Upscaling and Manufacturing of Ion-Selective Membranes for Energy Storage (IonMembrane)
Lead Research Organisation:
Imperial College London
Department Name: Chemical Engineering
Abstract
Electrochemical energy storage and conversion technologies play a significant role in the storage of energy produced by renewables such as wind and solar as well as in the generation and utilization of clean energy carriers (e.g., hydrogen). Redox flow batteries (RFBs) are promising for grid-scale long-duration energy storage as required for the integration of intermittent renewable energy into the grid. Nafion membrane takes up to 40% of the stack cost in RFBs. The design, development, and manufacturing of sustainable low cost polymer membranes with high selectivity and high stability represent a major challenge for the development of cost-effective electrochemical technologies for energy conversion and storage.
With the support of ERC-funded curiosity-driven fundamental research, we have developed a new generation of hydrocarbon-based membranes that overcome the performance limitations found in all existing ion exchange membranes, particularly for redox flow battery applications. This proof of concept grant would provide a timely opportunity to explore the pathways to commercialization of our new ion-selective membranes for grid-scale energy storage as well as for hydrogen technologies. We propose to work on: (1) Scaling up
polymer synthesis, (2) Manufacturing membranes via roll-to-roll casting to produce meter-square-sized membranes and engineering to optimize membrane performance, (3) Validating performance of these large-area membranes in flow battery stacks, instead of small single cells, for more intense evaluation of their performance under real-world conditions. This project will also involve collaboration with academic and industrial partners including large energy and small start-up companies, from green manufacturing to performance validation in battery stacks. The project will help advance the ground-breaking research toward commercialization.
With the support of ERC-funded curiosity-driven fundamental research, we have developed a new generation of hydrocarbon-based membranes that overcome the performance limitations found in all existing ion exchange membranes, particularly for redox flow battery applications. This proof of concept grant would provide a timely opportunity to explore the pathways to commercialization of our new ion-selective membranes for grid-scale energy storage as well as for hydrogen technologies. We propose to work on: (1) Scaling up
polymer synthesis, (2) Manufacturing membranes via roll-to-roll casting to produce meter-square-sized membranes and engineering to optimize membrane performance, (3) Validating performance of these large-area membranes in flow battery stacks, instead of small single cells, for more intense evaluation of their performance under real-world conditions. This project will also involve collaboration with academic and industrial partners including large energy and small start-up companies, from green manufacturing to performance validation in battery stacks. The project will help advance the ground-breaking research toward commercialization.
Publications
Cannon CG
(2024)
Methylene Blue in a High-Performance Hydrogen-Organic Rechargeable Fuel Cell.
in ACS applied energy materials
Tan R
(2024)
Interfacial Engineering of Polymer Membranes with Intrinsic Microporosity for Dendrite-Free Zinc Metal Batteries.
in Angewandte Chemie (International ed. in English)
Tan R
(2023)
Thin Film Composite Membranes with Regulated Crossover and Water Migration for Long-Life Aqueous Redox Flow Batteries.
in Advanced science (Weinheim, Baden-Wurttemberg, Germany)
Wang A
(2024)
Selective ion transport through hydrated micropores in polymer membranes.
in Nature
Yang D
(2025)
Solution-processable polymer membranes with hydrophilic subnanometre pores for sustainable lithium extraction
in Nature Water
| Description | With the support of ERC-funded fundamental research, we have developed a next-generation hydrocarbon-based membrane that overcomes the performance limitations of existing ion-exchange membranes, particularly for redox flow battery (RFB) applications. This proof-of-concept grant provides a timely opportunity to explore commercialization pathways for our novel ion-selective membranes in energy storage applications. The primary objectives of this project are to upscale polymer synthesis for membrane manufacturing and to demonstrate their application in various electrochemical devices. Additionally, a key goal is to strengthen collaborations with industrial partners, conduct market analysis, and finalize strategies for business models and commercialization pathways. Significant progress has been made in scalable polymer synthesis, with production reaching up to 100 g through multiple polymerization batches in flasks. We have also established a polymerization reactor and successfully conducted larger-scale polymerization in single-batch mode. In membrane manufacturing, we collaborated with the Dalian Institute of Chemical Physics to gain expertise in large-scale production techniques. We faced challenges in producing sufficient material (kg scale) for roll-to-roll processing. However, we were able to demonstrate the potential of membrane manufacturing and successfully tested their performance in flow battery stacks with an effective area exceeding 200 cm², validating their efficiency. Furthermore, we have developed anion exchange membrane water electrolyzers, fabricated membrane electrode assemblies, and validated membrane performance, incorporating the results into a patent application. On the commercialization front, the results generated from this project allowed us to validate more examples and supported the application of one strong patent. We participated in the IP4U University Tech Fair, where we showcased our membrane technology. Additionally, we have established collaborations with several industrial partners, including bp and Shell, and conducted feasibility studies with start-up companies. We have also developed a robust business plan and are laying the groundwork for forming a start-up company. |
| Exploitation Route | The outcomes of this research have the potential to be taken forward through both academic and industrial pathways. In academia, our novel membranes and polymer materials can serve as a foundation for further studies in electrochemical energy storage and conversion, with broad applications in redox flow batteries, hydrogen production, fuel cells, and environmental processes. We anticipate that research groups working on sustainable energy materials and electrochemical systems will build upon our findings, leading to new developments in membrane technology and energy storage technologies. From an industrial perspective, our membranes offer a cost-effective alternative to Nafion, making them attractive to flow battery manufacturers, electrolyzer developers, and companies involved in electrochemical technologies. We expect industry partners, including energy companies and technology developers, to integrate our membranes into commercial-scale energy storage systems and water electrolysis units. Through our collaboration with industrial partners such as BP and Shell, as well as start-ups in the clean energy sector (RFC Power and AquaBattery), we aim to facilitate the adoption of our technology in commercial applications. Additionally, the formation of a start-up company will help bridge the gap between research and market deployment, ensuring long-term impact in the energy sector. |
| Sectors | Chemicals Energy Environment Manufacturing including Industrial Biotechology |
| Description | This grant has great potential to generate substantial economic and societal benefits by advancing cost-effective membrane technology for energy storage and hydrogen applications. By providing a viable alternative to expensive Nafion membranes, our research enhances the UK's competitiveness in the global clean energy market, supporting domestic manufacturing and attracting investment in sustainable technologies. The development of a start-up company is in progress, which will create high-value jobs, foster innovation, and drive commercialization, contributing to the UK's low-carbon economy. Our technology also has broader societal benefits, improving the efficiency and affordability of renewable energy storage and hydrogen production. This can enhance energy security, reduce consumer costs, and support the UK's transition to net-zero. Additionally, our work informs industrial strategies and policy discussions on sustainable energy solutions, strengthening collaboration between academia, industry, and government. Academically, this research has catalyzed new studies in polymer membrane development, providing a platform for further advancements in electrochemical energy systems. The breakthroughs achieved in ion-selective membranes could lead to transformative developments in next-generation batteries, fostering long-term scientific innovation. Through publications, patents, and technology demonstrations, our work is already influencing both fundamental research and commercial technology adoption, ensuring lasting impact across multiple sectors. |
| First Year Of Impact | 2023 |
| Sector | Chemicals,Energy,Environment |
| Impact Types | Societal Economic |
| Description | SynHiSel |
| Amount | £7,328,275 (GBP) |
| Funding ID | EP/V047078/1 |
| Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 02/2022 |
| End | 01/2027 |
| Description | Collaboration with AquaBattery on development of ion exchange membranes |
| Organisation | AquaBattery |
| Country | Netherlands |
| Sector | Private |
| PI Contribution | Provide membranes for feasibility studies and discussed results associated with the acid-base flow batteries. |
| Collaborator Contribution | Testing of materials and provide feedback. |
| Impact | We are exploring avenues for further funding to progress this research through the EU grants. |
| Start Year | 2024 |
| Description | Collaboration with RFC Power on testing redox flow batteries |
| Organisation | RFC Power |
| Country | United Kingdom |
| Sector | Private |
| PI Contribution | Collaboration with RFC Power on testing of membranes in redox flow batteries |
| Collaborator Contribution | Technical analysis of results |
| Impact | Understanding associated with development of improved membranes. |
| Start Year | 2023 |
| Title | Ion exchange membranes |
| Description | The patent describes a new generation of polymers and applications as ion exchange membranes for energy conversion and storage, including redox flow batteries. |
| IP Reference | |
| Protection | Patent / Patent application |
| Year Protection Granted | 2023 |
| Licensed | No |
| Description | Delegation of visit from Singapore A-Star |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Policymakers/politicians |
| Results and Impact | A delegation of 5 members from Singapore A-star agency visited Imperial College, which involved discussion and lab tour, and further connection between UK and Singapore. |
| Year(s) Of Engagement Activity | 2024 |
| Description | Environmental Audit Committee visit |
| Form Of Engagement Activity | Participation in an open day or visit at my research institution |
| Part Of Official Scheme? | No |
| Geographic Reach | National |
| Primary Audience | Policymakers/politicians |
| Results and Impact | The Environmental Audit Committee, a cross-party group of MPs established to examine environment and sustainable development policies across government, held its 25th anniversary celebration at Imperial College London. The group visited our laboratory and heard about research and developments into batteries for large scale energy storage. |
| Year(s) Of Engagement Activity | 2023 |
| URL | https://www.imperial.ac.uk/news/243552/environmental-audit-committee-celebrates-25th-anniversary/ |
| Description | Visit of France's Minister of Higher Education and Research Sylvie Retailleau |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Policymakers/politicians |
| Results and Impact | A delegation led by France's Minister of Higher Education and Research Sylvie Retailleau visited Imperial to signal the growing scientific ties between the UK and France. Dr Song participated in the meeting and showcased research in flow batteries. |
| Year(s) Of Engagement Activity | 2024 |
| URL | https://www.imperial.ac.uk/news/251795/french-research-minister-commends-growing-uk-france/ |