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12 STACK DEVELOPMENT AND BATTERY SYSTEMS From the construction of prototype batteries to the development of industrial production processes for battery stacks, Fraunhofer ICT covers every stage in battery production. The institute can also carry out tests to certify flow batteries from the stack up to entire battery systems. Prototype development and tests on cell stacks The stack is a core component of redox-flow batteries. To- gether with the electrolyte solutions, its power output largely determines the efficiency and cost of the electricity storage device. Stacks are complex electrochemical flow reactors, in which a low pressure drop, an even flow distribution, a homogeneous electrochemical reaction as well as low internal resistance have to be achieved. However, depending on the requirements of the battery chemistry applied, stacks can differ considerably from each other. Besides technical design, cell and stack geometries can be in- vestigated using fluid simulations and electrochemical models, to determine their suitability and potential optimizations. The development of cell prototypes, their testing and subsequent scale-up to the finished stack is carried out using various manufacturing technologies suited to mass production, and is adjusted to industrial production processes. System tests Fraunhofer ICT has developed and constructed its own test rigs to investigate RFB stacks. The test rigs have comprehen- sive safety features and can be operated fully automatically. The simple, modular construction and control via an industrial programmable logic controller (PLC) means that the test rigs require little maintenance. For battery testing according to different battery standards, stress tests and long-duration studies, battery test systems with different performance categories are available: J All sizes up to 60 kW charge/discharge performance J Individual cell measurement module with 64 single-channel measurements up to 0-5 V each. 1 RFB stack with side con- nectors for single cell mea- surements. 2 Redox-flow stack test rig for power outputs up to 4 kW.PDF Image | REDOX-FLOW BATTERY
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