Mid-baffle interdigitated flow fields for proton exchange membrane fuel cells

A new design of an interdigitated flow field, called as a mid-baffle interdigitated flow field, was built and tested for its effect on the performance of proton exchange membrane (PEM) fuel cells. The results were compared to the conventional interdigitated flow field. Their performances at different oxidant gas flow rates and operating pressures were also examined and compared by using both O₂ and air as the cathode fuel reactants. The experimental results showed that when air was used as the cathode reactant, the cell with the mid-baffle interdigitated flow field outperformed the conventional one, giving a power output approximately 1.2-1.3 times higher depending on the air flow rates. The polarization curves of the mid-baffle interdigitated flow field showed larger limiting current densities at every air flow rate tested in this work. However, the performances of both flow fields were almost the same when the cathode reactant gas was O₂. The test also demonstrated that the flow field performance could be enhanced by increasing the oxidant gas flow rate and cell operating pressure.     

Non-active area water mitigation in PEM fuel cells via bipolar plate surface energy modification

The management of liquid water from either internal chemical reactions or externally humidified reactants is an important design consideration for proton exchange membrane (PEM) fuel cells because of the effects on both cell performance and durability. To achieve proper water management, significant effort has been devoted to developing new fuel cell materials, hardware designs, and appropriate stack operating conditions. However, water management in the region of the channel-to-manifold interfaces has received limited attention. This region covers the ends of the bipolar plate from where liquid water exits the active area to the entrance of the stack exhaust manifolds where excess reactant flows from individual cells are combined and leave the stack. For practical applications, there is a small driving force to expel liquid water in this region, especially in the anode flow field. Under severe operating conditions such as freezing temperatures, the buildup of water may cause a channel-scale blockage. In this study, hydrophilic and hydrophobic bipolar plate treatments were investigated to identify the effectiveness of water mitigation through ex-situ experiments performed using a dedicated freeze test rig. Water mitigation behavior with various locations of hydrophilic/hydrophobic coatings was characterized using measurements of differential pressure and gas flow rate. It was found that the hydrophilic coatings provide better performance, as water accumulation can be readily mitigated with less potential to cause full channel-scale blockages.     

Numerical investigation of pressure drop characteristics of gas channels and U and Z type manifolds of a PEM fuel cell stack

Fluid flow manifold plays a significant role in the performance of a fuel cell stack because it affects the pressure drop, reactants distribution uniformity and flow losses, significantly. In this study, the flow distribution and the pressure drop in the gas channels including the inlet and outlet manifolds, with U- and Z-type arrangements, of a 10-cell PEM fuel cell stack are analyzed at anode and cathode sides and the effects of inlet reactant stoichiometry and manifold hydraulic diameter on the pressure drop are investigated. Furthermore, the effect of relative humidity of oxidants on the pressure drop of cathode are investigated. The results indicate that increase of the manifold hydraulic diameter leads to decrease of the pressure drop and a more uniform flow distribution at the cathode side when air is used as oxidant while utilization of humidified oxidant results in increase of pressure drop. It is demonstrated that for the inlet stoichiometry of 2 and U type manifold arrangement when the relative humidity increases from 25% to 75%, the pressure drop increases by 60.12% and 116.14% for oxygen and air, respectively. It is concluded that there is not a significant difference in pressure drop of U- and Z-type arrangements when oxygen is used as oxidant. When air is used as oxidant, the effect of manifold type arrangement is more significant than other cases, and increase of the stoichiometry ratio from 1.25 to 2.5 leads to increase of pressure drop by 527.3%.     

Model prediction of effects of operating parameters on proton exchange membrane fuel cell performance

The performance of a proton exchange membrane (PEM) fuel cell is greatly affected by the operating parameters. Appropriate operating parameters are necessary for PEM fuel cells to maintain stable performance. A three-dimensional multi-phase fuel cell model (FCM) is developed to predict the effects of operating parameters (e.g. operating pressure, fuel cell temperature, relative humidity of reactant gases, and air stoichiometric ratio) on the performance of PEM fuel cells. The model presented in this paper is a typical nine-layer FCM that consists of current collectors, flow channels, gas diffusion layers, catalysts layers at the anode and the cathode as well as the membrane. A commercial Computational Fluid Dynamics (CFD) software package Fluent is used to solve this predictive model through SIMPLE algorithm and the modeling results are illustrated via polarization curves including I–V and I–P curves. The results indicate that the cell performance can be enhanced by increasing operating pressure and operating temperature. The anode humidification has more significant influences on the cell performance than the cathode humidification, and the best performance occurs at moderate air relative humidity while the hydrogen is fully humidified. In addition, the cell performance proves to be improved with the increase of air stoichiometric ratio. Based on these conclusions, several suggestions for engineering practice are also provided.     

Experimental and modelling studies of low temperature PEMFC performance

The performance of a PEMFC (Polymer Electrolyte Membrane Fuel Cell) is greatly influenced by the various operating variables like temperature, pressure, stoichiometry of reactants and humidity. The presented work deals with the experimental study of 30 cells low temperature PEM fuel cell stack employing Nafion®-212 membranes. Experimental results are discussed with polarization curves and compared with the steady state model results, developed in MATLAB. The model predicts increase PEMFC performance with increase in operating temperature, pressure and reactant humidity. The comparison shows good agreement between experimental and modeling results with deviations in the range of 7–15% only.     

Innovative cathode flow-field design for passive air-cooled polymer electrolyte membrane (PEM) fuel cell stacks

A novel cathode flow-field design suitable for a passive air-cooled polymer electrolyte membrane (PEM) fuel cell stack is proposed to enhance the water-retaining capability under excess dry air supply conditions. The innovative cathode flow-field is designed to supply more air to the cooling channels and further enables deceleration of the reactant air in the gas channels and acceleration of the coolant air in the cooling channels simultaneously along the air flow path. Therefore, the design facilitates the waste heat removal through the cooling channels while the water removal by the reactant air is minimized. The conceptual cathode flow-field design is validated using a three-dimensional PEM fuel cell model. The detailed simulation results clearly demonstrate that the new cathode flow-field design exhibits superior water-retaining capability compared with a conventional cathode flow-field design (parallel flow channel configuration) under typical air-cooled fuel cell operating conditions. This study provides a new strategy to design cathode flow-fields to alleviate notorious membrane dehydration and unstable performance issues in a passive air-cooled PEM fuel cell stack.     

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.     

Performance of a polymer electrolyte fuel cell for automotive applications

The objectives of this study were to fabricate a self‐humidifying fuel cell stack of 10 cells with 104 cm² cell areas humidified with water recovered at cathodes, and to measure and simulate the performance of the stack. This involves the simulation of a three‐dimensional model of the heat and mass transfer of the water and the gaseous reactants in the fuel cell components with a water‐cooling system. The results of the stack experiments indicated a maximum power of 250 kW at a current density of 0.5 A/cm². The simulation showed good agreement with the actual performance of the stack. The performance of the self‐humidifying stack with a vapor‐permeating membrane is comparable to a conventional stack with external humidifiers, and it appears very effective in simplifying stack systems. The modeling analysis indicated that for the gas flow directions, at anode and cathode, a parallel flow is superior to a cross flow, and that one cooling cell is necessary for two to three generating cells in order to maintain the fuel cell temperature below 100 °C. © 2002 Wiley Periodicals, Inc. Heat Trans Asian Res, 31(6): 421–429, 2002; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.10041     

A novel technique for measuring current distributions in PEM fuel cells

A novel and simple technique was developed to measure current distribution in PEM fuel cells with serpentine flow fields. In this technique, a specially designed measuring gasket was inserted between the flow field plate and the gas diffusion layer, and the current at each sub-area of the fuel cell was measured by each of the current collecting strips on the measuring gasket. The current distribution measurement gasket was independent of PEM fuel cells, and can be used in any fuel cell without the need of a special fuel cell or modification of any component of an existing fuel cell. More importantly, this technique can be easily used to measure current density distribution in any cell or every cell in a fuel cell stack. In addition, this technique is very inexpensive, with the only additional cost being that of the measuring gasket. In this work, this measurement gasket technique was used to study the influences of humidification temperatures, cell operating temperatures, reactant flow rates, and operating pressures on current distributions in a PEM fuel cell. Local membrane hydration, reactant depletion and possible cathode flooding can be deduced from the measurement results, and some potential improvements in fuel cell designs are suggested.     

An air-cooled proton exchange membrane fuel cell with combined oxidant and coolant flow

Combining the oxidant and coolant flow in an air-cooled proton exchange membrane fuel cell can significantly simplify the fuel cell design. In this paper, an air-cooled PEM fuel cell stack with an open cathode flow field, which supplied the oxidant and removed the heat produced in the fuel cell, was fabricated and tested. The influence of different operating parameters on cell voltage performance and the overall cell ohmic resistance, such as cell temperature and airflow rate, was investigated. The cell temperature and the temperature difference between the cell and the hydrogen humidifier were shown to serve important roles in reducing the fuel cell ohmic resistance. The test results also showed a noteworthy temperature gradient between each cell of a 5-cell stack. A hydrophilic treatment of the cathode flow field channels was demonstrated to be an effective way to mitigate water management issues caused at elevated operating temperatures.     

Experimental study of water transport in a polybenzimidazole-based high temperature PEMFC

The present work reports a systematic experimental analysis on water transport in a phosphoric acid doped polybenzimidazole-based high temperature PEM fuel cell. Two sets of polarization curves are run with dry and alternatively humidified reactants, covering a wide range of fuel cell operating temperatures and stoichiometries. With dry feed streams, up to 18% of water produced by electrochemical reaction is found on anode side proving the presence of water transport from cathode electrode. Under the investigated conditions, water transport across the membrane is independent of fuel cell temperature but strongly dependent on reactants stoichiometry and humidification. Such parameters can even determine a change in water transport direction. Humidification causes a limited drop in membrane proton resistivity (around 6 mΩ cm²); conversely a slight decrease in fuel cell performances (−5 to −20 mV) is measured.     

Non-dimensional analysis of PEM fuel cell phenomena by means of AC impedance measurements

AC impedance or electrochemical impedance spectroscopy (EIS) is becoming a fundamental technique used by researchers and scientists in proton exchange membrane (PEM) fuel cell analysis and development. In this work, in situ impedance measurements are presented for a series of operating conditions in a 50 cm² fuel cell. The electrode charge transfer resistance was determined from the corresponding arcs of the Nyquist diagrams. The analyses were performed for H₂/O₂ and H₂/air operation at different stoichiometric factors and reactant gases humidification. Characteristic time scales of charge transfer processes at the different operating conditions were estimated from the corresponding Bode plots. These values were used for a non-dimensional analysis of the different fuel cell electrochemical and transport processes, namely electrochemical reaction versus GDL reactant transport. Fuel cell adapted Damkhöler numbers are thus presented, where the results indicate that the GDL diffusion transport is the limiting process for the cases under analysis, especially when air is used as oxidant. Additional analysis of channel convective mass transport versus GDL diffusive mass transport is also presented.     

Experimental validation of variable temperature flow field concept for proton exchange membrane fuel cells

Variable temperature flow field concept allows maintaining close to 100% relative humidity along the entire flow field of the anode and the cathode side without external humidification using water generated during fuel cell operation for internal reactant humidification. This work deals with the experimental validation of the variable temperature flow field concept on a five-segment single cell. The experimental setup provides insight into the membrane water transport, temperature distribution on the current collectors and inside the channels, and the current density distribution along the cell. Variable temperature flow field operation with dry reactants is compared to isothermal operation with partially and fully humidified reactants. The polarization curve comparison shows that the variable temperature flow field operating efficiency is similar or better than the commonly used isothermal configuration with fully humidified reactants. The main contribution of the variable temperature flow field concept, when compared to isothermal operation, is the reduction of the mass transport losses at higher currents, since the generated water is evaporated in the stream of reactants, thereby minimizing the problem of liquid water removal from the cell.     

Network based optimization model for pin-type flow field of polymer electrolyte membrane fuel cell

The flow field of a bipolar plate distributes reactants for polymer electrolyte membrane (PEM) fuel cells and removes the produced water from the fuel cells. It greatly influences the performance of fuel cells, especially the concentration losses. Pin-type design, as one of the widely utilized flow field configurations, has the advantage of low pressure drop but the disadvantage of uneven flow distribution and stagnant areas. In this paper, a network-based optimization model was developed to optimize the pin-type flow field configuration. Two optimization cases, uniform flow distribution with and without considering reactant consumption along flow channels, were investigated and the corresponding optimized designs were developed. Three-dimensional numerical simulations of PEM fuel cell were conducted to validate the proposed optimization model and also to compare the performance of the fuel cells using the optimized designs and the regular pin-type design. The numerical results verified the designs generated with the present optimization model. Both the optimized designs exhibited substantially higher fuel cell performance compared to the regular pin-type configuration. Moreover, the optimized design with considering reactant consumption performed even better than the one without considering the consumption, emphasizing the significance of reactant consumption in the flow field optimization model.     

A flexible on-fiber H2O2 microfluidic fuel cell with high power density

To promote the simplification and integration of membraneless microfluidic fuel cell (MMFC) system and combine with flexible portable devices, a flexible on-fiber MMFC exploiting H₂O₂ as sole reactant is presented, eliminating the separation requirement of fuel and oxidant. Nickel (Ni) nano-particles and Prussian blue with multiwalled carbon nanotube (PB-MWCNT) are coated on hydrophilic braided carbon fibers (BCFs) to serve as the anode and cathode, respectively. The three-dimensional (3D) flow-through anode and cathode with a wealth of exposed electroactive sites improve reactant mass transfer. The anode and cathode are respectively wound on both sides of the middle cotton thread-based flow channel for separation. Under the combination of capillary force and gravity, reactants flow continuously through the fiber-based microchannels without external pumps. Importantly, the H₂O₂ MMFC achieves the highest maximum power density (MPD) of 14.41 mW cm^?2 so far in one-chamber or single-stream H₂O₂ fuel cells. Besides, no serious deterioration in the power-generation performance is observed in complex practical operating conditions including bending with various angles, repeated folding and dropping. Three presented flexible MMFCs are connected to power a handheld calculator, indicating the tremendous potential of developing micro power supplies based on abundant flexible materials as well as green and sustainable energy.     

Critical flow rate of anode fuel exhaust in a PEM fuel cell system

A manual purge line was added into the exterior fuel exhaust stream of a Ballard PEM stack in a Nexa™ power module. With the addition of manual exhaust purge, high levels of inert gases were intentionally added to the anode feed without changing normal operational procedures. A new method of determining the critical minimum flow rate in the anode exhaust stream was given by an anode mass balance. This type of operation makes dual use of membranes in the MEAs as both gas purifiers and as solid electrolytes. The PEM stack was successfully operated with up to ca. 7% nitrogen or carbon dioxide in the absence of a palladium-based hydrogen separator at ca. 200 W power level. Nitrogen in the anode stream was concentrated from 7.5% to 91.6%. The system maintained a fuel efficiency of 99% at a manual purge rate of 2.22 ml s⁻¹ and no auto purge. The fuel cell stack efficiency was 64% and the stack output efficiency was 75%. The overall system efficiency was 39%. After troublesome CO and H₂S poisons were removed, a hydrocarbon reformate containing high levels of CO₂ and H₂O was further used in the Nexa™ stack. The size and complexity of the fuel processing system may be reduced at a specified power level by using this operational method.     

Parametric analysis of a hybrid power system using organic Rankine cycle to recover waste heat from proton exchange membrane fuel cell

Using fuel cell systems for distributed generation (DG) applications represents a meaningful candidate to conventional plants due to their high power density and the heat recovery potential during the electrochemical reaction. A hybrid power system consisting of a proton exchange membrane (PEM) fuel cell stack and an organic Rankine cycle (ORC) is proposed to utilize the waste heat generated from PEM fuel cell. The system performance is evaluated by the steady-state mathematical models and thermodynamic laws. Meanwhile, a parametric analysis is also carried out to investigate the effects of some key parameters on the system performance, including the fuel flow rate, PEM fuel cell operating pressure, turbine inlet pressure and turbine backpressure. Results show that the electrical efficiency of the hybrid system combined by PEM fuel cell stack and ORC can be improved by about 5% compared to that of the single PEM fuel cell stack without ORC, and it is also indicated that the high fuel flow rate can reduce the PEM fuel cell electrical efficiency and overall electrical efficiency. Moreover, with an increased fuel cell operating pressure, both PEM fuel cell electrical efficiency and overall electrical efficiency firstly increase, and then decrease. Turbine inlet pressure and backpressure also have effects on the performance of the hybrid power system.     

Steady state and dynamic performance of proton exchange membrane fuel cells (PEMFCs) under various operating conditions and load changes

The steady-state performance and transient response for H₂/air polymer electrolyte membrane (PEM) fuel cells are investigated in both single fuel cell and stack configurations under a variety of loading cycles and operating conditions. Detailed experimental parameters are controlled and measured under widely varying operating conditions. In addition to polarization curves, feed gas flow rates, temperatures, pressure drop, and relative humidity are measured. Performance of fuel cells was studied using steady-state polarization curves, transient I–V response and electrochemical impedance spectroscopy (EIS) techniques. Different feed gas humidity, operating temperature, feed gas stoichiometry, air pressure, fuel cell size and gas flow patterns were found to affect both the steady state and dynamic response of the fuel cells. It was found that the humidity of cathode inlet gas had a significant effect on fuel cell performance. The experimental results showed that a decrease in the cathode humidity has a detrimental effect on fuel cell steady state and dynamic performance. Temperature was also found to have a significant effect on the fuel cell performance through its effect on membrane conductivity and water transport in the gas diffusion layer (GDL) and catalyst layer. The polarization curves of the fuel cell at different operating temperatures showed that fuel cell performance was improved with increasing temperature from 65 to 75 °C. The air stoichiometric flow rate also influenced the performance of the fuel cell directly by supplying oxygen and indirectly by influencing the humidity of the membrane and water flooding in cathode side. The fuel cell steady state and dynamic performance also improved as the operating pressure was increased from 1 to 4 atm. Based on the experimental results, both the steady state and dynamic response of the fuel cells (stack) were analyzed. These experimental data will provide a baseline for validation of fuel cell models.     

Quasi-stationary UI-characteristic model of a PEM fuel cell–Evaluating the option of self-humidifying operation

This work presents a zero-dimensional PEM fuel cell UI-characteristic model created in MATLAB Simulink® for operation with dry or humidified air supply. It is parameterised and validated based on the results of stack operation by varying stack temperature (50–80 °C), gas pressure (1.0–2.4 bar) and air humidification (0.0–1.0). The model is based on physical and electrochemical correlations and expanded by empirically assumptions concerning the influence of the humidification and limiting current density on the performance. The UI-model is intended to be integrated into a comprehensive zero-emission powertrain model. Since non-humidified operation of PEM fuel cell systems provides benefits for mobile applications by reducing space demand and system complexity, the objective of the model is to relate performance to the operating conditions and underlying physical parameters. Results confirm the feasibility of a self-humidifying stack operation at high performance by optimal parameter setting.     

A membraneless microfluidic fuel cell stack

A membraneless microfluidic fuel cell stack architecture is presented that reuses reactants from one cell to a subsequent one, analogous to PEMFC stacks. On-chip reactant reuse improves fuel utilization and power densities relative to single cells. The reactants flow separately through porous electrodes and interface with a non-reacting and conductive electrolyte which maintains their separation. The reactants remain separated downstream of the interface and are used in subsequent downstream cells. This fuel cell uses porous carbon for electrocatalysts and vanadium redox species as reactants with a sulfuric acid supporting electrolyte. The overall power density of the fuel cell increases with reactant flow rate and decreasing the separating electrolyte flow rate. The peak power, maximum fuel utilization, and efficiency nearly double when electrically connecting the cells in parallel.