Numerical study of optimized three-dimension novel Key-shaped flow field design for proton exchange membrane fuel cell

Key-shaped three-dimension (3D) flow field channel is designed to improve the performance and mass transfer of proton exchange membrane fuel cell (PEMFC). This study comprehensively analyses the impacts on the performance and mass transfer of the flow channel from multiple dimensions such as the size, shape, and placement of the blocks. In comparison with the conventional straight single flow field channel, the new channel with rectangular blocks can effectively improve performance by 30%. Semi-elliptical and quarter-elliptical blocks are designed to make forced convection and increase the diffusion area of oxygen. The results indicate that the flow velocity in the Z-axis direction can be increased to 0.08–0.2 m/s due to the narrow space formed by variable cross-sections. In conclusion, the Key-shaped design has a potential to improve the performance of mass transfer in the cathode channel, providing a new strategy for the development of flow field design in PEMFC field.     

Numerical study of cell performance and local transport phenomena in PEM fuel cells with various flow channel area ratios

Three-dimensional models of proton exchange membrane fuel cells (PEMFCs) with parallel and interdigitated flow channel designs were developed including the effects of liquid water formation on the reactant gas transport. The models were used to investigate the effects of the flow channel area ratio and the cathode flow rate on the cell performance and local transport characteristics. The results reveal that at high operating voltages, the cell performance is independent of the flow channel designs and operating parameters, while at low operating voltages, both significantly affect cell performance. For the parallel flow channel design, as the flow channel area ratio increases the cell performance improves because fuel is transported into the diffusion layer and the catalyst layer mainly by diffusion. A larger flow channel area ratio increases the contact area between the fuel and the diffusion layer, which allows more fuel to directly diffuse into the porous layers to participate in the electrochemical reaction which enhances the reaction rates. For the interdigitated flow channel design, the baffle forces more fuel to enter the cell and participate in the electrochemical reaction, so the flow channel area ratio has less effect. Forced convection not only increases the fuel transport rates but also enhances the liquid water removal, thus interdigitated flow channel design has higher performance than the parallel flow channel design. The optimal performance for the interdigitated flow channel design occurs for a flow channel area ratio of 0.4. The cell performance also improves as the cathode flow rate increases. The effects of the flow channel area ratio and the cathode flow rate on cell performance are analyzed based on the local current densities, oxygen flow rates and liquid water concentrations inside the cell.     

Local transport phenomena and cell performance of PEM fuel cells with various serpentine flow field designs

The flow field design in bipolar plates is very important for improving reactant utilization and liquid water removal in proton exchange membrane fuel cells (PEMFCs). A three-dimensional model was used to analyze the effect of the design parameters in the bipolar plates, including the number of flow channel bends, number of serpentine flow channels and the flow channel width ratio, on the cell performance of miniature PEMFCs with the serpentine flow field. The effect of the liquid water formation on the porosities of the porous layers was also taken into account in the model while the complex two-phase flow was neglected. The predictions show that (1) for the single serpentine flow field, the cell performance improves as the number of flow channel bends increases; (2) the single serpentine flow field has better performance than the double and triple serpentine flow fields; (3) the cell performance only improves slowly as the flow channel width increases. The effects of these design parameters on the cell performance were evaluated based on the local oxygen mass flow rates and liquid water distributions in the cells. Analysis of the pressure drops showed that for these miniature PEMFCs, the energy losses due to the pressure drops can be neglected because they are far less than the cell output power.     

A flow channel design procedure for PEM fuel cells with effective water removal

Proper water management in polymer electrolyte membrane (PEM) fuel cells is critical to achieve the potential of PEM fuel cells. Membrane electrolyte requires full hydration in order to function as proton conductor, often achieved by fully humidifying the anode and cathode reactant gas streams. On the other hand, water is also produced in the cell due to electrochemical reaction. The combined effect is that liquid water forms in the cell structure and water flooding deteriorates the cell performance significantly. In the present study, a design procedure has been developed for flow channels on bipolar plates that can effectively remove water from the PEM fuel cells. The main design philosophy is based on the determination of an appropriate pressure drop along the flow channel so that all the liquid water in the cell is evaporated and removed from, or carried out of, the cell by the gas stream in the flow channel. At the same time, the gas stream in the flow channel is maintained fully saturated in order to prevent membrane electrolyte dehydration. Sample flow channels have been designed, manufactured and tested for five different cell sizes of 50, 100, 200, 300 and 441 cm². Similar cell performance has been measured for these five significantly different cell sizes, indicating that scaling of the PEM fuel cells is possible if liquid water flooding or membrane dehydration can be avoided during the cell operation. It is observed that no liquid water flows out of the cell at the anode and cathode channel exits for the present designed cells during the performance tests, and virtually no liquid water content in the cell structure has been measured by the neutron imaging technique. These measurements indicate that the present design procedure can provide flow channels that can effectively remove water in the PEM fuel cell structure.     

Fluid-dynamic characterization of real-scale raceway reactors for microalgae production

The fluid dynamic characterization of a 100 m length × 1 m wide channel raceway photobioreactor was carried out. The effects of water depth, liquid velocity and the presence, or absence, of sump baffles to improve the CO₂ supply transfer were considered in relation to on the power consumption, residence time and mixing in the reactor was studied. When operated at a depth of 20 cm, the power consumption was between 1.5 and 8.4 W m⁻³ depending on the forward velocity, with higher values occurring when the baffle was in place. Residence times and the degree of mixing at each section of the raceway (paddlewheel, bends, channels and sump) were measured experimentally. Mixing occurred mainly in the sump, paddlewheel and bends, with a maximum dispersion coefficient of 0.07 m² s⁻¹. These sections, however, only contributed a small fraction to the total volume of the raceway. Bodenstein numbers from 200 to 540 for the channel sections indicated plug-flow characteristics. Mixing times ranged from 1.4 to 6 h, with the presence of the baffle greatly increasing these times despite higher specific power consumption. A total of 15–20 circuits of the raceway were needed to achieve complete mixing without the baffle, compared to 30–40 cycles with the baffle. Vertical mixing was very poor whereas axial mixing was similar to that achieved in closed photobioreactors. The methodologies applied were shown to be useful in determining the fluid dynamics of a raceway photobioreactor. Equations useful in simulating the power consumption as a function of the design and operation parameters have been validated.     

A flow field enabling operating direct methanol fuel cells with highly concentrated methanol

In this work, an anode flow field that allows a direct methanol fuel cell (DMFC) to operate with highly concentrated methanol is developed and tested. The basic idea of this flow field design is to vaporize methanol solution in the flow field by utilizing the heat generated from the fuel cell so that the methanol concentration in the anode catalyst layer can be controlled to an appropriate level. The flow field is composed of two parallel flow channel plates, separated with a gap. The upper plate with a grooved serpentine flow channel is to vaporize a highly concentrated methanol solution to ensure the fuel to be completely vaporized before it enters the gap, while the lower plate, perforated to form a serpentine flow channel and located between the gap and the membrane electrode assembly (MEA), is to uniformly distribute the fuel onto the anode surface of the MEA. The test results show that this unique flow field design enables the DMFC operating with 16.0-M methanol to yield a power output similar to that with the conventional flow field design with 2.0-M methanol, significantly increasing the specific energy of the DMFC system. Finally, the effects of methanol solution flow rates and operating temperature on cell performance are investigated.     

Direct measurement of current density under the land and channel in a PEM fuel cell with serpentine flow fields

One of the most common types of flow field designs used in proton exchange membrane (PEM) fuel cells is the serpentine flow field. It is used for its simplicity of design, its effectiveness in distributing reactants and its water removal capabilities. The knowledge about where current density is higher, under the land or the channel, is critical for flow field design and optimization. Yet, no direct measurement data are available for serpentine flow fields. In this study a fuel cell with a single channel serpentine flow field is used to separately measure the current density under the land and channel, which is either catalyzed or insulated on the cathode. In this manner, a systematic study is conducted under a wide variety of conditions and a series of comparisons are made between land and channel current density. The results show that under most operating conditions, current density is higher under the land than that under the channel. However, at low voltage, a rapid drop off in current density occurs under the land due to concentration losses. The mechanisms for the direct measurement results and general guidelines for serpentine flow field design and optimizations are provided.     

Numerical simulation of water droplet transport characteristics in cathode channel of proton exchange membrane fuel cell with tapered slope structures

In proton exchange membrane fuel cells (PEMFC), the design of the cathode flow field is very important, because an excellent flow channel design can not only accelerate the transmission rate of liquid water, but also affect the distribution of electrode reactants and electrode products which influence the electrochemical performance of the fuel cell. This study presents three new channels (models 1,2 and 3), which were created using two unilateral slopes and a bilateral slope structure with tapered tube lengths of 0.4, 1.2 and 0.8 mm, respectively. The dynamic behavior of liquid water under the three design schemes is numerically studied based on the volume of fluid method. And the influence on the performance of fuel cell was analyzed synthetically. The results indicate that the introduction of a tapered and sloping structure can improve the transmission efficiency of the droplets in the flow channel, and the maximum droplet removal time of the new channel can be reduced by 24.4%compare with standard conventional flow channel. The slope structure guides the flow path of water droplet and reduces the occurrence of droplet spatter. Influenced by the slope and tapered structures, the turbulence of airflow near the bottom surface (gas diffusion layer)of the flow channel is enhanced and Oxygen concentration in the cathode is raised, which improves the mass transfer capacity and average current density of reactive surface. In conclusion, the new type of channel with a tapered and sloping structure has a potential to improve the performance of water management in the cathode channel of PEMFC.     

Design Approaches to Mitigate Electrical Installation Problems in Nuclear Power Generating Stations

Large power generating stations have experienced a constant rise in the in-plant costs of electrical installation. Many techniques can be employed such as computerized cable and conduit schedules open type raceway supports, bulk cable pulling, setting up of planning teams for cable, termination, etc. The improvements recommended in this study can result in significant cost savings as shown in Table 2 as a result of minimized rework during construction, increased productivity of field personnel, and construction schedule improvements. The methods include additional design details to the constructor, improved design of cable tray supports, increased use of computer aided design for electrical raceways and cable pulling and cable termination, without using cable lugs. The implementation of these methods on the Large Scale Prototype Breeder Plant has resulted in an estimated installation cost saving of over $11 million.     

Assisted water management in a PEMFC with a modified flow field and its effect on performance

This work designed and tested innovative flow channels in order to improve water management in a polymer electrolyte membrane fuel cell (PEMFC). The design employed slanted channels with an angle of 20° in a flow plate to collect the liquid water that permeated from the gas diffusion layers. The effects of orientations of the slanted channels in up-slanted and down-slanted directions and relative humidity levels on the cell performance were investigated. The experimental results showed that modifying the anode flow field using down-slanted channels provided higher cell performance. Water concentration at the gas diffusion layer is reduced resulting in more back diffusion of water from the cathode to anode, thus inducing membrane hydration and improving the conductivity. Promotion of water removal by applying down-slanted channels in the cathode side did not improve the performance. This work has demonstrated that channel cross-section design alone could improve the PEM fuel cell performance. The anode down-slanted cell indeed improved the performances at extremely wet condition and the power was equally good as that without modified flow channel at less wet condition.     

Three-dimensional numerical study on cell performance and transport phenomena of PEM fuel cells with conventional flow fields

In this paper, a three-dimensional numerical model of the proton exchange membrane fuel cells (PEMFCs) with conventional flow field designs (parallel flow field, Z-type flow field, and serpentine flow field) has been established to investigate the performance and transport phenomena in the PEMFCs. The influences of the flow field designs on the fuel utilization, the water removal, and the cell performance of the PEMFC are studied. The distributions of velocity, oxygen mass fraction, current density, liquid water, and pressure with the convention flow fields are presented. For the conventional flow fields, the cell performance can be enhanced by adding the corner number, increasing the flow channel length, and decreasing the flow channel number. The cell performance of the serpentine flow field is the best, followed by the Z-type flow field and then the parallel flow field.     

An improved serpentine flow field with enhanced cross-flow for fuel cell applications

The paper describes a flow field design which is based on the improvement of the local cross-flow conditions in a split serpentine flow field. The layout of the flow field is such that the cross-flow is higher in the oxygen-depleted portion of the adjacent serpentine channel in a split serpentine flow field with more than one serpentine channels. The present arrangement offers the quadruple advantage of uniform reactant distribution over the entire cell active area; low overall pressure drop, thereby reducing the parasitic power losses; effective liquid water evacuation in the U-bends; and more oxygen replenishment in the oxygen-deficient portions of the serpentine channel. Computational fluid dynamics (CFD) and experimental analysis carried out on the proposed design with three serpentine channels confirm the benefits.     

Development of a new airlift-driven raceway reactor for algal cultivation

This paper presents the development and analysis of a new airlift-driven raceway reactor configuration for energy-efficient algal cultivation. A theoretical analysis of the energy requirements for traditional paddlewheel-driven raceway reactors and the proposed airlift-driven raceway reactors is presented. A hydrodynamic model was developed to predict the liquid circulation velocity in the reactor system based on theoretical energy balance. The predicted liquid velocity agreed well with experimentally measured liquid velocity with r² = 0.89. Based on the results of this analysis, the energy required for maintaining typical raceway velocity of 14 cm/s for mixing and keeping the cultures in suspension in a paddlewheel-driven raceway could be reduced by as much as 80% with the proposed configuration. Growth of Scenedesmus sp. was evaluated in a laboratory scale, 20 L version of the proposed reactor configuration using artificial lighting under ambient temperatures without any supplementary carbon dioxide sparging. The volumetric algal biomass productivity achieved in the proposed configuration (0.16 ± 0.03 dry g/L day) is comparable or better than that reported in the literature for paddlewheel-driven raceways.     

A novel cathode flow field for PEMFC and its performance analysis

A good flow field design is important to the proton exchange membrane fuel cell (PEMFC) performance, especially under a high current density region, which is dominated by concentration polarization. Motivated by the variable cross-section channel idea, in this study, a novel flow field containing a converging-diverging (C-D) pattern is proposed. A three-dimensional multiphase model is established to study its performance. The numerical results show that it outperforms the conventional straight channel and only depth-variant channel. In the novel flow field the enhanced under land cross flow and higher effective mass transfer coefficient both improve the reactant transport. The effects of operating conditions, like stoichiometric ratio and operating pressure, on cell output performance are studied. It is found that a higher promotion rate can be obtained by increasing the stoichiometric ratio, but increasing the operating pressure has little effect. The droplet dynamic behavior in the C-D channel and straight channel are studied, and the results prove the better drainage capability of the novel flow field.     

Performance of unit PEM fuel cells with a leaf-vein-simulating flow field-patterned bipolar plate

This study was conducted to investigate the performance of 25-cm²-unit polymer electrolyte fuel cells, the bipolar plate of which has a flow field that simulates leaf veins. The test flow fields were serpentine, parallel, and net leaf flow fields mimicking ginkgo and dicotyledonous leaves. The maximum power density for the ginkgo flow field was 7% lower than that for the serpentine flow field, and 40% higher than that for the parallel flow field under normal operating conditions. However, the air-feeding power required by the ginkgo was only 3% of that required by the serpentine. The usable power density for the ginkgo flow field was the highest among all flow fields. Additionally, the water-removal capability of the ginkgo flow field was superior to that of the parallel and net leaf flow fields, but inferior to that of the serpentine flow field. Furthermore, the amount of water remaining in the flow field channels was found to be correlated to the length of the unit channel. Therefore, the ginkgo pattern can be considered to be an optimal flow field design for the fuel cell.     

Numerical simulation and experimental study on the effect of symmetric and asymmetric bionic flow channels on PEMFC performance under gravity

In proton exchange membrane fuel cell (PEMFC), bionic flow field design is to apply the biological characteristics of nature to the structure design of flow field. The flow field designed by bionics can improve the water balance of the fuel cell and make the fuel distribute uniformly in the flow field. In order to study the PEMFC performance of symmetric and asymmetric bionic flow channel under gravity, the simulation and visualization experiments are used to study the bionic flow channel in different orientations. Under the influence of gravity, the distribution characteristics of liquid water are changed in the flow channel, and the difference of the transport process of liquid water in two different bionic flow channel under gravity is obtained. The results of the simulation and visualization experiments show that the gravity has a significant effect on the transport process of liquid water in the bionic flow channel, and the water transport process in the two types of bionic flow channel is obviously different. Meanwhile, the performance of the fuel cells with two bionic flow channel at different orientations is tested by experiments. The results show that gravity has a significant effect on the performance of PEMFC with bionic flow field. And there are significant differences between symmetrical and asymmetric bionic flow channel on PEMFC performance. The results of I–V curve show that when the PEMFC with asymmetric bionic flow channel has the best performance in the orientation of perpendicularity.     

Investigation of bio-inspired flow channel designs for bipolar plates in proton exchange membrane fuel cells

Proton exchange membrane (PEM) fuel cell performance is directly related to the flow channel design on bipolar plates. Power gains can be found by varying the type, size, or arrangement of channels. The objective of this paper is to present two new flow channel patterns: a leaf design and a lung design. These bio-inspired designs combine the advantages of the existing serpentine and interdigitated patterns with inspiration from patterns found in nature. Both numerical simulation and experimental testing have been conducted to investigate the effects of two new flow channel patterns on fuel cell performance. From the numerical simulation, it was found that there is a lower pressure drop from the inlet to outlet in the leaf or lung design than the existing serpentine or interdigitated flow patterns. The flow diffusion to the gas diffusion layer was found be to more uniform for the new flow channel patterns. A 25 cm² fuel cell was assembled and tested for four different flow channels: leaf, lung, serpentine and interdigitated. The polarization curve has been obtained under different operating conditions. It was found that the fuel cell with either leaf or lung design performs better than the convectional flow channel design under the same operating conditions. Both the leaf and lung design show improvements over previous designs by up to 30% in peak power density.     

Channel aspect ratio effect for serpentine proton exchange membrane fuel cell: Role of sub-rib convection

A complete three-dimensional, two-phase, non-isothermal model for proton exchange membrane (PEM) fuel cells was used to investigate the effect of the sub-rib convection on the performances for the single and triple serpentine flow fields at various channel aspect ratios and different thermal constraints. The occurrence of sub-rib convection, which is affected by the serpentine flow field, significantly influences the cell performance if the oxygen supply or membrane moisture content was limited. For single serpentine flow field in which sub-rib convection presents under all ribs, changing channel aspect ratio has minimal effects on cell performance since the oxygen supply is sufficient. For triple serpentine flow field or for serpentine cell with poor external heat loss, owing to limited sub-rib convection or to low membrane moisture content, decrease in channel aspect ratio significantly enhances cell performance. Blocking up the sub-rib convection markedly reduces cell performance. Flow field design for PEM fuel cell should take into consideration the effects of sub-rib convection flow on cell performance.     

Experimental study and optimization of flow field structures in proton exchange membrane fuel cell under different anode modes

As one of the critical components in the proton exchange membrane fuel cell (PEMFC), the flow field is crucial to the improvement of cell performance. However, the current research on flow field structure lacks consideration of the influence of different anode modes, which makes the existing flow field structure rules have limitations in the practical application of PEMFC. In this paper, the PEMFC characteristics of parallel flow field, S-shaped flow field, multi-serpentine flow field and single-serpentine flow field at the cathode side are compared experimentally in the dead-end anode (DEA) mode and hydrogen circulation anode (HCA) mode, respectively. Especially, the spatial current density distribution and parasitic power of different flow field structures are measured. The results show that the performance trends of different flow field structures change with the DEA and HCA anode modes. In DEA mode, the PEMFC is prone to flooding, and the flow field with high gas velocity in the channel has better drainage ability, which can obtain higher cell performance. The HCA mode is helpful for the discharge of water in the PEMFC, which effectively alleviates the adverse impact of water accumulation on the overall performance, and the mass transport ability of the flow field structure plays a leading role in the cell performance improvement. In addition, although the high gas flow velocity has better drainage ability in the flow field, it may lead to a decrease in the current density distribution uniformity and PEMFC net output power density. Based on the comprehensive consideration of the experimental results, the multi-serpentine flow field is more suitable for DEA mode, and the S-shaped flow field is more suitable for HCA mode.     

A critical review of two-phase flow in gas flow channels of proton exchange membrane fuel cells

Water management in PEM fuel cells has received extensive attention due to its key role in fuel cell performance. The unavoidable water, from humidified gas streams and electrochemical reaction, leads to gas-liquid two-phase flow in the flow channels of fuel cells. The presence of two-phase flow increases the complexity in water management in PEM fuel cells, which remains a challenging hurdle in the commercialization of this technology. Unique water emergence from the gas diffusion layer, which is different from conventional gas-liquid two-phase flow where water is introduced from the inlet together with the gas, leads to different gas-liquid flow behaviors, including pressure drop, flow pattern, and liquid holdup along flow field channels. These parameters are critical in flow field design and fuel cell operation and therefore two-phase flow has received increasing attention in recent years. This review emphasizes gas-liquid two-phase flow in minichannels or microchannels related to PEM fuel cell applications. In situ and ex situ experimental setups have been utilized to visualize and quantify two-phase flow phenomena in terms of flow regime maps, flow maldistribution, and pressure drop measurements. Work should continue to make the results more relevant for operating PEM fuel cells. Numerical simulations have progressed greatly, but conditions relevant to the length scales and time scales experienced by an operating fuel cell have not been realized. Several mitigation strategies exist to deal with two-phase flow, but often at the expense of overall cell performance due to parasitic power losses. Thus, experimentation and simulation must continue to progress in order to develop a full understanding of two-phase flow phenomena so that meaningful mitigation strategies can be implemented.