In recent years, zinc-air flow batteries have regained importance as promising energy storage system for mobile and stationary applications. This revived importance is driven by the increased demand of high-performance, efficient, safe and environmentally friendly energy storage solutions to meet the challenges of modern energy supply systems with high amounts of renewable energy. These energy storage systems need to address variable power, capacity and profitability requests. Zinc-air batteries with a specific energy density higher than lithium-ion and low cost, highly available, eco-friendly active materials are suitable to fulfill these requirements. The use of a flow battery type with zinc-particles suspended in alkaline solution (zinc-slurry) in addition with oxygen reduction electrodes developed for the chloralkali process allows the development of high-power zinc-air batteries. This setup also enables the independent scaling of capacity and power.

The cooperative research project ZnMobil, supported by the Federal Ministry of Economic Affairs and Energy in Germany, combines the experience of industrial and academic partners (Covestro Deutschland AG; Grillo-Werke AG; VARTA Microbattery GmbH; Accurec Recycling GmbH; Technical University Freiberg, Gottfried Wilhelm Leibniz University Hannover; University of Duisburg-Essen; The fuel cell research center ZBT GmbH) to develop a low-cost zinc-air flow battery with high performance.

Here we present the electrochemical performance of the new zinc-air flow battery with respect to different zinc-slurry compositions. The battery system consists of a 100 cm² copper plate as current collector for the zinc-suspension electrode and an oxygen reduction electrode with gas-diffusion layer (supplied by Covestro). The zinc-slurry contains zinc particles (supplied by Grillo) suspended in alkaline solution (30 wt-% KOH) and stabilized with polyacrylic acid.

Current voltage curves and depth of discharge were measured as a function of slurry composition (e.g. zinc content, additives) and different flow velocities of the zinc slurry. Corresponding zinc-slurry conductivities were evaluated in a flow-through conductivity measurement setup. Depending on the selected parameters, it is possible to achieve discharge current densities higher than 4 kA/m².