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Scaling Up Phase-Separated Electrodes for High-Performance Flow Battery Stacks (PhaseUP)

Objective

Redox flow batteries are promising for grid-scale energy storage, but their widespread adoption is limited by critical performance and cost limitations arising from suboptimal porous electrodes and stack design. Conventional fibrous electrodes, repurposed from fuel cells, suffer from poor mass transport and limited accessible surface area, while current stack architectures cannot mitigate local performance heterogeneities – leading to uneven aging, reduced durability, and high system costs. In our ongoing ERC Starting Grant (FAIR-RFB), we have pioneered a new class of electrode materials by integrating advanced computational models and synthetic methods to achieve highly controlled electrode morphologies.

In this ERC Proof of Concept project (PhaseUP), we propose a paradigm shift where these novel electrode architectures are integrated in segmented stacks, and these are optimized in tandem. Using non-solvent induced phase separation (NIPS), we have developed porous carbon electrodes with tunable, fully interconnected microstructure ideally suited for flow electrochemistry. These electrodes deliver unprecedently high and near-theoretical power densities (>1.8 W cm-2) in all-vanadium flow batteries at laboratory scale and are protected by recent intellectual property filings.

PhaseUP will scale this innovation into modular short-stack architectures (>200 cm2), co-optimizing electrode properties and flow frame designs to ensure uniform performance across segments and benchmarking against commercial carbon felts. This work directly targets key barriers to RFB competitiveness by lowering manufacturing costs, improving efficiency, and enabling tailored electrode geometries. If successful, PhaseUP will establish NIPS as a platform technology for porous electrodes, enabling next-generation energy storage by bridging fundamental materials innovation and real-world deployment.

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Programme(s)

Topic(s)

Funding Scheme

HORIZON-ERC-POC - HORIZON ERC Proof of Concept Grants

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Call for proposal

(opens in new window) ERC-2026-POC

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Host institution

TECHNISCHE UNIVERSITEIT EINDHOVEN
Net EU contribution
€ 150 000,00
Address
GROENE LOPER 3
5612 AE Eindhoven
Netherlands
Region
Zuid-Nederland Noord-Brabant Zuidoost-Noord-Brabant
Activity type
Higher or Secondary Education Establishments
Links
Total cost
No data

Beneficiaries (1)