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Journal of Power Sources 325 (2016) 329e336

Contents lists available at ScienceDirect

Journal of Power Sources


journal homepage: www.elsevier.com/locate/jpowsour

A high-performance dual-scale porous electrode for vanadium redox


flow batteries
X.L. Zhou, Y.K. Zeng, X.B. Zhu, L. Wei, T.S. Zhao*
Department of Mechanical and Aerospace Engineering, The Hong Kong University of Science and Technology, Clear Water Bay, Kowloon, Hong Kong, China

h i g h l i g h t s

 A dual-scale porous electrode is developed for flow batteries.


 The developed electrode offers high specific surface area.
 The battery with the dual-scale electrode offers high performance.

a r t i c l e i n f o a b s t r a c t

Article history: In this work, we present a simple and cost-effective method to form a dual-scale porous electrode by
Received 20 April 2016 KOH activation of the fibers of carbon papers. The large pores (~10 mm), formed between carbon fibers,
Received in revised form serve as the macroscopic pathways for high electrolyte flow rates, while the small pores (~5 nm), formed
5 June 2016
on carbon fiber surfaces, act as active sites for rapid electrochemical reactions. It is shown that the
Accepted 9 June 2016
Brunauer-Emmett-Teller specific surface area of the carbon paper is increased by a factor of 16 while
maintaining the same hydraulic permeability as that of the original carbon paper electrode. We then
apply the dual-scale electrode to a vanadium redox flow battery (VRFB) and demonstrate an energy
Keywords:
Dual-scale
efficiency ranging from 82% to 88% at current densities of 200e400 mA cm2, which is record breaking as
Flow battery the highest performance of VRFB in the open literature.
Electrode © 2016 Elsevier B.V. All rights reserved.

1. Introduction made significant progress in market penetration, owing to its high


cost [11e14]. The capital cost, expressed in terms of the unit cost of
Electricity generated from intermittent renewable energy power (US$/kW) or the unit cost of energy capacity (US$/kWh), is
sourcesdsuch as solar and wind need to be harnessed in order to inarguably the largest contributor of high expenditure by sector.
supplant the grid for cheap, efficient and reliable energy deploy- The total capital cost of a VRFB system consists primarily of the
ment. To do this, large-scale energy storage technologies are electrolyte cost and stack cost, which can be expressed as [12]:
indispensable for tackling the issues of intermittent supply and
variable demand [1e3]. Among the selection of energy storage
technologies, redox flow batteries (RFBs) offer unique characteris-
tics, including excellent scalability, high efficiency, long cycle life
.  . 
and are generally safe [4e6]. In particular, the vanadium redox flow Ctot zCs þ Ce zUs t$I$Veff þ Ue Veff $UE (1)
battery (VRFB) has been recognized as one of the most promising
technologies, primarily because it uses the same element in both
where Ctot, Cs and Ce are the total cost, stack cost and electrolyte cost
half-cells, which avoids the issue associated with cross-
($ per kWh), respectively; Us is the unit cost of the stack including
contamination between the two half-cell electrolytes [7e10].
electrodes, membranes and bipolar plates ($ per m2); Ue is the unit
Despite its attractive merits, however, VRFB technology has not
cost of the electrolyte including redox elements and supporting
salts/acids ($ per Ah); UE is the electrolyte utilization; I is the cur-
rent density (A m2); t is the designed discharge duration (h); and
* Corresponding author. Veff is the effective discharge cell voltage (V). The effective discharge
E-mail address: metzhao@ust.hk (T.S. Zhao). cell voltage can be estimated by Ref. [12]:

http://dx.doi.org/10.1016/j.jpowsour.2016.06.048
0378-7753/© 2016 Elsevier B.V. All rights reserved.
330 X.L. Zhou et al. / Journal of Power Sources 325 (2016) 329e336

graphenes) onto the carbon fiber surfaces [29e34]. Although this


Veff ¼ Vrev  hact  hohm  hcon (2) approach increases the surface area of the electrode, it still suffers
from several issues. For instance, dip-coating is typically adopted to
where Vrev is the reversible voltage; hact, hohm, and hcon are the coat carbon surfaces; the major disadvantage associated with this
activation, ohmic and concentration losses, respectively. According method is the fact that attachment between the high-surface-area
to eqns. (1) and (2), a reduction in the capital cost for RFBs with materials and the carbon fiber surfaces relies on weak Van der
given redox couples like VRFBs can only be accomplished by Waals forces. Flowing electrolyte can easily destroy or disrupt the
simultaneously maximizing the operating current density and attachment, causing a severe problem in durability [35]. Several
minimizing the voltage losses. Namely, improving the rate capa- groups have reported to synthesize carbon nanotubes (CNTs), car-
bility and efficiency of the VRFB through cost-effective approaches bon nanofibers (CNFs) or graphene directly on the carbon fiber
is critical for commercialization. surfaces via chemical vapor deposition (CVD) processes, aiming to
Electrode design is essential to achieving a high performance connect the high surface area material with carbon fiber surfaces
and efficient VRFB primarily because it contributes to the system via covalent bonds [35e38]. However, issues associated with the
polarization through not only the ohmic polarization, but also CVD process including the high price of metal precursors, and
through activation polarization and concentration polarization. complex and tedious preparation hinder its mass production
Therefore, ideal porous electrodes for high-power VRFBs should significantly. Furthermore, the issue of hydraulic permeability
possess the following properties: i) high surface activity and spe- reduction and therefore large concentration loss still stands during
cific surface area for electrochemical reactions to minimize the battery operation, as previously reported [30]. The ideal solution
activation loss; ii) large hydraulic permeability for efficient elec- would be to compose a low-cost porous electrode structure with
trolyte transportation to minimize the concentration loss and high surface area that does not sacrifice permeability.
pumping work; and iii) excellent electronic conductivity to mini- The bi-dispersed porous structure is one of the common struc-
mize the ohmic loss. The most commonly used materials for VRFB tures in porous media and is issued in the evaporators of heat pipes.
electrodes are carbon fiber-based materials (graphite felts, carbon It is composed of clusters (at macro-level), which are agglomerated
felts, and carbon papers) for their high electronic conductivity, high by small particles (at micro-level) [39,40]. This unique structure
hydraulic permeability, chemical and electrochemical inertness for features higher permeability than the mono-dispersed porous
a wide variety of chemicals and a wide range of potentials [15e20]. structure that is composed of macro-level clusters as well as higher
However, issues associated with the use of these materials surface area due to the micro-level particles [40]. Inspired from the
including low specific surface area and poor electrochemical ac- concept of a bi-dispersed porous structure, we form a dual-scale
tivity limit the VRFB to be operated at a low current density porous electrode (DPCE) that has a bimodal distribution of pore
(~50 mA cm2) [21e23]. Extensive efforts have been devoted to sizes by selecting carbon papers (CPs) that have large primary pores
improving the surface catalytic activities towards the redox re- (~10 mm) as starting materials and employing KOH activation
actions. One strategy is to introduce functional groups onto the method to etch the carbon fiber surfaces to form the desired small
carbon fiber surfaces to create abundant active sites and increasing secondary pores (~5 nm), as shown in Fig. 1. With this unique
hydrophilicity. It was found that the oxygen functional groups porous structure, large primary pores serve as the macroscopic
introduced by simple acid or thermal treatment can effectively pathways for electrolyte flow; small secondary pores that are well-
catalyze the vanadium redox reactions [24e27]. Additionally, metal connected to primary pores provide ample active sites for elec-
and metal oxide materials have been investigated as efficient cat- trochemical reactions. The expectation is that the surface area is
alysts for VRFBs. However, many of them are sensitive to parasitic dramatically increased without compromising on the permeability
reactions (hydrogen evolution) or are rare metals [10]. Recently, because of presence of the secondary pores. Our results match this
researchers from Pacific Northwest National Laboratory (PNNL) expectation and we show that the specific surface area of the novel
reported several types of catalysts of low cost and high catalytic electrode structure can reach as high as 42.7 m2 g1, which is one
activity [21,22], including Bi metal, Nb2O5. VRFBs with these cata- order of magnitude higher than conventional carbon electrodes
lysts deliver significantly improved rate capability and cyclability. (2.6 m2 g1). It is demonstrated that the VRFB with the present
By incorporating Bi nanoparticles onto the solid surfaces of a electrodes can stably operate at 400 mA cm2 with an energy ef-
negative porous electrode, the VRFB can be operated at ficiency over 80%. To the best of our knowledge, it represents one of
160 mA cm2 with an energy efficiency of 79%. the highest VRFB performances in the open literature. In addition,
Although some progress has been made in improving the sur- the preparation method is both straightforward and cost-effective
face catalytic activity of carbon-fiber based electrodes, low specific making it particularly appropriate for mass production. This dual-
surface area is still a central issue for developing high-power VRFBs scale porous electrode represents a significant step toward the
and has yet to be fully-resolved due to its conflict with the transport advancement of VRFBs, and in principle, other RFBs as well.
properties of the electrode [2]. In the conventional carbon fiber-
based electrodes, the pores are several tens of micrometers in 2. Experimental
diameter and are typically formed by the voids between the fibers.
These micron-scale pores can construct efficient electrolyte trans- 2.1. Electrode fabrication
port pathways, offering high hydraulic permeability and thus low
concentration loss and pump work. However, the specific surface Pristine CP (SGL 10 AA), provided by Union Chemical Industrial
area is extremely low (0.1e3 m2 g1) due to the large pore sizes Co., Ltd., was selected as the starting material. The pristine carbon
[28]. The most straightforward strategy to increase the surface area paper (CP-p) was first heat treated in a tube furnace at 500  C in air
would be to use carbon fibers with smaller dimeters to form the for 5 h [15]. In order to create nanopores on the carbon fiber sur-
electrode for a reduction of pore sizes. Unfortunately, this method faces, the oxidized CP was thoroughly mixed with KOH slurries at
will also induce a significant reduction in hydraulic permeability, different carbon paper/KOH weight ratios of 1:0.5, 1:1 and 1:2. The
leading to increased pump work and concentration polarization [1]. obtained mixture was then heat treated (heating ramp rate of
Hence, to increase the specific surface area without sacrificing too 3  C min1) in a horizontal furnace under a nitrogen flow at 800  C
much permeability, the common strategy is to coat high surface for 1.5 h to form the DPCE. The resulting DPCE was rinsed several
area materials (such as carbon blacks, carbon nanotubes and times with 6 M HCl to remove inorganic salts, and subsequently
X.L. Zhou et al. / Journal of Power Sources 325 (2016) 329e336 331

Fig. 1. The schematic of the conventional carbon-fiber based electrode and the proposed dual-scale porous carbon electrode.

rinsed with distilled water until the establishment of a neutral pH. conducted using an ArbinBT 2000 at a constant current density
Finally, the DPCE was dried in an oven at 90  C for 3 h. ranging from 200 to 500 mA cm2.

2.2. Characterization
3. Results and discussion

The material morphology was acquired by scanning electron


3.1. Electrode design, fabrication and characterization
microscope (SEM, JEOL-6700F and JSM-6300) under an accelera-
tion voltage of 20 kV. Transmission electron microscopy (TEM)
As shown in Fig. 1, the basic idea is to form the DPCE which has
images were obtained by operating a high-resolution JEOL 2010F
pores in two different scalesdmicron-scale primary pores and
TEM system with a LaB6 lament at 200 kV. The samples were
nanometer-scale secondary pores. To compose the proposed
dispersed in ethanol, sonicated and dripped onto the carbon-
structure, we adopted the carbon paper as starting materials which
coated Cu grids. Surface elemental composition was characterized
have primary pores (~10 mm) and use KOH to etch carbon fiber
with X-ray photoelectron spectroscopy (XPS, Axis Ultra DLD, UK).
surfaces to form the secondary pores (~5 nm). It should be
N2 adsorption/desorption measurement was conducted with a gas
mentioned that the pristine carbon papers were thermally treated
analyzer (ASAP2420, Micromeritics) after degassing at 120  C for
in air before etching to introduce the oxygen functional groups to
3 h to investigate the pore structure of the materials. The Brunauer-
increase the surface activity and hydrophilicity [26]. The mecha-
Emmett-Teller (BET) and Barrerr-Joyner-Halenda (BJH) method
nism of the etching process, known as KOH activation, has been
were adopted to calculate the specific surface areas and aperture
documented previously [41]. It is suggested that the activation of
distribution of electrodes.
carbon with KOH proceeds as 6KOH þ C / 2K þ 3H2 þ 2K2CO3,
followed by the decomposition of K2CO3 and the reaction of CO2
2.3. Electrochemical measurements with C. The surface morphology of CP-air and prepared DPCEs with
KOH/CP weight ratio of 1:0.5 (DPCE-0.5), 1:1 (DPCE-1) and 1:2
Cyclic voltammetry tests were conducted using a typical three- (DPCE-2) are depicted in Fig. 2. Fig. 2a showed that the carbon fiber
electrode cell. Carbon paper was used as the working electrode surfaces of CP-air have nearly no pores, which is consistent with the
with a geometric size of 0.1 cm2, and was connected to a platinum results reported [18]. In contrast, all of the DPCE samples have
wire with a reference electrode (Saturated calomel electrode), and rough surfaces with uniform nano-scale pores generated by the
counter electrode (Pt mesh) in 0.2 M VOSO4 in 3 M H2SO4 solution well-dispersed KOH activation agent (Fig. S1). In addition, with the
(Sigma-Aldrich, 98%) [15]. A single flow cell with an active electrode increase in the KOH/CP weight ratio, the nano-scale pores will be
area of 4 cm2 was assembled for charge/discharge tests. The in- enlarged due to the further reaction between KOH and C.
house designed zero-gap flow battery with a serpentine flow To investigate the surface structure of the carbon fibers, TEM
field was used in this study. Two layers of carbon paper were used images were taken. Fig. 3 revealed a relatively sharp contrast at the
with the compression ratio of 60% and Nafion 212 was adopted as edge of each carbon fiber and the depths of the created nano-scale
the membrane material. Electrolytes of 50 ml were fed into the pores are around 20 nm, indicating that the carbon fiber surface
compartments using the acrylic flow channels and were circulated was successfully etched during activation and did not significantly
to and from the reservoirs at 15 ml s1 using a 2-channel peristaltic change the carbon fiber structure. Since the depth of the nano-scale
pump (WT-600-2J, Longerpump, China). Measurements were pores is only 20 nm, the reactant ions can easily diffuse from the
conducted with 50 ml 1 M V (IV) þ 3 M H2SO4 solution as the bulk electrolytes into the pores for the electrochemical reactions
positive electrolyte and 50 ml 1 M V (III) þ 3 M H2SO4 solution as and the product ions can diffuse back to the bulk electrolytes after
the negative electrolyte. Charge-discharge and cycling tests were the reactions, as shown in Fig. 1.
332 X.L. Zhou et al. / Journal of Power Sources 325 (2016) 329e336

Fig. 2. The scanning electron microscopy images of carbon fiber surfaces of CP-air (a), DPCE-0.5 (b), DPCE-1 (c) and DPCE-2 (d).

importantly, as shown in Fig. 4b, pore sizes of the created pores in


DPCEs usually range from 5 to 12 nm, which are beneficial for the
electrochemical reactions due to the reason that pores with pore
size of around 5 nm can enable fast diffusion of active species [42].
As previously reported in Ref. [42], the diffusivity of redox
species in pores with diameter of 5 nm is 100 times higher than that
in pores with diameter of 2 nm. If we assume that pores that have
diameters larger than 5 nm can provide the effective surface area
for the redox reactions, the effective surface areas of DPCE-0.5,
DPCE-1, DPCE-2, CP-a, CP-p should be 12.80 m2 g1, 14.52 m2 g1,
15.32 m2 g1, 6.21 m2 g1 and 1.04 m2 g1, respectively.
We further used XPS to characterize the surface properties of
the CP-air and DPCEs, as shown in Fig. 5. The XPS results showed
that the O/C ratio of CP decreased after the KOH activation, due to
the fact that KOH can remove oxygen functional groups at high
temperatures, as expected. In addition, the percentage of different
oxygen containing functional groups is also altered. It is apparent
that the air treated CP has a much higher number of CeOH groups
while post KOH treatment increased C]O group content, since
CeOH groups can be partially converted to C]O groups during the
activation process, as summarized in Table 1.

Fig. 3. The transmission electron microscopy image of carbon fiber of DPCE-1. 3.2. Electrochemical performance

The electrochemical activities of CP-air and DPCEs were inves-


To test and verify our assumption that the specific surface area tigated in a typical three-electrode system. As depicted in Fig. 6, the
can be increased by this dual-scale porous structure, the N2 peak currents of each redox reaction are mainly governed by the
adsorption/desorption measurements were conducted. Fig. 4 diffusion of the vanadium ions to the electrode surface [43] and
showed the N2-absorption and pore-width distribution of pristine thus no obvious difference was found between the different elec-
CP, air-treated CP and DPCEs. Significantly, the DPCEs have one trodes, indicating that the effect of surface area on the electro-
order of magnitude higher specific surface area than the CP-p chemical behavior cannot be well-reflected by the peak currents.
(2.6 m2 g1). The specific surface area of DPCE-0.5, DPCE-1 and Hence, we use the potential separation for the reduction and
DPCE-2 is 62.3 m2 g1, 42.7 m2 g1 and 26.9 m2 g1. The specific oxidation peaks to characterize the surface activity here. The CV
surface area decrease with the KOH/CP weight ratio due to the curve of the CP-air in V(IV) electrolyte showed relatively large
nano-scale pores were enlarged by the further reaction between separation for the reduction and oxidation peaks for the V(II)/V(III)
KOH and C, which is consistent with the SEM images. More and V(IV)/V(V) redox reactions, as shown in Fig. 6a. In contrast, the
X.L. Zhou et al. / Journal of Power Sources 325 (2016) 329e336 333

Fig. 4. The nitrogen sorption isotherm plot (a) and the corresponding pore size distribution plot (b) of the CP-p, CP-air and DPCEs.

Fig. 5. O1s XPS spectra of CP-air (a), DPCE-0.5 (b), DPCE-1 (c) and DPCE-2 (d). The dark cyan line, blue line and orange line represent the fitted peaks of HeOeH, CeO and C]O. (For
interpretation of the references to colour in this figure legend, the reader is referred to the web version of this article.)

Table 1 To further investigate the electrochemical performance of the


Atomic fractions of C, O of CP-air, DPCE-0.5, DPCE-1 and DPCE-2. prepared electrodes, we conducted a symmetrical half-cell flow
Components CP-air DPCE-0.5 DPCE-1 DPCE-2 battery test to test the positive and negative sides of a VRFB sepa-
rately [43]. Fig. 6b and c compare the polarization curves of CP-air
O 1s (%) 6.54 4.18 3.06 2.15
C¼O (%) 1.21 1.78 1.27 0.96 and DPCEs in the negative symmetric cell (0.5 M V(II)/0.5 M V(III))
CeOH (%) 3.94 1.29 1.13 0.61 and positive symmetric cell (0.5 M V(IV)/0.5 M V(V)). It is shown
C 1s (%) 93.46 94.79 95.82 96.88 that all the DPCE samples exhibit lower overpotential than the air-
treated CP. With an increase in the KOH/C weight ratio, the per-
formance of DPCEs in the negative symmetric cell increases initially
DPCE-0.5 had much faster kinetics than the CP-air, as evidenced by and then decreases. It can be explained that the effective surface
a smaller voltage separation, which can be explained by the cata- area increases with the weight ratio but the number of functional
lytic effect of C]O functional groups, which is consistent with [33]. groups decrease and thus the surface electrochemical activity de-
The C]O functional groups may increase the density of states and creases. DPCE-1 and DPCE-2 have much larger effective surface
cause the carbon to behave more like a metal, facilitating the areas than that of DPCE-0.5. For the performance of DPCEs in the
adsorption of the positive charged ions [33,44]. In addition, the positive symmetric cell, the performance of DPCEs increases with
electrochemical activity of DPCE decreased with the increase in the increased amount of KOH loadings, which is a different trend
KOH/CP weight ratio due to fewer C]O functional groups, as with the situation in the negative symmetric cell. While the func-
expected. tional groups have a large influence on the electrochemical activity
334 X.L. Zhou et al. / Journal of Power Sources 325 (2016) 329e336

Fig. 6. a) CV in a scan rate of 10 mV s1 for CP-air, DPCE-0.5, DPCE-1 and DPCE-2 in 0.2 M V(V) þ 3 M H2SO4 solution; potentiostatic measurements of air-treated CP DPCE-0.5, DPCE-
1 and DPCE-2 with the cell active area of 4 cm2 in the negative (b) and positive symmetrical cells (c).

toward the V(IV)/V(V) reactions under the low vanadium concen- with the KOH/C ratio increase, the effective surface area increases
tration, as shown in Fig. 6, it has been shown that the kinetics of and thus the kinetics of V(IV)/V(V) reaction increases.
V(IV)/V(V) reaction has relatively low dependence on carbon sur-
face for high vanadium concentration solutions [43]. Hence, in the 3.3. VRFB charge-discharge and cycling performance
practical case with high vanadium concentration, the influence of
carbon surface on the kinetics of V(IV)/V(V) reaction is quite limited Fig. 7a shows the charge-discharge curves of the CP-air and
and the effective surface area becomes the dominant factor. Hence, DPCE samples between 0.8 and 1.65 V at a current rate of

Fig. 7. (a) Charge-discharge curves of VRFBs with CP-air, DPCE-0.5, DPCE-1 and DPCE-2 at the current density of 200 mA cm2; (b) charge-discharge curves of VRFBs with DPCE-1 at
the current densities of 200e500 mA cm2; (c) the energy efficiency and columbic efficiency of VRFBs with different electrodes at the current densities of 200e500 mA cm2; (d)
the discharge capacity of VRFBs with different electrodes at the current densities of 200e500 mA cm2; (e) the energy efficiency and columbic efficiency of VRFBs with DPCE-1
during 120 cycles; (f) the discharge capacity of VRFBs with DPCE-1 during 120 cycles.
X.L. Zhou et al. / Journal of Power Sources 325 (2016) 329e336 335

200 mA cm2. The CP-air in this work can deliver an energy effi- knowledge, it represents one of the highest VRFB performances in
ciency of 73% at the current density of 200 mA cm2, which is the open literature. This dual-scale porous electrode represents a
consistent with the value reported by other groups [27]. As significant step toward the advancement of VRFBs, and in principle
compared to the CP-air, all the DPCE samples showed remarkably other flow batteries as well. Further optimization of pore size and
decreased overpotential in both charge and discharge processes. pore shape of the dual scale porous electrode will help to further
The DPCE-1 exhibited the best performance among the sample improve the battery performance in the future.
prepared, primary because of the trade-off between the effective
surface area and the surface properties, which is consistent with Acknowledgements
the symmetrical battery test. It should be mentioned that the
pristine CP shows even poorer performance than that of the CP-air, The work described in this paper was fully supported by a grant
as shown in Fig. S2. Fig. 7b shows the rate capability of the VRFBs from the Research Grants Council of the Hong Kong Special
with DPCE-1, showing that the battery can operate at ultra-high Administrative Region, China (Project No. 623313).
current densities (400 mA cm2 or 500 mA cm2) with relative
low overpotential. Fig. 7c and d summarize the coulombic effi- Appendix A. Supplementary data
ciency, voltage efficiency, energy efficiency and discharge capacity
of VRFBs with different electrodes at current densities ranging from Supplementary data related to this article can be found at http://
200 mA cm2 to 500 mA cm2. It can be clearly seen that VRFBs dx.doi.org/10.1016/j.jpowsour.2016.06.048.
with DPCE-1 can deliver an energy efficiency ranging from 82% to
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