Enhancing Flow Batteries: Topology Optimization of Electrode Porosity and Shape Optimization of Cell Design

This research focuses on the improvement of porosity distribution within the electrode of an all‐vanadium redox flow battery (VRFB) and on optimizing novel cell designs. A half‐cell model, coupled with topology and shape optimization framework, is introduced. The multiobjective functional in both cases aims to minimize pressure drop while maximizing reaction rate within the cell. Topology optimization results reveal dependencies on initial value, porosity constraint, and flow rate. The distribution with lower porosity is preferred downstream of the inlet manifold. This design enhances active surface area, thus facilitating more effective conversion of incoming educts and improving mass transport of products. Compared to homogeneous electrodes, two‐part design demonstrates superior performance at specific porosity values. For combined porosities of 0.7 and 0.95, optimized distribution results in 81 % reduction in pressure drop, while conversion rate decreases by 7%. As regards various cell designs, optimization suggests a need to reconsider the vertical format of a rectangular cell. Horizontal cells are favored for nearly all porosities and flow rates. Trapezoidal and radial designs characterized by reduced downstream cross sections lead to higher pressure drops and are not preferred. This work provides further valuable insight into optimizing VRFB electrodes and challenges conventional cell design assumptions.