Heat and mass transfer analysis in single cell of PEFC using different PEM and GDL at higher temperature

According to the H₂ and fuel cell road map in Japan, the target operating temperature of polymer electrolyte fuel cell (PEFC) should be 90 °C from 2020 to 2025. In this study, the impact of polymer electrolyte membrane (PEM) and gas diffusion layer (GDL)'s thickness on heat and mass transfer characteristics as well as power generation performance of PEFC is investigated at operating temperature of 90 °C. The in-plane temperature distributions on anode and cathode separator are also measured using thermograph. As a result, it is observed that the increase in power from 1 W to 5 W at the current density of 0.80 A/cm² as well as even temperature distribution within 1 °C can be obtained at operating temperature of 90 °C by decrease in GDL's thickness from 190 μm to 110 μm. In addition, the power is increased from 3 W to 4 W at the current density of 0.80 A/cm² operated at 90 °C by decrease in the PEM's thickness from 127 μm to 25 μm.     

A review of gas diffusion layers for proton exchange membrane fuel cells—With a focus on characteristics,characterization techniques,materials and designs

Proton exchange membrane (PEM) fuel cells are at the dawn of commercialization. Their operation and design characteristics, hence their performance, are closely linked to the multiphase transport of mass, heat, and electricity in the cell constituents, a critical of which is the gas diffusion layer (GDL). The GDL's transport capability is represented by its effective transport properties: an effective diffusion coefficient for the diffusional transport of mass, absolute and relative permeabilities for the convective transport of mass, effective thermal conductivity for the heat transport, and effective electron conductivity for the electricity transport; in addition, surface wettability impacts the transport of liquid water. These transport properties depend on the GDL's mechanical, morphological, microstructural, and physical characteristics, which are in turn controlled by its materials and design parameters. This review article therefore focuses on the insights and comprehensive understanding of three critical issues of the GDLs: (i) their morphological, microstructural, and physical characteristics, (ii) ex- and in-situ characterization techniques for the determination of their effective transport and mechanical properties, and (iii) frequently used materials and design strategies and their relevant influences on the effective transport properties in order to achieve reliable and durable performance of PEM fuel cells with high power densities.     

Effect of water distribution in gas diffusion layer on proton exchange membrane fuel cell performance

Water management of proton exchange membrane fuel cells remains a prominent issue in research concerning fuel cells. In this study, the gas diffusion layer (GDL) of a fuel cell is partially treated with a hydrophobic agent, and the effect of GDL hydrophobicity on the water distribution in the fuel cell is examined. First, the effect of the position of the cathode GDL hydrophobic area relative to the channel on the fuel cell performance is investigated. Then, the water distribution in the fuel cell cathode GDL is observed using X-ray imaging. The experimental results indicate that when the hybrid GDL's hydrophobic area lies on the channel, water tends to accumulate under the rib, and the water content in the channel is low; this improves the fuel cell performance. When the hydrophobic area is under the rib, the water distribution is more uniform, but the performance deteriorates.     

A novel constitutive stress-strain law for compressive deformation of the gas diffusion layer

Substantial compressive deformation occurs in the gas diffusion layer (GDL) under the pressure applied during the fuel cell assembly. The GDL deformation has a direct impact on the efficiency and performance of the fuel cell since it leads to the alteration of the GDL microstructure and porosity. This makes the accurate characterization of the GDL compressive behavior crucial for analyzing the fuel cell performance and its optimal design. In this paper, analytical, experimental, and numerical methods have been employed to comprehensively study the constitutive law of the GDL under compression. Starting from the recently developed stress-density relations, the constitutive stress-strain equations are derived for the GDL and the relation between the stress-density and stress-strain laws are revealed. Experimental compression tests have been performed on GDL samples and the capability of the proposed constitutive law in capturing the real behavior of the material has been proved. It has been observed that the simplifying assumption of constant zero Poisson's ratio in the through-plane direction made in many previous studies cannot accurately represent the GDL material behavior and a modification is proposed. The developed constitutive law has been successfully implemented in a finite element model of the GDL-bipolar plate assembly in the fuel cell structure and the variations of the GDL porosity, density, and through-plane Young's modulus and Poisson's ratio have been investigated for different vertical displacements of the bipolar plate.     

Coupled mechanical stress and multi-dimensional CFD analysis for high temperature proton exchange membrane fuel cells (HT-PEMFCs)

We use a combined finite element method (FEM)/computational fluid dynamics (CFD) methodology to numerically investigate the effects of gas diffusion layer (GDL) compression/intrusion on the performance of a phosphoric acid-doped polybenzimidazole (PBI) membrane-based high temperature proton exchange membrane fuel cell (HT-PEMFC). Three-dimensional (3-D) FEM simulations are conducted under various displacement clamping conditions to analyze cell deformation characteristics. Then, a multi-dimensional HT-PEMFC CFD model is applied to the deformed cell geometries to study transport and electrochemical processes during HT-PEMFC operations. Our numerical simulation results reveal that the maximum stresses in the deformed GDLs always occur near the edge of the ribs. The combined effects of GDL compression/intrusion considerably increase spatial non-uniformity in the species and current density distributions, and reduce cell performance.     

Numerical modeling and experimental study of the influence of GDL properties on performance in a PEMFC

This work is to study the effect of properties of gas diffusion layer (GDL) on performance in a polymer electrolyte membrane fuel cell (PEMFC) by both numerical simulation and experiments. The 1-dimension numerical simulation using the mixture-phase model is developed to calculate polarization curve. We are able to estimate optimum GDL properties for cell performance from numerical simulation results. Various GDLs which have different properties are prepared to verify accuracy of the simulation results. The contact angle and gas permeability of GDLs are controlled by polytetrafluoroethylene (PTFE) content in micro-porous layers (MPLs). MPL slurry is prepared by homogeneous blending of carbon powder, PTFE suspension, isopropyl alcohol and glycerol. Then the slurry is coated on gas diffusion mediums (GDMs) surface with controlled thickness by blade coating method. Non-woven carbon papers which have different thicknesses of 200 μm and 380 μm are used as GDMs. The prepared GDLs are measured by surface morphology, contact angle, gas permeability and through-plane electrical resistance. Moreover, the GDLs are tested in a 25 cm² single cell at 70 °C in humidified H₂/air condition. The contact angle of GDL increases with increasing PTFE content in MPL. However, the gas permeability and through-plane electrical conductivity decrease with increasing PTFE content and thickness of GDM. These changes in properties of GDL greatly influence the cell performance. As a result, the best performance is obtained by GDL consists of 200 μm thick non-woven carbon paper as GDM and MPL contained 20 wt.% PTFE content.     

Combined effect of channel to rib width ratio and gas diffusion layer deformation on high temperature – Polymer electrolyte membrane fuel cell performance

The present study investigates the combined influence of Channel to Rib Width (CRW) ratio and clamping pressure on the structure and performance of High Temperature-Polymer Electrolyte Membrane Fuel Cell (HT-PEMFC) using a three-dimensional numerical model developed previously. It also considers the impact of interfacial contact resistance between the Gas Diffusion Layer (GDL) and Bipolar Plate (BPP). The structural analysis of the single straight channel HT-PEMFC geometry shows that the von-Mises stress greatly increases in the GDL under the ribs as the CRW ratio increases resulting in considerably high deformation. The cell performance analysis depicts the significance of ohmic resistance and concentration polarization for different CRW ratios, particularly at higher operating current densities. However, in low to medium current density regions, the CRW ratio has little influence on cell performance. A substantial impact on the species, overpotential, and current distributions is observed. The findings also reveal that the CRW ratio significantly affects the temperature distribution in the cell.     

A numerical study on the performance of PEMFC with wedge-shaped fins in the cathode channel

The gas flow field design has a significant influence on the overall performance of a proton exchange membrane fuel cell (PEMFC). A single-channel PEMFC with wedge-shaped fins in the cathode channel was proposed, and the effects of fin parameters such as volume (0.5 mm³, 1.0 mm³, and 1.5 mm³), number (3, 5, and 9), and porosity of the gas diffusion layer (GDL) (0.2, 0.4, 0.6, and 0.8) on the performance of PEMFC were numerically examined based on the growth rate of power density (GRPD) and polarization curve. It was shown that wedge-shaped fins could effectively improve the PEMFC performance. With an increase in fin volume, the distributions of oxygen mass fraction in the outlet area of the cathode channel were lower, the drainage effect of the PEMFC improved, and GRPD also increased accordingly. Similar results were obtained as the number of fins increased. The GDL porosity had a greater effect than the wedge-shaped fins on the improvement in PEMFC performance, but the influence of GDL porosity weakened and the GRPD of porosity decreased as the porosity increased. This study provides an effective guideline for the optimization of the cathode channel in a PEMFC.     

Thermal management in PEMFCs: The respective effects of porous media in the gas flow channel

This study aims to evaluate the convective heat transfer enhancement of the proton exchange membrane fuel cells (PEMFC) numerically. As the higher heat transfer surfaces lead to higher heat transfer rates, a flat plate porous layer is utilized in the gas flow channel (GFC). This enhancement in heat transfer stems from the corresponding modification in the temperature and velocity profiles. The influencing parameters on these profiles are the thickness, permeability, and porosity of the GFC porous layer. After performing the simulations, the results indicate that convective heat transfer has a direct relationship with GFC porous layer's thickness and permeability. However, lower values of porosity lead to the higher Nusselt numbers. Previous investigations have also mentioned the positive impact of the microporous layer (MPL) on the water management of these fuel cells. Therefore, six different sizes of MPL and the gas diffusion layer (GDL) are utilized to evaluate their impacts on the thermal management. Results indicate that although these sizes have negligible effects on the heat transfer, Nu increases by enhancing the total size of MPL and GDL. The results also show that thicker MPLs lead to higher heat transfer rates. The evaluation of the friction factor also indicates the adverse effect of the GFC porous layer, although this undesirable effect is negligible. Finally, all the simulated values are utilized to train an artificial neural network (ANN) model with high precision. This ANN model can produce more data for sensitivity analysis and presenting respective 3D diagrams of the influencing parameters on heat transfer.     

Analysis of surface and interior degradation of gas diffusion layer with accelerated stress tests for polymer electrolyte membrane fuel cell

The effects of surface and interior degradation of the gas diffusion layer (GDL) on the performance and durability of polymer electrolyte membrane fuel cells (PEMFCs) have been investigated using three freeze-thaw accelerated stress tests (ASTs). Three ASTs (ex-situ, in-situ, and new methods) are designed from freezing ?30 °C to thawing 80 °C by immersing, supplying, and bubbling, respectively. The ex-situ method is designed for surface degradation of the GDL. Change of surface morphology from hydrophobic to hydrophilic by surface degradation of GDL causes low capillary pressure which decreased PEMFC performance. The in-situ method is designed for the interior degradation of the GDL. A decrease in the ratio of the porosity to tortuosity by interior degradation of the GDL deteriorates PEMFC performance. Moreover, the new method showed combined effects for both surface and interior degradation of the GDL. It was identified that the main factor that deteriorated the fuel cell performance was the increase in mass transport resistance by interior degradation of GDL. In conclusion, this study aims to investigate the causes of degraded GDL on the PEMFC performance into the surface and interior degradation and provide the design guideline of high-durability GDL for the PEMFC.     

Investigation of effects of non‐homogenous deformation of gas diffusion layer in a PEM fuel cell

Proton exchange membrane fuel cells have been promoted due to improved breakthrough and increased commercialization. The assembly pressure put on a single cell and a fuel cell stack has important influence on the geometric deformation of the gas diffusion layers (GDLs) resulting in a change in porosity, permeability, and the resistance for heat and charge transfer in proton exchange membrane fuel cells. In this paper, both the finite element method and the finite volume method are used, respectively, to predict the GDL deformation and associated effects on the geometric parameters, porosity, mass transport property, and the cell performance. It is found that based on the isotropic Young's modulus and the finite element method, the porosity and thickness under a certain assembly pressure are non‐homogeneous across the fuel cell in the in‐plane direction. The variations of the porosity change and compression ratio in the cross‐section plane are localized by three zones, that is, a linear porosity zone, a constant porosity zone, and a nonlinear porosity zone. The results showed that the GDL porosity and compression ratios maintain linear and nonlinear changes in the zone above the shoulders and the zone under the channel but close to the shoulder, respectively. However, a constant value is kept above the middle of the channel. The obtained non‐homogeneous porosity distribution is applied together with the deformed GDL for further computational fluid dynamics analysis, in which the finite volume method is implemented. The computational fluid dynamic results reveal that a higher assembly pressure decreases the porosity, GDL thickness, gas flow channel cross‐sectional areas, oxygen diffusion coefficient, oxygen concentration, and cell performance. The maximum oxygen mole fraction occurs where the maximum porosity exists. A sufficient GDL thickness is required to ensure transfer of fresh gas to the reaction sites far away from the channel. However, the reduction of porosity is a dominating factor that decreases the cell performance compared with the decreased gas channel flow area and GDL thickness in the assembly condition. Therefore, the assembly pressure should be balanced to consider both the cell performance and gas sealing security. Copyright © 2017 John Wiley & Sons, Ltd.     

Compress effects on porosity,gas‐phase tortuosity,and gas permeability in a simulated PEM gas diffusion layer

Among the parameters to take into account in the design of a proton exchange membrane fuel cell (PEMFC), the energy conversion efficiency and material cost are very important. Understanding in deep the behavior and properties of functional layers at the microscale is helpful for improving the performance of the system and find alternative materials. The functional layers of the PEMFC, i.e., the gas diffusion layer (GDL) and catalyst layer, are typically porous materials. This characteristic allows the transport of fluids and charges, which is needed for the energy conversion process. Specifically, in the GDL, structural parameters such as porosity, tortuosity, and permeability should be optimized and predicted under certain conditions. These parameters have effects on the performance of PEMFCs, and they can be modified when the assembly compression is effected. In this paper, the porosity, gas‐phase tortuosity, and through‐plane permeability are calculated. These variables change when the digitally created GDL is under compression conditions. The compression effects on the variables are studied until the thickness is 66% of the initial value. Because of the feasibility to handle problems in the porous media, the fluid flow behavior is evaluated using the lattice Boltzmann method. Our results show that when the GDL is compressed, the porosity and through‐plane permeability decrease, while the gas‐phase tortuosity increases, i.e., increase the gas‐phase transport resistance. Copyright © 2015 John Wiley & Sons, Ltd.     

Parametric study of the cathode and the role of liquid saturation on the performance of a polymer electrolyte membrane fuel cell—A numerical approach

A two-dimensional two-phase steady state model of the cathode of a polymer electrolyte membrane fuel cell (PEMFC) is developed using unsaturated flow theory (UFT). A gas flow field, a gas diffusion layer (GDL), a microporous layers (MPL), a finite catalyst layer (CL), and a polymer membrane constitute the model domain. The flow of liquid water in the cathode flow channel is assumed to take place in the form of a mist. The CL is modeled using flooded spherical agglomerate characterization. Liquid water is considered in all the porous layers. For liquid water transport in the membrane, electro-osmotic drag and back diffusion are considered to be the dominating mechanisms. The void fraction in the CL is expressed in terms of practically achievable design parameters such as platinum loading, Nafion loading, CL thickness, and fraction of platinum on carbon. A number of sensitivity studies are conducted with the developed model. The optimum operating temperature of the cell is found to be 80-85 °C. The optimum porosity of the GDL for this cell is in the range of 0.7-0.8. A study by varying the design parameters of the CL shows that the cell performs better with 0.3-0.35 mg cm⁻² of platinum and 25-30 wt% of ionomer loading at high current densities. The sensitivity study shows that a multi-variable optimization study can significantly improve the cell performance. Numerical simulations are performed to study the dependence of capillary pressure on liquid saturation using various correlations. The impact of the interface saturation on the cell performance is studied. Under certain operating conditions and for certain combination of materials in the GDL and CL, it is found that the presence of a MPL can deteriorate the performance especially at high current density.     

Study of the mechanical behavior of paper-type GDL in PEMFC based on microstructure morphology

As the softest part in a proton exchange membrane fuel cell (PEMFC), the gas diffusion layer (GDL) could have a large deformation under assembly pressure imposed by bipolar plate, which would have an impact on the cell performance. So, there is an urgent need to clearly reveal the mechanical behavior of GDL under certain pressure. In this paper, the mechanical behavior of paper-type GDL of PEMFC is studied, considering the complex contact environment in the fibrous layered structure. The microstructure of GDL is reconstructed stochastically, then the stress-strain relationship of GDL is explored from the perspective of solid mechanics by using the finite element method. Based on microstructure morphology, it is found that contact pairs and pore space of microstructure are two key factors determining the nonlinearity of the compressive curve. The equivalent Young's modulus increases with the decrease of porosity and carbon fiber diameter but it is not very sensitive to the carbon paper thickness. The results indicate that with the increase in acting pressure, the average porosity of the carbon paper decreases, and the nonuniformity of porosity along the through-plane direction increases. Furthermore, a reasonable explanation for the increase of concentration loss and the decrease of ohmic loss is given from the microstructure findings of the present study.     

Implications of non-uniform porosity distribution in gas diffusion layer on the performance of a high temperature PEM fuel cell

The present study discusses a detailed investigation on the implications of non-uniform porosity distribution in the gas diffusion layer (GDL) on the performance of proton exchange membrane fuel cell (PEMFC). A three-dimensional, single-phase, isothermal model of high-temperature PEMFC is employed to study the effect of non-uniform porosity distribution in GDL. The different porosity configurations with stepwise, sinusoidal, and logarithmic variation in porosity along the streamwise direction of GDL are considered. The numerical experiments are performed, keeping average porosity as constant in the GDL. The electrochemical characteristics such as the oxygen molar concentration, power density, current density, total power dissipation density, average diffusion coefficient, vorticity magnitude, and overpotential are studied for a range of porosity distributions. Furthermore, the variations of oxygen concentration, average diffusion coefficient, and vorticity magnitude are also discussed to showcase the influence of non-uniform porosity distribution. Our study reveals that the PEM fuel cell performance is the best when the porosity of the GDL decreases logarithmically in the streamwise direction. On the contrary, the performance deteriorates when the GDL porosity decreases sinusoidally. Also, it has been observed that the effects of non-uniform porosity distribution are more pronounced, especially at higher current densities. The outcomes of present investigation have potential utility in GDL fabrication and membrane assembly's sintering process for manufacturing high valued PEMFC products.     

Effects of an MPL on water and thermal management in a PEMFC

In this study, the effects of adding a microporous layer (MPL) as well as the impact of its physical properties on polymer electrolyte fuel cell (PEMFC) performance with serpentine flow channels were investigated. In addition, numerical simulations were performed to reveal the effect of relative humidity and operating temperature. It is indicated that adding an extra between the gas diffusion layer (GDL) and catalyst layer (CL), a discontinuity in the liquid saturation shows up at their interface because of differences in the wetting properties of the layers. In addition, results show that a higher MPL porosity causes the liquid water saturation to decrease and the cell performance is improved. A larger MPL thickness reduces the cell performance. The effects of MPL on temperature distribution and thermal transport of the membrane prove that the MPL in addition to being a water management layer also improves the thermal management of the PEMFC.     

Influence of properties of gas diffusion layers on the performance of polymer electrolyte-based unitized reversible fuel cells

Polymer electrolyte-based unitized reversible fuel cells (URFCs) combine the functionality of a fuel cell and an electrolyzer in a single device. In a URFC, titanium (Ti)-felt is used as a gas diffusion layer (GDL) of the oxygen electrode, whereas typical carbon paper is used as a GDL of the hydrogen electrode. Different samples of Ti-felt with different structural properties (porosity and fiber diameter) and PTFE content were prepared for use as GDLs of the oxygen electrode, and the relation between the properties of the GDL and the fuel cell performance was examined for both fuel cell and electrolysis operation modes. Experimental results showed that the cell with a Ti-felt GDL of 80 μm fiber diameter had the highest round-trip efficiency due to excellent fuel cell operation under relatively high-humidity conditions despite degradation in performance in the electrolysis mode.     

Lattice Boltzmann method modeling and experimental study on liquid water characteristics in the gas diffusion layer of proton exchange membrane fuel cells

Water transport through the gas diffusion layer (GDL) is vital to proton exchange membrane fuel cells (PEMFCs), especially under flooding conditions. In this paper, a two-dimensional (2D) lattice Boltzmann method (LBM) is applied to reveal the water dynamic characteristics in GDL, and the computational domain is reconstructed based on the experiment. In-situ experiments, including I–V performance and electrochemical impedance spectroscopy (EIS) tests under flooding conditions, are carried out and analyzed. It is found that the porosity distribution inside the GDL is a crucial factor in water dynamic behavior research. The horizontal liquid water saturation (HS_w) under the channel of real GDL (with porosity distribution) at 0.4 relative thickness are 3.2 times, 2.1 times and 3.4 times higher than the ideal GDL (without porosity distribution) in the case of 0.8 mm, 1.2 mm and 2.0 mm, respectively. The numerical simulation and experimental study show that water dynamic characteristics under the rib influence cell performance directly. In our LBM model, the GDL water distribution inconsistency (Var_w) under 2.0 mm width rib is 43.1% and 28.0% higher than that under the 0.8 mm and 1.2 mm rib, respectively. With the rib wider from 0.8 mm to 2.0 mm, some parts of cell impedance such as R_mt, R_ct, and L_mt increase 64.22%, 98.89%, and 47.46%, respectively. However, GDL under the channel shows no influence on water transport process.     

Numerical study for in-plane gradient effects of cathode gas diffusion layer on PEMFC under low humidity condition

A numerical study about in-plane porosity and contact angle gradient effects of cathode gas diffusion layer (GDL) on polymer electrolyte membrane fuel cell (PEMFC) under low humidity condition below 50% relative humidity is performed in this work. Firstly, a numerical model for a fuel cell is developed, which considers mass transfer, electrochemical reaction, and water saturation in cathode GDL. For water saturation in cathode GDL, porosity and contact angle of GDL are also considered in developing the model. Secondly, current density distribution in PEMFC with uniform cathode GDL is scrutinized to design the gradient cathode GDL. Finally, current density distributions in PEMFC with gradient cathode GDL and uniform cathode GDL are compared. At the gas inlet side, the current density is higher in GDL with a gradient than GDL with high porosity and large contact angle. At the outlet side, the current density is higher in GDL with a gradient than GDL with low porosity and small contact angle. As a result, gradient cathode GDL increases the maximum power by 9% than GDL with low porosity and small contact angle. Moreover, gradient cathode GDL uniformizes the current density distribution by 4% than GDL with high porosity and large contact angle.     

PEM fuel cell performance improvement through numerical optimization of the parameters of the porous layers

A numerical model for a PEM fuel cell has been developed and used to investigate the effect of some of the key parameters of the porous layers of the fuel cell (GDL and MPL) on its performance. The model is comprehensive as it is three-dimensional, multiphase and non-isothermal and it has been well-validated with the experimental data of a 5 cm² active area-fuel cell with/without MPLs. As a result of the reduced mass transport resistance of the gaseous and liquid flow, a better performance was achieved when he GDL thickness was decreased. For the same reason, the fuel cell was shown to be significantly improved with increasing the GDL porosity by a factor of 2 and the consumption of oxygen doubled when increasing the porosity from 0.40 to 0.78. Compared to the conventional constant-porosity GDL, the graded-porosity (gradually decreasing from the flow channel to the catalyst layer) GDL was found to enhance the fuel cell performance and this is due to the better liquid water rejection. The incorporation of a realistic value for the contact resistance between the GDL and the bipolar plate slightly decreases the performance of the fuel cell. Also the results show that the addition of the MPL to the GDL is crucially important as it assists in the humidifying of the electrolyte membrane, thus improving the overall performance of the fuel cell. Finally, realistically increasing the MPL contact angle has led to a positive influence on the fuel cell performance.