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 does not pass 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 a second outlet conduit to the reservoir, such that a majority of the mixture passes through the permeable electrode in each flow cell before reaching the second 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 a first 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 a first inlet manifold opening and a first and a second outlet manifold openings;

the first inlet manifold is formed by aligned first 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 the charge mode, flowing a first purge stream comprising a minority of the metal halide electrolyte provided from the reservoir through a second inlet manifold in the stack of cell frames to the flow channel located between adjacent flow cell electrodes in the stack, and from the flow channel through the second outlet manifold in the stack of cell frames to the reservoir; and

in the discharge mode, flowing a second purge stream comprising a minority of the mixture provided from the reservoir through the second inlet manifold in the stack of cell frames to the flow channel located between adjacent flow cell electrodes in the stack, and from the flow channel through the second outlet manifold in the stack of cell frames to the reservoir.

5. The method of claim 4 , further comprising controlling an amount of flow through each flow cell by adjusting at least one of a first valve located in the inlet conduit and a second valve located in the at least one of the first or second outlet conduits, such that in the charge mode the majority of the metal halide electrolyte does not pass through the permeable electrode in each flow cell before reaching the first outlet conduit, and in the discharge mode, the majority of the mixture passes through the permeable electrode in each flow cell before reaching the second outlet conduit.

6. The method of claim 5 , wherein the step of controlling comprises adjusting the second valve to provide a higher liquid flow rate through the first outlet manifold than the second outlet manifold in the charge mode, and adjusting the second valve to provide a lower liquid flow rate through the first outlet manifold than the second outlet manifold in the discharge mode.

7. The method of claim 4 , further comprising using a single pump in a single flow loop to pump the metal halide electrolyte from the reservoir to the inlet conduit in the charge mode, and to pump the metal halide electrolyte and the concentrated halogen reactant from the reservoir to the inlet conduit in the discharge mode.

8. The method of claim 4 , further comprising combining outlet flow streams from the first outlet conduit and the second outlet conduit in both charge and discharge mode and providing a combined flow streams to the reservoir in both charge and discharge mode.

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

10. The method of claim 9 , wherein the step of controlling comprises using flow control valves or a combination of a flow restrictor and an on/off valve.

11. The method of claim 4 , further comprising:

in the charge mode, directing a minority of the electrolyte through the second outlet conduit and through a flow restrictor into the reservoir, and directing the majority of the electrolyte from the first outlet conduit into the reservoir without passing through the flow restrictor; and

in the discharge mode, directing a minority of the mixture through the first outlet conduit and through the flow restrictor into the reservoir, and directing the majority of the mixture from the second outlet conduit into the reservoir without passing through the flow restrictor.

12. The method of claim 4 , further comprising:

providing only the metal halide electrolyte into the stack without providing the first purge stream into the stack in the charge mode;

providing only the mixture into the stack without providing the second purge stream into the stack in the discharge mode;

controlling a flow rate of outlet flow streams in the first and the second outlet conduits; and

providing separate outlet flow streams into the reservoir.

13. The method of claim 12 , wherein the step of controlling comprises using a combination of a flow restrictor and an on/off valve.

14. The method of claim 1 , wherein 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.

15. The method of claim 14 , 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.

16. The method of claim 14 , 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.

17. The method of claim 16 , further comprising pumping the concentrated halogen reactant with a second pump prior to mixing.

18. The method of claim 16 , 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.

19. 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.