Coordination of European Research on Industrial Safety towards Smart and Sustainable Growth
Redox Flow Batteries (RFBs) are increasingly recognised as key technologies for large-scale energy storage, supporting grid stability and the integration of renewable energy sources. Current RFB systems, however, rely on membranes and auxiliary components that contain per- and polyfluoroalkyl substances (PFAS) and other substances of concern due to their chemical stability and electrochemical performance. These substances are persistent, potentially toxic and subject to increasing regulatory scrutiny, raising concerns for both environmental protection and occupational health and safety. Workers may be exposed during membrane manufacturing, system operation, maintenance, recycling and end-of-life treatment, particularly when mechanical processing generates fine and ultrafine particles. At present, there is limited systematic knowledge on the identity, release behaviour and toxicity of PFAS and alternative materials in RFB systems. In addition, existing assessment approaches rarely integrate environmental impacts, occupational risks and social aspects in a coherent framework. PFESS addresses these gaps by generating evidence-based knowledge to support the transition towards PFAS-free, safe and sustainable redox flow battery technologies.
The project investigates which PFAS, substances of concern and substances of very high concern are present in current RFB components and how they can be systematically identified and documented. It examines whether PFAS-free membrane alternatives can meet electrochemical and durability requirements while reducing environmental and occupational risks. The project explores how manufacturing and recycling processes influence particle and contaminant release and how these releases differ between conventional and alternative materials. Further research questions address the human and ecotoxicological effects of released particles, the feasibility of in-situ monitoring of membrane degradation and electrolyte contamination, and the prediction of membrane lifetime. The project also investigates how life-cycle assessment, chemical footprint analysis and OHS-driven social life cycle assessment can be combined to identify risk hotspots and support Safe-and-Sustainable-by-Design decision-making for energy storage technologies.
PFESS will deliver a comprehensive product inventory of RFB components identifying PFAS, substances of concern and viable PFAS-free alternatives together with their functional requirements. The project will generate experimental data on particle and contaminant release during simulated manufacturing and recycling processes, supported by human toxicity and ecotoxicity testing. Validated methods for in-situ monitoring of membrane performance, degradation and electrolyte contamination will be developed. Comparative life-cycle, chemical footprint and social impact assessments will be produced to identify environmental and occupational risk hotspots. The project will deliver a set of Safe-and-Sustainable-by-Design key performance indicators and evidence-based recommendations to support industrial development and regulatory decision-making for PFAS-free RFB systems.
The project is implemented over 24 months through five interconnected work packages. - WP1 – Product inventory and life-cycle considerations: identifies PFAS, substances of concern and PFAS-free alternatives in redox flow battery components and maps exposure pathways across the full life cycle. - WP2 – Experimental circularity, toxicity assessment and PFAS monitoring: simulates manufacturing and recycling processes to assess particle and contaminant release and evaluates associated human and ecotoxicological effects. - WP3 – Risk-based LCA and social impact analysis: applies life-cycle assessment, chemical footprinting and OHS-driven social LCA to identify environmental and occupational risk hotspots. - WP4 – SSbD KPIs and sustainability recommendations: defines and validates Safe-and-Sustainable-by-Design key performance indicators and comparative assessment models for membrane technologies. - WP5 – Project management and dissemination: ensures overall coordination, reporting, dissemination of results and engagement with relevant stakeholders.
BMK
Austria
OSALAN
Spain
