Lab Notebook Entry #8

A less crappy experiment but still need to dial in PP print settings
lab notebook
research
flow batteries
Author

Kirk Pollard Smith

Published

March 23, 2026

Ran another test like last time but with a new PP reservoir printed at .45 mm line width and 105% infill. It still leaked a small amount but way less, however still enough to tank the test, though not as bad as the last time.

Going to now explicitly mention the git commit corresponding to the RFB dev kit I’m using, as well as the types of gaskets used.

Also, here is a pic of the current setup:

Table 1: Test conditions
Electrolyte Composition (molarity, per L solution) 0.95 M ZnCl2, 1.82 M NH4Cl, 0.78 M KI, 0.34 M triethylene glycol, 42.99 M H2O
Electrolyte Composition (molality, per kg solution) 0.75 m ZnCl2, 1.45 m NH4Cl, 0.62 m KI, 0.27 m triethylene glycol, 34.20 m H2O
Electrolyte Volume 5.5 mL (anolyte) + 5.5 mL (catholyte)
Electrolyte Density 1.3 g/mL
RFB Dev Kit commit a411703e47
Cell Geometric Area 2 cm2
Separator Daramic AA-900
Anode Configuration Grafoil + 3.2 mm graphite felt
Cathode Configuration Grafoil + 3.2 mm graphite felt
Gaskets Outer and inner, 0.40 mm silicone (measured with micrometer)
Current Density 20 mA/cm2
Charging Conditions To 100 mAh (about 9 Ah/L) or 1.7 V
Discharging Conditions To 0 V
Flow Conditions Kamoer KHPP50KPK200 24 V brushless peristaltic pumps at 40% duty cycle (about 1500 rpm) with 3x5 mm Tygon Chemical (PTFE-lined BPT) tubing

Here are the raw data of the test with the conditions shown in Table 1.

Changed the rolling mean variable from 1 to 2 to cope with the raw data that was splitting the 5th cycle otherwise.

Code
import pandas as pd
from tqdm import tqdm, notebook
import numpy as np
import scipy
import plotly.express as px
import plotly.graph_objects as go
import kaleido
from IPython.display import Image

tqdm_disabled = True  # True for website, change to False for local work

sampling = True

MIN_POINTS0 = 500
DIFF_LIMIT = 0.1


# electrolyte component masses, in g
MASS_ZnCl2  = 1.42
MASS_NH4Cl  = 1.07
MASS_KI     = 3.33
MASS_H2O    = 8.52
MASS_TriEG  = 0.56

total_mass_kg = (MASS_ZnCl2 + MASS_KI + MASS_H2O + MASS_TriEG)/1000.

TOTAL_VOLUME = 11  # electrolyte volume in mL, approx, measured by taking as much electrolyte as possible up into a 12 mL syringe

MASS_TO_RESERVOIRS = 14.37 # g of electrolyte actually loaded into system, based on weighing syringe before/after loading reservoirs
# molecular weights in g/mol

density = MASS_TO_RESERVOIRS/TOTAL_VOLUME

MW_ZnCl2  = 136.315
MW_NH4Cl  = 53.49
MW_KI     = 166.0028 
MW_H2O    = 18.01528
MW_TriEG  = 150.174

molality_ZnCl2 = MASS_ZnCl2/MW_ZnCl2/total_mass_kg
molality_NH4Cl = MASS_NH4Cl/MW_NH4Cl/total_mass_kg
molality_KI = MASS_ZnCl2/MW_KI/total_mass_kg
molality_TriEG = MASS_TriEG/MW_TriEG/total_mass_kg
molality_H2O = MASS_H2O/MW_H2O/total_mass_kg

molarity_ZnCl2 = MASS_ZnCl2/MW_ZnCl2/TOTAL_VOLUME*1000.
molarity_NH4Cl = MASS_NH4Cl/MW_NH4Cl/TOTAL_VOLUME*1000.
molarity_KI = MASS_ZnCl2/MW_KI/TOTAL_VOLUME*1000.
molarity_TriEG = MASS_TriEG/MW_TriEG/TOTAL_VOLUME*1000.
molarity_H2O = MASS_H2O/MW_H2O/TOTAL_VOLUME*1000.

if not tqdm_disabled:
    print("Electrolyte Composition:")


    print("Molarities (moles/L solution): {:.2f} M ZnCl~2~, {:.2f} M NH~4~Cl, {:.2f} M KI, {:.2f} M triethylene glycol, {:.2f} M H~2~O\n".format(molarity_ZnCl2, molarity_NH4Cl, molarity_KI, molarity_TriEG, molarity_H2O))
    print("Molalities (moles/kg solution): {:.2f} m ZnCl~2~, {:.2f} m NH~4~Cl, {:.2f} m KI, {:.2f} m triethylene glycol, {:.2f} m H~2~O\n".format(molality_ZnCl2, molality_NH4Cl, molality_KI, molality_TriEG, molality_H2O))
    print("Density approx. {:.1f} g/mL".format(density))


filenames = ["22-03-2026-KPS-4.txt"]

all_data = []
for f in filenames:
    if len(all_data) == 0:
        if "Potentiostat_project" in f:
            all_data.append(pd.read_csv(f))
        else:
            all_data.append(pd.read_csv(f, delimiter="\t"))
    else:
        df0 = pd.read_csv(f, delimiter="\t")
        df0["Elapsed time(s)"] += all_data[-1]["Elapsed time(s)"].iat[-1]
        all_data.append(df0)

df = pd.concat(all_data, ignore_index=True)

df["mean_current"] = df["Current(A)"].rolling(2).mean()
df["prev_current"] = df["mean_current"].shift(-1)
df["VChange"] = df["Potential(V)"].diff().abs()
df["is_change"] = (
    ((df["mean_current"] > 0) & (df["prev_current"] < 0))
    | ((df["mean_current"] < 0) & (df["prev_current"] > 0))
).astype(int)

idx_changes = list(df[df["is_change"] == 1].index)
idx_changes.append(len(df) - 1)

all_curves = []
idx_start = 0
for idx in tqdm(idx_changes, disable=tqdm_disabled):
    if len(df.iloc[idx_start:idx, :]) > 50:
        all_curves.append(df.iloc[idx_start:idx, :])
    idx_start = idx

results = []
n_curves = np.max([1, int(np.floor(len(all_curves) / 2))])

for CN in notebook.tnrange(n_curves, disable=tqdm_disabled):
    CURVE_N1 = CN * 2
    CURVE_N2 = CN * 2 + 1

    # Process charge data

    if sampling:
        N_TERM_POINTS = int(np.min([MIN_POINTS0, len(all_curves[CURVE_N1]) / 2.0]))
        MIN_POINTS = int(
            np.min([MIN_POINTS0, len(all_curves[CURVE_N1]) - N_TERM_POINTS * 2])
        )

        df0 = pd.concat(
            [
                all_curves[CURVE_N1].iloc[:N_TERM_POINTS],
                all_curves[CURVE_N1]
                .iloc[N_TERM_POINTS:-N_TERM_POINTS]
                .sample(n=MIN_POINTS),
                all_curves[CURVE_N1].iloc[-N_TERM_POINTS:],
            ]
        ).sort_values("Elapsed time(s)", ascending=True)
        df0 = df0[df0["VChange"] < DIFF_LIMIT]
    else:
        df0 = all_curves[CURVE_N1].copy()
    df0["mAh"] = np.abs(
        scipy.integrate.cumulative_trapezoid(
            df0["Current(A)"], df0["Elapsed time(s)"], initial=0
        )
        * 1000.0
        / 3600.0
    )
    total_energy0 = scipy.integrate.cumulative_trapezoid(
        df0["Current(A)"].abs() * df0["Potential(V)"],
        df0["Elapsed time(s)"],
        initial=0.0,
    )[-1]

    # Process discharge data
    if sampling:
        N_TERM_POINTS = int(np.min([MIN_POINTS0, len(all_curves[CURVE_N2]) / 2.0]))
        MIN_POINTS = int(
            np.min([MIN_POINTS0, len(all_curves[CURVE_N2]) - N_TERM_POINTS * 2])
        )
        df1 = pd.concat(
            [
                all_curves[CURVE_N2].iloc[:N_TERM_POINTS],
                all_curves[CURVE_N2]
                .iloc[N_TERM_POINTS:-N_TERM_POINTS]
                .sample(n=MIN_POINTS),
                all_curves[CURVE_N2].iloc[-N_TERM_POINTS:],
            ]
        ).sort_values("Elapsed time(s)", ascending=True)
        df1 = df1[df1["VChange"] < DIFF_LIMIT]
    else:
        df1 = all_curves[CURVE_N2].copy()

    df1["mAh"] = np.abs(
        scipy.integrate.cumulative_trapezoid(
            df1["Current(A)"], df1["Elapsed time(s)"], initial=0.0
        )
        * 1000.0
        / 3600.0
    )
    total_energy1 = scipy.integrate.cumulative_trapezoid(
        df1["Current(A)"].abs() * df1["Potential(V)"],
        df1["Elapsed time(s)"],
        initial=0.0,
    )[-1]

    CE = 100.0 * (df1["mAh"].iloc[-1] / df0["mAh"].iloc[-1])
    EE = 100.0 * (total_energy1 / total_energy0)
    VE = 100.0 * EE / CE
    results.append(
        {
            "Number": CN + 1,
            "CE": CE,
            "VE": VE,
            "EE": EE,
            "Charge_potential": df0["Potential(V)"].mean(),
            "Discharge_potential": df1["Potential(V)"].mean(),
            "Charge_stored": df1["mAh"].iloc[-1] / TOTAL_VOLUME,
            "Energy_density_discharge": total_energy1 / TOTAL_VOLUME / 3600.0 * 1000,
        }
    )

    # Save the modified DataFrames back to the all_curves list
    all_curves[CURVE_N1] = df0
    all_curves[CURVE_N2] = df1

results_df = pd.DataFrame(results)

# results_df = results_df[:4] #only first 4 cycles are worth plotting

if not tqdm_disabled:
    print(results_df)
    print("")
    print(results_df.mean())

# Plot charge/discharge curves
fig1 = go.Figure()
for CN in range(n_curves):
    CURVE_N1 = CN * 2
    CURVE_N2 = CN * 2 + 1
    fig1.add_trace(
        go.Scatter(
            x=all_curves[CURVE_N1]["mAh"] / TOTAL_VOLUME,
            y=all_curves[CURVE_N1]["Potential(V)"],
            mode="lines",
            name=f"Charge {CN+1}",
            line=dict(color="blue", dash="solid"),
        )
    )
    fig1.add_trace(
        go.Scatter(
            x=all_curves[CURVE_N2]["mAh"] / TOTAL_VOLUME,
            y=all_curves[CURVE_N2]["Potential(V)"],
            mode="lines",
            name=f"Discharge {CN+1}",
            line=dict(color="grey", dash="solid"),
        )
    )
fig1.update_layout(
    title="Charge and Discharge Curves",
    xaxis_title="Capacity (Ah/L)",
    yaxis_title="Potential (V)",
)

fig1.show()
Figure 1: Charge/discharge curves
Code
# Plot efficiency
fig2 = px.scatter(
    results_df,
    x="Number",
    y=["CE", "VE", "EE"],
    labels={"value": "Efficiency (%)", "variable": "Metric"},
    title="Efficiency by Cycle",
)
fig2.update_traces(mode="markers")
fig2.update_layout(\
    yaxis=dict(range=[-10, 100])
)



fig2.show()

# Plot potential
# fig3 = px.scatter(results_df, x="Number", y=["Charge_potential", "Discharge_potential"],
#                labels={"value": "Potential (V)", "variable": "Metric", "Number": "Cycle Number"},
#                title="Mean Potential by Cycle")
# fig3.show()
Figure 2: Charge/discharge efficiencies of zinc-iodide chemistry decaying due to a leak
Code
# Plot discharge charge capacity
# fig4 = px.scatter(results_df, x="Number", y="Charge_stored",
#                labels={"Charge_stored": "Discharge Capacity (Ah/L)", "Number": "Cycle Number"},
#                title="Discharge Capacity by Cycle")
# fig4.show()

# Plot discharge energy capacity
fig5 = px.scatter(
    results_df,
    x="Number",
    y="Energy_density_discharge",
    labels={
        "Energy_density_discharge": "Energy Density on Discharge (Wh/L)",
        "Number": "Cycle Number",
    },
    title="Energy Density by Cycle",
)
fig5.show()
Figure 3: Discharge energy densities decaying
Code
table_df = (
    results_df.describe().loc[["mean", "std"]]
    .round(decimals=1)
    .drop(columns=["Number", "Charge_potential", "Discharge_potential"])
    .rename(
        columns={
            "CE": "Coulombic Efficiency (%)",
            "EE": "Energy Efficiency (%)",
            "VE": "Voltaic Efficiency (%)",
            "Charge_stored": "Discharge Capacity (Ah/L)",
            "Energy_density_discharge": "Energy Density (Wh/L)",
        }
    )
)

# Bar chart of efficiencies with error bars
eff_cols = ["Coulombic Efficiency (%)", "Voltaic Efficiency (%)", "Energy Efficiency (%)"]
eff_labels = ["Coulombic", "Voltaic", "Energy"]

means = table_df.loc["mean", eff_cols].values
stds = table_df.loc["std", eff_cols].values
Code
fig6 = go.Figure()
fig6.add_trace(go.Bar(
    x=eff_labels,
    y=means,
    error_y=dict(type="data", array=stds, visible=True),
    name="Efficiency",
    marker_color=["#1f77b4", "#ff7f0e", "#2ca02c"]
))
fig6.update_layout(
    title="Efficiencies with Standard Deviations",
    yaxis_title="Efficiency (%)",
    yaxis=dict(range=[0, 100])
)
fig6.show()
Figure 4: Mean efficiency values with standard deviation
Code
cap_cols = ["Discharge Capacity (Ah/L)"]
cap_labels = ["Discharge Capacity"]

cap_means = table_df.loc["mean", cap_cols].values
cap_stds = table_df.loc["std", cap_cols].values

fig7 = go.Figure()
fig7.add_trace(go.Bar(
    x=cap_labels,
    y=cap_means,
    error_y=dict(type="data", array=cap_stds, visible=True),
    name="Capacity",
    marker_color="#1f77b4"
))
fig7.update_layout(
    title="Discharge Capacity with Standard Deviation",
    yaxis_title="Discharge Capacity (Ah/L)"
)
fig7.show()
Figure 5: Mean discharge capacity value with standard deviation
Code
ed_cols = ["Energy Density (Wh/L)"]
ed_labels = ["Energy Density"]

ed_means = table_df.loc["mean", ed_cols].values
ed_stds = table_df.loc["std", ed_cols].values

fig8 = go.Figure()
fig8.add_trace(go.Bar(
    x=ed_labels,
    y=ed_means,
    error_y=dict(type="data", array=ed_stds, visible=True),
    name="Energy Density",
    marker_color="#2ca02c"
))
fig8.update_layout(
    title="Energy Density with Standard Deviation",
    yaxis_title="Energy Density (Wh/L)"
)
fig8.show()
Figure 6: Mean energy density value on discharge with standard deviation

Well, it’s better, but still pretty bad. On the to next one.

Next steps

Now printing another double reservoir at 107% infill (vs. 105%), same line width, for another test.

Also, Daniel just posted some of his latest findings on the Zn-Br sulfamate stability issue!

Citation

BibTeX citation:
@online{smith2026,
  author = {Smith, Kirk Pollard},
  title = {Lab {Notebook} {Entry} \#8},
  date = {2026-03-23},
  url = {https://dualpower.supply/posts/lab-notebook-8/},
  langid = {en}
}
For attribution, please cite this work as:
K.P. Smith, Lab Notebook Entry #8, (2026). https://dualpower.supply/posts/lab-notebook-8/.