Fluidic architecture for metal-halogen flow battery

1. A method of operating a flow battery comprising a stack of flow cells where each flow cell in the stack comprises a fluid permeable electrode, a fluid impermeable electrode, and a reaction zone between the permeable and impermeable electrodes, the method comprising:

(a) in charge mode, plating a metal layer on the impermeable electrode of each cell in the reaction zone by:

(i) flowing a metal halide electrolyte from a reservoir through an inlet conduit to the reaction zone of each flow cell in the stack in a first direction, such that a majority of the metal halide electrolyte enters the reaction zone from the inlet conduit without first flowing through the permeable electrode in the flow cell or through a flow channel located between adjacent flow cell electrodes in the stack; and

(ii) flowing the metal halide electrolyte from the reaction zone of each flow cell in the stack through a first outlet conduit to the reservoir, such that the majority of the metal halide electrolyte passes through the permeable electrode in each flow cell before reaching the first outlet conduit; and

(b) in discharge mode, de-plating the metal layer on the impermeable electrode of each cell in the reaction zone by:

(i) flowing a mixture of the metal halide electrolyte and a concentrated halogen reactant from the reservoir through the inlet conduit to the reaction zone of each flow cell in the stack in the first direction, such that a majority of the mixture enters the reaction zone from the inlet conduit without first flowing through the permeable electrode in the flow cells or through the flow channel located between adjacent flow cell electrodes in the stack; and

(ii) flowing the mixture from the reaction zone of each flow cell in the stack through the first outlet conduit to the reservoir, such that a majority of the mixture passes through the permeable electrode in each flow cell before reaching the first outlet conduit.

2. The method of claim 1 , wherein:

the stack of flow cells comprises a vertical stack of horizontally positioned flow cells;

the stack of flow cells is supported by a stack of cell frames;

a portion of the inlet conduit comprises an inlet manifold;

a portion of the first outlet conduit comprises a first outlet manifold;

a portion of the second outlet conduit comprises a second outlet manifold;

each cell frame in the stack of cell frames comprises an inlet manifold opening and a first and a second outlet manifold openings;

the first inlet manifold is formed by aligned inlet manifold openings in the stack of cell frames; and

the first and the second outlet manifolds are formed by respective aligned first and second outlet manifold openings in the stack of cell frames.

3. The method of claim 1 , wherein:

the metal halide electrolyte comprises zinc bromide;

the concentrated halogen reactant comprises complexed bromine;

the metal layer comprises zinc;

the permeable electrode comprises porous ruthenized titanium; and

the non-permeable electrode comprises titanium that is coated with the zinc metal layer during the charge mode.

4. The method of claim 1 , further comprising:

in charge mode, flowing the metal halide electrolyte from the reaction zone of each flow cell in the stack through a second outlet conduit such that a minority of the metal halide does not pass through the permeable electrode in each flow cell before reaching the second outlet conduit; and

in discharge mode, flowing the mixture from the reaction zone of each flow cell in the stack through the second outlet conduit to the reservoir, such that a minority of the mixture does not pass through the permeable electrode in each flow cell before reaching the second outlet conduit.

5. The method of claim 4 , further comprising controlling a flow rate of outlet flow streams in the first and second outlet conduits by a flow restrictor located in the second outlet conduit and providing separate outlet flow streams into the reservoir.

6. The method of claim 4 , wherein:

the majority flow for the charge and discharge mode is greater than 50%; and

flowing a mixture of the metal halide electrolyte and a concentrated halogen reactant from the reservoir comprises flowing the metal halide electrolyte through a first feed line fluidly connected to the reservoir and flowing the concentrated halogen reactant through a second feed line fluidly connected to the reservoir.

7. The method of claim 6 , wherein the first feed line comprises an intake fluidly connected to an upper portion of the reservoir and the second feed line comprises an intake fluidly connected to a lower portion of the reservoir.

8. The method of claim 7 , further comprising mixing the metal halide electrolyte and the concentrated halogen reactant prior to providing the mixture to a first pump in a single flow loop.

9. The method of claim 8 , further comprising pumping the concentrated halogen reactant with a second pump prior to mixing.

10. The method of claim 1 , wherein in the charge mode no concentrated halogen reactant flows into the stack via the second feed line and in the discharge mode the concentrated halogen reactant flows into the stack via the second feed line.

11. The method of claim 1 , further comprising controlling an amount of flow through each flow cell by adjusting at least one of a first variable valve located in the first outlet conduit and a second variable valve located in the second outlet conduit.