In-Situ Resource Utilization-Derived Iron Perchlorate Redox Flow Battery for Mars: Electrolyte Characterization and Extreme Cold Performance Validation

Chris Z. Liu^1,2Kaiyue Deng³Kun Fu³Hansan Liu^1*

• ¹Talos Tech LLC, New Castle, United States
• ²Charter School of Wilmington, Wilmington, United States
• ³University of Delaware, Newark, United States

Sustained habitation on Mars demands robust energy storage systems capable of reliable operation under extreme cold, especially during night and dust storm periods that render conventional lithium-ion batteries ineffective. This work introduces an in-situ resource utilization (ISRU) strategy for constructing iron perchlorate redox flow batteries, fully leveraging Martian-available materials to achieve extreme cold resilience. Eutectic freezing points and ionic conductivities of three Martain-available electrolytes (iron sulfate, iron chloride, and iron perchlorate) were systematically characterized. Iron perchlorate aqueous solution at 45 wt% displayed a eutectic freezing point of - 78°C, outperforming iron chloride (-55°C) and iron sulfate (-10°C). Laboratory-scale single cells were developed via computer-aided design and 3D printing, then tested under simulated Martian low-temperature conditions. The iron perchlorate system maintained 56% of its room-temperature capacity at -50°C and remained operational at -70°C, while iron chloride cells retained only 25% at - 50°C and lost functionality at lower temperatures. Electrochemical impedance measurements revealed that, although electrolyte resistance increases at lower temperature, charge transfer resistance becomes the dominant limiting factor under extreme cold. The results establish that ISRU-derived iron perchlorate flow batteries offer a feasible, cold-resilient solution for reliable energy storage in future Mars surface operations and settlement, with further performance gains likely through advanced perchlorate brine formulation.