Numerical and experimental study of three-dimensional fluid flow in the bipolar plate of a PEM electrolysis cell

The bipolar plate is one of the key components in proton exchange membrane (PEM) electrolysis cell stacks for hydrogen production. Bipolar plates of electrolysis cells must be properly designed to distribute reactant (water) evenly, and efficient PEM electrolysis cell stacks will require optimized bipolar plates. Numerical simulations and experimental measurements of three-dimensional water flow were performed for the purpose of examining pressure and velocity distributions in the bipolar plate of a PEM electrolysis cell. For the studied flow range, the computed pressure drops agree very favorably with the measurements. Results show that pressure decreases from the inlet tube to the exit tube along the diagonal direction. Both velocity and temperature distributions are very non-uniform in the channels. A minimum of the peak values of mainstream velocity component in the channels develops in the center of the test plate. The maximum of these peak values appears in the channel near the exit tube. For the studied flow levels, these lines along which the mainstream velocity component is a peak in the channel almost overlay with each other, except that minor difference can be noticed in the channel near the exit tube.     

A comprehensive review on PEM water electrolysis

Hydrogen is often considered the best means by which to store energy coming from renewable and intermittent power sources. With the growing capacity of localized renewable energy sources surpassing the gigawatt range, a storage system of equal magnitude is required. PEM electrolysis provides a sustainable solution for the production of hydrogen, and is well suited to couple with energy sources such as wind and solar. However, due to low demand in electrolytic hydrogen in the last century, little research has been done on PEM electrolysis with many challenges still unexplored. The ever increasing desire for green energy has rekindled the interest on PEM electrolysis, thus the compilation and recovery of past research and developments is important and necessary. In this review, PEM water electrolysis is comprehensively highlighted and discussed. The challenges new and old related to electrocatalysts, solid electrolyte, current collectors, separator plates and modeling efforts will also be addressed. The main message is to clearly set the state-of-the-art for the PEM electrolysis technology, be insightful of the research that is already done and the challenges that still exist. This information will provide several future research directions and a road map in order to aid scientists in establishing PEM electrolysis as a commercially viable hydrogen production solution.     

Solar and wind energy in Poland as power sources for electrolysis process - A review of studies and experimental methodology

The production of hydrogen is still a major challenge, due to the high costs and often also environmental burdens it generates. It is possible to produce hydrogen in emission-free way: e.g. using a process of electrolysis powered by renewable energy. The paper presents the concept of a research, experimental stand for the storage of renewable energy in the form of hydrogen chemical energy with the measurement methodology. The research involves the use of proton exchange membrane electrolysis technology, which is characterized by high efficiency and flexibility of energy extraction for the process of electrolysis from renewable sources. The system consist of PV panel, PEM electrolyzer, battery, programmable logic controller system and optional a wind turbine. Preliminary experimental tests results have shown that the electrolyzer can produce in average 158.1 cc/min of hydrogen with the average efficiency 69.87%.     

PEM water electrolyzers: From electrocatalysis to stack development

Proton Exchange Membrane (PEM) water electrolysis can be used to produce hydrogen from renewable energy sources and can contribute to reduce CO₂ emissions. The purpose of this paper is to report on recent advances made in PEM water electrolysis technology. Results obtained in electrocatalysis (recent progresses made in low-cost electrocatalysis offer new perspectives for decentralized and domestic applications), on low-cost membrane electrode assemblies (MEAs), cell efficiency, operation at high current density, electrochemical performances and gas purity issues during high-pressure operation, safety considerations, stack design and optimization (for electrolyzers which can produce up to 5 Nm³ H₂/h) and performance degradations are presented. These results were obtained in the course of the GenHyPEM project, a 39 months long (2005–2008) research program supported by the European Commission. PEM technology has reached a level of maturity and performances which offers new perspectives in view of the so-called hydrogen economy.     

质子交换膜燃料电池双极板的设计与模拟分析

质子交换膜燃料电池是直接将化学能转换为电能的装置,双极板上的流道结构对燃料电池的工作性能具有较大的影响。根据应用要求设计了具有平行流道、蛇形流道及希尔伯特分形流道的双极板结构,模拟计算了氢气在不同类型的流道和气体扩散层中的分布状态,分析了燃料电池的输出电流密度和功率密度随电极间电压的变化特点,比较了不同的流道结构对燃料电池输出电流密度的影响,以及不同的工作温度及气体压强的情况下,燃料电池输出电流密度随温度及压强的变化规律。     

Design and economic analysis of high-pressure proton exchange membrane electrolysis for renewable energy storage

The proton exchange membrane (PEM) electrolysis with a high-pressure cathode can help avoid the utilization of a hydrogen compressor and improve the efficiency of hydrogen transmission. The economic analysis of the entire process from hydrogen production to transportation was conducted in this study, and the advantages of high-pressure PEM electrolysis were proved. The economic analysis has also illustrated the influence of the cathode pressure and membrane thickness involved in PEM electrolysis on the energy consumption and capital expenditure of the electrolyzer from the perspectives of hydrogen permeability, ohmic impedance, and structural design. Although the output pressure of hydrogen is increased several tens of times, the proper structure and unchanged thickness of the membrane can help satisfy the strength and safety requirements of the electrolyzer simultaneously. In addition, the energy consumption and cost increase associated with the high-pressure electrolyzer can be limited to an acceptable range. The impact of the renewable energy scale on the decision and selection for PEM or ALK is also analyzed; PEM has an advantage over ALK in large-scale renewable energy hydrogen production scenarios because of its own wider upper and lower load limits compared to those of ALK.     

PEM electrolysis for production of hydrogen from renewable energy sources

PEM electrolysis is a viable alternative for generation of hydrogen from renewable energy sources. Several possible applications are discussed, including grid independent and grid assisted hydrogen generation, use of an electrolyzer for peak shaving, and integrated systems both grid connected and grid independent where electrolytically generated hydrogen is stored and then via fuel cell converted back to electricity when needed. Specific issues regarding the use of PEM electrolyzer in the renewable energy systems are addressed, such as sizing of electrolyzer, intermittent operation, output pressure, oxygen generation, water consumption and efficiency.     

Effect of flow field design on performances of high temperature PEM fuel cells: Experimental analysis

Among all types of fuel cells, attention is being drawn lately on high temperature Polybenzimidazole (PBI) PEM because their operative temperature range (120-180 °C) increases the tolerance to carbon monoxide. This feature allows working with low quality hydrogen produced by hydrocarbon reformation. Most of the literature on PBI PEM deals with membrane and MEA related issues, however, cell efficiency and specially, commercial feasibility are conditioned by other fuel cell components as bipolar plates. In the present study the focus is on the effect of the flow field geometry of high temperature PBI PEM composite bipolar plates on the overall performance of the cell. For this purpose, three different channel geometries are studied: two serpentine flow fields and parallel channels flow field. Results show that serpentine geometry yields higher performance though it introduces higher pressure drop along the cell as well.     

Effective utilization of by-product oxygen from electrolysis hydrogen production

To avoid fossil-fuel consumption and greenhouse-gas emissions, hydrogen should be produced by renewable energy resources. Water electrolysis using proton exchange membrane (PEM) is considered a promising hydrogen-production method, although the cost of the hydrogen from PEM would be very high compared with that from other mature technologies, such as steam methane reforming (SMR). In this study, we focus on the effective utilization of by-product oxygen from electrolysis hydrogen production and discuss the potential demand for it, as well as evaluating its contribution to improving process efficiency. Taking as an example the utilization of by-product oxygen for medical use, we compare the relative costs of hydrogen production by means of PEM electrolysis and SMR.     

Development of titanium bipolar plates fabricated by additive manufacturing for PEM fuel cells in electric vehicles

Bipolar plates (BPs) are one of the main parts of proton exchange membrane (PEM) fuel cell stacks, which constitute a significant percentage of a PEM fuel cell system in terms of cost, weight, and structural strength. Although frequently used graphite BPs have low density, high conductivity, and high corrosion resistance, machining the desired flow channels on these plates is challenging. On the other hand, BPs made of various materials rather than graphite can be also fabricated by additive manufacturing methods. These methods can be considered as a reasonable alternative to conventional machining for the fabrication of graphite BPs in PEM fuel cells regarding material cost, fabrication of flow channels, and some post-processes in which the large-scale manufacturing of graphite BPs is more complex. This study offers a comparison of formed stainless-steel, additive manufactured titanium and machined composite graphite plates having the same flow-field geometry as a bipolar plate. In addition, titanium BPs are coated with gold and their performances are compared. Among the cells tested, the highest peak power of 639 mWcm^?2 is measured from the cell with 450 nm gold coated titanium BP, whereas those of the cell with conventional graphite and stainless-steel BP are only around 322 mWcm^?2 and 173 mWcm^?2, respectively. Moreover, a new titanium bipolar plate design providing high specific power density is also presented.     

Mass transport in PEM water electrolysers: A review

While hydrogen generation by alkaline water electrolysis is a well-established, mature technology and currently the lowest capital cost electrolyser option; polymer electrolyte membrane water electrolysers (PEMWEs) have made major advances in terms of cost, efficiency, and durability, and the installed capacity is growing rapidly. This makes the technology a promising candidate for large-scale hydrogen production, and especially for energy storage in conjunction with renewable energy sources – an application for which PEMWEs offer inherent advantages over alkaline electrolysis. Improvements in PEMWE technology have led to increasingly high operational current densities, which requires adequate mass transport strategies to ensure sufficient supply of reactant and removal of products. This review discusses the current knowledge related to mass transport and its characterisation/diagnosis for PEMWEs, considering the flow channels, liquid-gas diffusion layer, and polymer electrolyte membrane in particular.     

Cell failure mechanisms in PEM water electrolyzers

PEM water electrolysis offers an efficient and flexible way to produce “green-hydrogen” from renewable (intermittent) energy sources. Most research papers published in the open literature on the subject are addressing performances issues and to date, very few information is available concerning the mechanisms of performance degradation and the associated consequences. Results reported in this communication have been used to analyze the failure mechanisms of PEM water electrolysis cells which can ultimately lead to the destruction of the electrolyzer. A two-step process involving firstly the local perforation of the solid polymer electrolyte followed secondly by the catalytic recombination of hydrogen and oxygen stored in the electrolysis compartments has been evidenced. The conditions leading to the onset of such mechanism are discussed and some preventive measures are proposed to avoid accidents.     

Influence of geometric parameters of the flow fields on the performance of a PEM fuel cell. A review

The proton Exchange membrane fuel cell (PEMFC) performance depends not only on many factors including the operation conditions, transport phenomena inside the cell and kinetics of the electrochemical reactions, but also in its physical components; membrane electrode assembling (MEA) and bipolar plates (BPs). Among the PEM stack components, bipolar plates are considered one of the crucial ones, as they provide one of the most important issues regarding the performance of a stack, the homogeneous distribution of the reactive gases all over the catalyst surface and bipolar plate areas through, the so call, flow channels; physical flow patterns or paths fabricated on the BPs surfaces to guide the gases all along the BPs for its correct distribution. The failure in flow distribution among different unit cells may severely influence the fuel cell stack performance. Thus, to overcome such possible failures, the design of more efficient flow channels has received considerable attention in the research community for the last decade.     

Optimization of porous current collectors for PEM water electrolysers

Water electrolysers using proton exchange membranes (PEM) offer high prospective potentialities for the production of pure hydrogen. Main components of PEM cells are (i) solid polymer electrolyte, (ii) electrocatalytic layers, (iii) porous current collectors and (iv) bipolar plates used to separate individual cells. The work presented in this paper is devoted to the optimization of the microstructure of current collectors, the role of which is to provide efficient electric contact between electrocatalytic layers and bipolar plates and to insure efficient gas/water transport between them. Optimum pore sizes, plate thicknesses and porosities of current collectors have been determined from both experimental and modeling approaches, for operation at high current densities (up to 2 A cm⁻²) in PEM water electrolysis cells.     

Investigation on PEM water electrolysis cell design and components for a HyCon solar hydrogen generator

Hydrogen as a secondary energy carrier promises a large potential as a long term storage for fluctuating renewable energies. In this sense a highly efficient solar hydrogen generation is of great interest especially in southern countries having high solar irradiation. The patented Hydrogen Concentrator (HyCon) concept yields high efficiencies combining multi-junction solar cells with proton exchange (PEM) membrane water electrolysis. In this work, a special PEM electrolysis cell for the HyCon concept was developed and investigated. It is shown that the purpose-made PEM cell shows a high performance using a titanium hybrid fiber sinter function both as a porous transport layer and flow field. The electrolysis cell shows a high performance with 1.83 V at 1 A/cm² and 24 °C working under natural convection with a commercially available catalyst coated membrane. A theoretical examination predicts a total efficiency for the HyCon module from sunlight to hydrogen of approximately 19.5% according to the higher heating value.     

Pure hydrogen production by PEM electrolysis for hydrogen energy

Last years hydrogen as energy carrier becomes one of the best solutions of energy and ecological problems. Intensive development of fuel cells, especially based on proton exchange membrane (PEM), where pure hydrogen is needed, stimulates electrolyzers development for the future application in hydrogen energy and technology. From point of view of the authors PEM electrolysis is very perspective for this goal. Advantages and possible fields of applications of this type of electrolyzers in comparison with another one are reviewed. Some results achieved up to now in PEM electrolysis, including last achievement of the authors, are summarized.     

PEM电解水制氢技术的研究现状与应用展望

基于4种电解水制氢技术性能的差异和优劣,对PEM电解槽的膜电极、多孔传输层、双极板的研究现状进行总结并展望,最后结合PEM电解水制氢技术的优势,分析该技术成本发展趋势并展望该技术的应用场景和发展方向。     

Analytical modelling and experimental validation of proton exchange membrane electrolyser for hydrogen production

Proton Exchange Membrane (PEM) Electrolysers (ELSs) are considered as pollution-free with enhanced efficiency technology. Hydrogen can be easily produced from different resources like biomass, water electrolysis, natural gas, propane, and methanol. Hydrogen generation from water electrolysis, which is the splitting of water molecules into hydrogen and oxygen using electricity, can be beneficial when used in combination with variable Renewable Energy (RE) technologies such as solar and wind. When the electricity used for water electrolysis is produced by a variable RE source, the hydrogen stores the unused energy for a later use and can be considered as a renewable fuel and energy resource for the transport and energy sectors.This paper aims to propose a novel graphical model design for the PEM-ELS for hydrogen production based on the electrochemical, thermodynamical and thermal equations. The model under study is experimentally validated using a small-scale laboratory electrolyser. Simulation results, using Matlab-Simulink?, show an adequate parameter agreement with those found experimentally. Therefore, the impact of the different parameters on the electrolyser dynamic performance is introduced and the relevant analytical-experimental comparison is shown. The temperature effect on the PEM-ELS dynamic behaviour is also discussed.     

Flow distribution in a bipolar plate of a proton exchange membrane fuel cell: experiments and numerical simulation studies

An experimental and numerical research has been performed in order to study the flow distribution in a bipolar plate of a commercial PEM fuel cell. Planar laser induced fluorescence (PLIF) trace tracking has been applied to visualize the flow pattern and to measure the velocity in the plate channels. Simultaneously, the problem has been studied numerically, simulating the flow under similar operational conditions as those fixed in the experiments. Results obtained reveal a defective design of the bipolar plate. Based on the experimental visualization and on the numerical simulations it is concluded that the flow preferentially moves through the lateral channels, resulting in an inappropriate distribution on the electrode surfaces. Velocity measurements also confirm the above statements, showing high values at the lateral channels, while the flow is nearly stagnant in the central region. With this non-homogeneous flow distribution at the bipolar plate, a low performance of the fuel cell energy conversion could be expected.