A unified multi-physics model for co-design: Enhancing efficiency and enabling compact thermal management in vanadium redox flow battery stacks

Jacer  Hamrouni; Leila  Abdelgader; Chafaa  Hamrouni; Abdennaceur Kachouri Kachouri; Mounir  Baccar

doi:10.59400/adecp3811

A unified multi-physics model for co-design: Enhancing efficiency and enabling compact thermal management in vanadium redox flow battery stacks

Jacer Hamrouni
Advanced Fluid Dynamics, Energetics and Environment Laboratory, Department of Mechanical Engineering, National School of Engineers of Sfax, University of Sfax, Sfax 3029, Tunisia
Leila Abdelgader
Advanced Department of Computer Sciences, Khurma University College, Taif University, Al-Khurma 2935, Saudi Arabia
Chafaa Hamrouni
Advanced Department of Computer Sciences, Khurma University College, Taif University, Al-Khurma 2935, Saudi Arabia
Abdennaceur Kachouri Kachouri
AFD2E Laboratory, National Engineering School, Sfax University, Sfax 3029, Tunisia
Mounir Baccar
Advanced Fluid Dynamics, Energetics and Environment Laboratory, Department of Mechanical Engineering, National School of Engineers of Sfax, University of Sfax, Sfax 3029, Tunisia

Article ID: 3811

Keywords: vanadium redox flow battery; integrated physicochemical modeling; dynamic system control; coupled differential-algebraic systems; flow field optimization; parasitic current loss; thermal management strategy; system design simplification

Abstract

This work develops a control-oriented, lumped-parameter model for vanadium redox flow battery (VRFB) stacks. The framework integrates mass, charge, energy, and momentum transport with electrochemical kinetics via a coupled system of ordinary differential equations (ODEs) and algebraic constraints, bridging system dynamics and electrochemical engineering. A key methodological advancement is the application of a hydraulic-electrical network analogy, utilizing Kirchhoff's laws to simulate electrolyte flow and shunt current pathways across a 20-cell stack, thereby transforming complex three-dimensional physics into a tractable, control-oriented formulation. The model directly links physical fidelity to actionable performance insights. Simulations identify that non-uniform flow distribution induces significant local state-of-charge gradients, exacerbating shunt currents. This parasitic effect can reduce effective charging current by up to 2.1% and increase discharge overpotentials. Through analysis of these coupled interactions, the study demonstrates that optimized flow management and thermal control can mitigate losses. Specifically, regulating stack temperature below 40 °C via a novel targeted tank-cooling strategy rather than full-system cooling prevents vanadium precipitation while improving round-trip efficiency, achieving a 27.2% reduction in cooling energy consumption. Furthermore, the model reveals that tank-based heat rejection dominates convective heat transfer (85.8%), enabling a transformative redesign where thermal management is consolidated at the tanks. This permits a more compact stack enclosure and reduces balance-of-plant complexity. The work establishes a validated mathematical framework that advances the fundamental understanding of coupled transport in VRFBs and provides a direct pathway to designing more efficient, compact, and cost-effective systems.

Published

2026-02-10

How to Cite

Hamrouni, J., Abdelgader, L., Hamrouni, C., Kachouri, A. K., & Baccar, M. (2026). A unified multi-physics model for co-design: Enhancing efficiency and enabling compact thermal management in vanadium redox flow battery stacks. Advances in Differential Equations and Control Processes, 33(1). https://doi.org/10.59400/adecp3811

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Vol. 33 No. 1 (2026)

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Article

This work is licensed under a Creative Commons Attribution 4.0 International License.

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