: B60L 53/51 Photovoltaic means
• CPC Class Codes: B60L 53/52 Wind-driven generators
• CPC Class Codes: B60L 53/54 Fuel cells
• CPC Class Codes: H01M 8/188 by recharging of redox couples containing fluids; Redox flow type batteries
• CPC Class Codes: H01M 8/20 Indirect fuel cells, e.g. fuel cells with redox couple being irreversible H01M8/18 takes precedence
• CPC Class Codes: H01M 8/2455 with liquid, solid or electrolyte-charged reactants
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/12 Electric charging stations
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10T 29/49108 Electric battery cell making

Abstract

A large stack redox flow battery system provides a solution to the energy storage challenge of many types of renewable energy systems. Independent reaction cells arranged in a cascade configuration are configured according to state of charge conditions expected in each cell. The large stack redox flow battery system can support multi-megawatt implementations suitable for use with power grid applications. Thermal integration with energy generating systems, such as fuel cell, wind and solar systems, further maximize total energy efficiency. The redox flow battery system can also be scaled down to smaller applications, such as a gravity feed system suitable for small and remote site applications.

Claims

1. A redox flow battery energy storage system, comprising:

a redox flow battery stack assembly comprising an array of cell layers comprising a plurality of cells arranged along a reactant flow path through the cell layers,

wherein each of the plurality of cells comprises a separator membrane configured according to its position along the reactant flow path so that the separator membrane in one of the plurality of cells located at a first end of the reactant flow path has lower selectivity than the separator membrane in one of the plurality of cells located at a second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

2. The redox flow battery energy storage system of claim 1, wherein each of the plurality of cells within each stack cell layer is configured as planar components assembled in a stack, comprising:

a first bipolar frame, wherein the first bipolar frame is electrically insulating, except for an active area of the cell;

a first electrode material positioned adjacent to the first bipolar frame and adjacent to the separator membrane;

a second electrode material positioned adjacent to the separator membrane; and

a second bipolar frame positioned adjacent to the second electrode material, wherein the second bipolar frame is electrically insulating, except for the active area of the cell.

3. The redox flow battery energy storage system of claim 1, further comprising four electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly and configured so that a first tank holds charge catholyte, a second tank holds discharged catholyte, a third tank holds charge anolyte and a fourth tank holds discharge anolyte.

4. The redox flow battery energy storage system of claim 1, further comprising electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly, the electrolyte storage tanks comprising a heat exchanger configured to heat the electrolyte to a temperature of 40°

C. to 65°

C.

5. The redox flow battery energy storage system of claim 1, further comprising a heat exchanger fluidically coupled to the reactant flow path and configured so that reactant entering one of the plurality of cells located at the first end of the reactant flow path is at a higher temperature than reactant entering one of the plurality of cells located at the second end of the reactant flow path.

6. A redox flow battery energy storage system, comprising:

a redox flow battery stack assembly comprising an array of cell layers comprising a plurality of cells arranged along a reactant flow path through the cell layers,

wherein each of the plurality of cells is configured according to its position along the reactant flow path with an electrode material having a charge catalyst that enhances reduction-oxidation reactions and suppresses hydrogen generation reactions on its surface with a loading selected so that the electrode material in one of the plurality of cells located at the first end of the reactant flow path has a greater charge catalyst loading than the electrode material in the one of the plurality of cells located at the second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

7. The redox flow battery energy storage system of claim 6, wherein each of the plurality of cells within each stack cell layer is configured as planar components assembled in a stack, comprising:

a first bipolar frame, wherein the first bipolar frame is electrically insulating, except for an active area of the cell;

a first electrode material positioned adjacent to the first bipolar frame;

a separator membrane positioned adjacent to the first electrode material;

a second electrode material positioned adjacent to the separator membrane; and

a second bipolar frame positioned adjacent to the second electrode material, wherein the second bipolar frame is electrically insulating, except for the active area of the cell.

8. The redox flow battery energy storage system of claim 6, further comprising four electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly and configured so that a first tank holds charge catholyte, a second tank holds discharged catholyte, a third tank holds charge anolyte and a fourth tank holds discharge anolyte.

9. The redox flow battery energy storage system of claim 6, further comprising electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly, the electrolyte storage tanks comprising a heat exchanger configured to heat the electrolyte to a temperature of 40°

C. to 65°

C.

10. The redox flow battery energy storage system of claim 6, further comprising a heat exchanger fluidically coupled to the reactant flow path and configured so that reactant entering one of the plurality of cells located at the first end of the reactant flow path is at a higher temperature than reactant entering one of the plurality of cells located at the second end of the reactant flow path.

11. A redox flow battery energy storage system, comprising:

a redox flow battery stack assembly comprising an array of cell layers comprising a plurality of cells arranged along a reactant flow path through the cell layers,

wherein each of the plurality of cells is configured according to its position along the reactant flow path with an electrode material having a charge catalyst that enhances reduction-oxidation reactions and suppresses hydrogen generation reactions on its surface with an activity selected so that the electrode material in one of the plurality of cells located at the first end of the reactant flow path has a greater charge catalyst activity than the electrode material in one of the plurality of cells located at the second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

12. The redox flow battery energy storage system of claim 11, wherein each of the plurality of cells within each stack cell layer is configured as planar components assembled in a stack, comprising:

a first bipolar frame, wherein the first bipolar frame is electrically insulating, except for an active area of the cell;

a first electrode material positioned adjacent to the first bipolar frame;

a separator membrane positioned adjacent to the first electrode material;

a second electrode material positioned adjacent to the separator membrane; and

a second bipolar frame positioned adjacent to the second electrode material, wherein the second bipolar frame is electrically insulating, except for the active area of the cell.

13. The redox flow battery energy storage system of claim 11, further comprising four electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly and configured so that a first tank holds charge catholyte, a second tank holds discharged catholyte, a third tank holds charge anolyte and a fourth tank holds discharge anolyte.

14. The redox flow battery energy storage system of claim 11, further comprising electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly, the electrolyte storage tanks comprising a heat exchanger configured to heat the electrolyte to a temperature of 40°

C. to 65°

C.

15. The redox flow battery energy storage system of claim 11, further comprising a heat exchanger fluidically coupled to the reactant flow path and configured so that reactant entering one of the plurality of cells located at the first end of the reactant flow path is at a higher temperature than reactant entering one of the plurality of cells located at the second end of the reactant flow path.

16. A redox flow battery energy storage system, comprising:

a redox flow battery stack assembly comprising an array of cell layers comprising a plurality of cells arranged along a reactant flow path through the cell layers,

wherein each one of the plurality of cells comprises a separator membrane configured according to its position along the reactant flow path so that the separator membrane in one of the plurality of cells located at the first end of the reactant flow path exhibits a lower reactant mass transport rate through its thickness than the separator membrane in one of the plurality of cells located at the second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

17. The redox flow battery energy storage system of claim 16, wherein each of the plurality of cells within each stack cell layer is configured as planar components assembled in a stack, comprising:

a first bipolar frame, wherein the first bipolar frame is electrically insulating, except for an active area of the cell;

a first electrode material positioned adjacent to the first bipolar frame;

a separator membrane positioned adjacent to the first electrode material;

a second electrode material positioned adjacent to the separator membrane; and

a second bipolar frame positioned adjacent to the second electrode material, wherein the second bipolar frame is electrically insulating, except for the active area of the cell.

18. The redox flow battery energy storage system of claim 16, further comprising four electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly and configured so that a first tank holds charge catholyte, a second tank holds discharged catholyte, a third tank holds charge anolyte and a fourth tank holds discharge anolyte.

19. The redox flow battery energy storage system of claim 16, further comprising electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly, the electrolyte storage tanks comprising a heat exchanger configured to heat the electrolyte to a temperature of 40°

C. to 65°

C.

20. The redox flow battery energy storage system of claim 16, further comprising a heat exchanger fluidically coupled to the reactant flow path and configured so that reactant entering one of the plurality of cells located at the first end of the reactant flow path is at a higher temperature than reactant entering one of the plurality of cells located at the second end of the reactant flow path.

21. A redox flow battery energy storage system, comprising:

a redox flow battery stack assembly comprising an array of cell layers comprising a plurality of cells arranged along a reactant flow path through the cell layers, the flow path having a first end and a second end, wherein each of the plurality of cells is configured according to its position along the reactant flow path; and

a heat exchanger fluidically coupled to the reactant flow path and configured so that reactant entering one of the plurality of cells located at the first end of the reactant flow path is at a higher temperature than reactant entering one of the plurality of cells located at the second end of the reactant flow path,

wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

22. The redox flow battery energy storage system of claim 21, wherein each of the plurality of cells within each stack cell layer is configured as planar components assembled in a stack, comprising:

a first bipolar frame, wherein the first bipolar frame is electrically insulating, except for an active area of the cell;

a first electrode material positioned adjacent to the first bipolar frame;

a separator membrane positioned adjacent to the first electrode material;

a second electrode material positioned adjacent to the separator membrane; and

a second bipolar frame positioned adjacent to the second electrode material, wherein the second bipolar frame is electrically insulating, except for the active area of the cell.

23. The redox flow battery energy storage system of claim 21, further comprising four electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly and configured so that a first tank holds charge catholyte, a second tank holds discharged catholyte, a third tank holds charge anolyte and a fourth tank holds discharge anolyte.

24. The redox flow battery energy storage system of claim 21, wherein the heat exchanger is configured to heat the electrolyte to a temperature of 40°

C. to 65°

C.

25. A redox flow battery energy storage system, comprising:

a redox flow battery stack assembly comprising an array of cell layers comprising a plurality of cells arranged along a reactant flow path through the cell layers, wherein each of the plurality of cells is configured according to its position along the reactant flow path; and

a reactant storage tank fluidically coupled to the redox flow battery stack assembly, the reactant storage tank comprising a tank separator configured to inhibit mixing of charged reactant with discharged reactant.

26. The redox flow battery energy storage system of claim 25, wherein the tank separator is buoyant, includes a valve mechanism which when opened allows reactant to flow through the tank separator, and is configured within the reactant storage tank so that when the valve mechanism is closed and discharged reactant enters the tank on top of the tank separator mixing of charged reactant with discharged reactant is inhibited, and when the valve mechanism is opened the tank separator will float to a top surface of the reactant.

27. The redox flow battery energy storage system of claim 25, wherein the tank separator is positioned vertically within the reactant storage tank and the reactant storage tank and the tank separator are configured so that the tank separator moves as reactant is pumped into the reactant storage tank on one side of the tank separator and is drawn out of the reactant storage tank from the other side of the tank separator so that mixing of charged reactant with discharged reactant is inhibited.

28. The redox flow battery energy storage system of claim 25, wherein each of the plurality of cells within each stack cell layer is configured as planar components assembled in a stack, comprising:

a first bipolar frame, wherein the first bipolar frame is electrically insulating, except for the active area of the cell;

a first electrode material positioned adjacent to the first bipolar frame;

a separator membrane positioned adjacent to the first electrode material;

a second electrode material positioned adjacent to the separator membrane; and

a second bipolar frame positioned adjacent to the second electrode material, wherein the second bipolar frame is electrically insulating, except for the active area of the cell.

29. The redox flow battery energy storage system of claim 25, further comprising electrolyte storage tanks fluidically coupled to the redox flow battery stack assembly, the electrolyte storage tanks comprising a heat exchanger configured to heat the electrolyte to a temperature of 40°

C. to 65°

C.

30. The redox flow battery energy storage system of claim 25, wherein each of the plurality of cells comprises a separator membrane configured so that the separator membrane in one of the plurality of cells located at a first end of the reactant flow path has lower selectivity than the separator membrane in one of the plurality of cells located at a second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

31. The redox flow battery energy storage system of claim 25, wherein each of the plurality of cells is configured with an electrode material having a charge catalyst that enhances reduction-oxidation reactions and suppresses hydrogen generation reactions on its surface with a loading selected so that the electrode material in one of the plurality of cells located at the first end of the reactant flow path has a greater charge catalyst loading than the electrode material in the one of the plurality of cells located at the second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

32. The redox flow battery energy storage system of claim 25, wherein each one of the plurality of cells is configured with an electrode material having a charge catalyst that enhances reduction-oxidation reactions and suppresses hydrogen generation reactions on its surface with an activity selected so that the electrode material in one of the plurality of cells located at the first end of the reactant flow path has a greater charge catalyst activity than the electrode material in one of the plurality of cells located at the second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

33. The redox flow battery energy storage system of claim 25, wherein each one of the plurality of cells is configured so that the separator membrane in one of the plurality of cells located at the first end of the reactant flow path exhibits a lower reactant mass transport rate through its thickness than the separator membrane in one of the plurality of cells located at the second end of the reactant flow path, wherein the redox flow battery energy storage system is configured so that reactant flows through the redox flow battery stack assembly from the first end to the second end for discharging or from the second end to the first end for charging.

34. The redox flow battery energy storage system of claim 25, further comprising a heat exchanger fluidically coupled to the reactant flow path and configured so that reactant entering one of the plurality of cells located at the first end of the reactant flow path is at a higher temperature than reactant entering one of the plurality of cells located at the second end of the reactant flow path.