Recently, novel concepts of electrochemical cells have been spotlighted for ultra-charge energy storage system. Among these cells, magnesium alloy (AZ31) air batteries have attracted much attention as promising energy conversion devices due to their high theoretical energy density, eco-friendly materials and low fabrication cost. Although AZ31–air battery is a primary battery, the AZ31–air battery can be re-used or recharged mechanically by replacing the consumed AZ31 anode and turbid electrolyte with a fresh AZ31 anode and electrolyte, refering to “re-fuelable” During the discharge process, the AZ31 anode is oxidized to ionized Mg, producing two electrons, while at the opposite carbon air-cathode, oxygen molecules pass through the gas diffusion layer and is then reduced to OH− by reaction with H2O and electrons. The theoretical voltage of the AZ31–air battery is 1.2 V and the specific energy density is 2.2 kW h kg−1. Though AZ31–air batteries have a relative high voltage and energy density, there are still scientific problems limiting their pilot scale application. The main issue of cell is the high polarization and low coulombic efficiency. These problems are caused by the corrosion of the metal anode arising from the reaction of metal ions and the electrolyte, and the sluggish by-product kinetics in the air-cathode. In this work, we combined Mg-air batteries with electrolyte flow system, called metal-air flow battery (MAFB) in order to enhance the discharge properties and lifetime by solving the sluggish by-product problems. The components of anode and electrolyte were AZ31 (magnesium alloy) as a fuel and 18wt% saline aqueous solution. The circulation of electrolyte flow efficiently reduces the coagulation of Mg(OH)2 by-product in the unit-cells. As a result, the anode surface efficiency has increased from 72 to above 90 % after the use of flow system. In addition, we have successfully design and developed the metal-air flow battery from unit-cell to rack system. The rack system is made up of 25 series of electrically wired unit-cells for modules and 4-level of modules with electrolyte flow system. The flow system conducted simultaneously in each unit-cells by electrolyte supply tank in the top and by-product filter tank in the bottom. From the rack system, a pilot scale MAFB with 400 pieces of unit-cells was developed and fabricated for ultra-large energy storage system. The 704 kWh of energy storage system demonstrated by 25s-16p electrical wiring with 4-rack flow systems. As a result, it is the first report about the MAFB using AZ31 anodes in pilot-scale energy storage system. It has shown a large potential for future energy conversion devices for smart grid applications. Figure 1
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