Degradation analysis of the core components of metal plate proton exchange membrane fuel cell stack under dynamic load cycles

The durability of metal plate proton exchange membrane fuel cell (PEMFC) stack is still an important factor that hinders its large-scale commercial application. In this paper, we have conducted a 1000 h durability test on a 1 kW metal plate PEMFC stack, and explored the degradation of the core components. After 1000 h of dynamic load cycles, the voltage decay percentage of the stack under the current densities of 1000 mA cm^?2 is 5.67%. By analyzing the scanning electron microscopy (SEM) images, the surfaces of the metal plates are contaminated locally by organic matter precipitated from the membrane electrode assembly (MEA). The SEM images of the catalyst coated membrane (CCM) cross section indicate that the MEA has undergone severe degradation, including the agglomeration of the catalyst layer, and the thinning and perforation of the PEM. These are the main factors that cause the rapid increase in hydrogen crossover flow rate and performance decay of the PEMFC stack.     

Flow field simulation and pressure drop modeling by a porous medium in PEM fuel cells

For proton-exchange membrane fuel cells, the distribution of reactant flow in the stack is critical to the fuel cell's efficiency. The uneven distribution of reactant flow in the stack may cause poor current density, low performance, and material degradation. To understand and accurately predict the flow field in the proton-exchange membrane fuel cell system, the present study aims to develop a simple correlation to analyze the pressure drop in fuel cell stacks. The flow channel in each cell of a stack is treated as a porous medium, and a power-law model is used to approximate the porous medium momentum source term. For the stacks with fewer cell numbers, namely, 1, 5, and 10 cells, the parameters in the power law are established based on the experimental data. Then, a correlation is developed to simulate the flow and predict the pressure drop in the stack with higher cell numbers (ie, 20 and 40 cells). The simulations show that the pressure drop in each cell of a stack is almost invariable, and the average pressure drop decreases with increasing the number of cells. The flow uniformity in the stacks with different cell numbers is evaluated using the dimensionless pressure drop and the pressure drop ratios. It suggests that the lower the cell number, the more uniform the pressure drop. The developed model is conducive to efficiently designing the flow channel for a fuel cell stack with large cell numbers.     

Effect of different control strategies on rapid cold start-up of a 30-cell proton exchange membrane fuel cell stack

Many places experience extreme temperatures below −30 °C, which is a great challenge for the fuel cell vehicle (FCV). The aim of this study is to optimize the strategy to achieve rapid cold start-up of the 30-cell stack at different temperature conditions. The test shows that the stack rapidly starts within 30 s at an ambient temperature of −20 °C. Turning on the coolant at −25 °C show stability of the cell voltage at both ends due to the end-plate heating, however, voltage of intermediate cells fluctuates sharply, and successful start-up is completed after 60 s. The cold start strategy changes to load-voltage cooperative control mode when the ambient temperature reduced to −30 °C, the voltage of multiple cells in the middle of the stack fluctuate more drastic, and start-up takes 113 s. The performance and consistency of the stack did not decay after 20 cold start-up experiments, which indicates that our control strategies effectively avoided irreversible damage to the stack caused by freeze-thaw process.     

Two-dimensional temperature distribution estimation for a cross-flow planar solid oxide fuel cell stack

The uniform temperature distribution of a cross-flow planar solid oxide fuel cell (SOFC) stack plays an essential role in stack thermal safety and electrical property. However, because of the strict requirements in stack sealing struture, it is hard to acquire the temperature inside the stack using thermal detection devices within an acceptable cost. Therefore, accurately estimating the two-dimensional (2-D) temperature distribution of the cross-flow stack is crucial for its thermal management. In this paper, Firstly, a 2-D mechanism model of a cross-flow planar SOFC stack is established. The stack is divided into 5*5 nodes along the gas flow directions, which can reflect the stack states with moderate computational burden. Then, experimental test data is utilized to modify and validate the stack model, guaranteeing the model accuracy as well as the reliability of model-based state estimator design. Finally, easily-measured stack inputs and outputs are selected, and a temperature distribution estimator combined with unscented kalman filter (UFK) approach is developed to achieve accurate and fast temperature distribution estimation of a cross-flow SOFC stack. Simulation results demonstrate that the UKF-based temperature distribution estimator can precisely and quickly achieve the temperature distribution estimation of the cross-flow stack under both static state and dynamic state changes and is applicable to cross-flow stacks with different size or cell number as well, the maximum estimated absolute error is less than 0.15 K with an absolute error rate of 0.015%, which indicates the developed estimator has good estimation performances.     

烟道流量计量标准装置

为了解决我国烟道流量计的量值溯源问题,中国计量科学研究院建立了烟道流量计量标准装置。装置使用可溯源至标准转盘的激光多普勒测速仪作为原级标准器,采用激光多普勒流速剖面扫描和超声流量计波动修正的方式测量标准流量,经校准的8声道超声流量计为工作级标准表,具备了908~104840m3/h的测量能力,扩展不确定度为0.62%(k=2),可对最大口径为1m的流量计进行校准。装置下游测试段包括圆形管段和矩形管段,能够开展烟道流量计测量性能的研究。     

Experimental investigation on the voltage uniformity for a PEMFC stack with different dynamic loading strategies

The operating life of the proton exchange membrane fuel cell stack is mainly decided by performances of its weakest single cell because of the “Buckets effect”, thus high voltage uniformity during a dynamic loading process is key to the stack durability. In this work, a 3-kW stack is examined experimentally on its voltage uniformity (voltage coefficient variation (Cv)) under conditions of loading from open-circuit state (0 A) to nominal current (165 A) and stack temperatures of 30 °C, 45 °C and 65 °C. Different dynamic loading strategies, namely constant loading rate strategy, decreasing loading rate strategy, and increasing loading rate (square/cube increasing loading rate) strategy, are examined and compared. Results display that during the loading process, (a) the voltage uniformity rises abruptly and goes down quickly when the loading current is small (e.g. from 0 A to 22 A), (b) the voltage uniformity under a small loading current is better than that under the open-circuit state, and (c) voltage uniformity decreases as the loading current increases from a small value to the nominal current. Comparisons of different current loading strategies show that as the stack temperature rises from 30 °C to 65 °C, the stack Cv value under the open-circuit state increases from 1.12 to 1.84 and decreases from 3.85 to 2.45 in the nominal current state. The maximum Cv for the decreasing loading rate strategy decreases from 16.25 to 9.49 and that of the constant loading rate strategy also decreases from 5.85 to 4.96. Cv values of the square current increasing loading rate strategy keep below 3.85 under conditions of the three stack temperatures and display a slight fluctuation during the whole current loading process, which indicates that the strategy can effectively make the stack being of an excellent voltage uniformity during the instantaneous response process.     

Experimental study on vibration-induced clamping force reduction in fuel cell structures

When applied to transportation systems, fuel cell structures are exposed to external mechanical disturbance including shocks and harmonic excitations from operating components. To minimize performance degradation from machine operations, the fuel cell structure needs to be examined via vibration reliability tests. In this study, the reduction in the clamping force of the stack by random vibrations was investigated by experiments. The stack mass and gasket were clamped with bolts for vibration tests. The vibration induced shear movements between clamped stacks. To estimate the vibration input magnitudes, the Dirlik method was used. The reduction in the stack clamping force was estimated using the Basquin's power law. The clamping force decreased by the shear vibration input to the stack structure. The degree of clamping force reduction was larger for the heavier stack. When the stacks were separated by the gasket the reduction became smaller. Through the Dirlik method, the vibration reliability of the stack was evaluated. This information provides severity of the external vibration on the stack functionality.     

Analytical Model to Characterize the Efficiency of Disk Stack Separators

Up to now the prediction of separation efficiency for disk stack separators is largely based on the concept of equivalent clarification area, short Σ-theory, firstly published in 1949. An improved analytical model with a closed-form solution is presented in which the assumptions of uniform flow and unhindered solids transport are dropped. The contributions of distributor and solids holding space to the total separation efficiency are considered. The model is validated by comprehensive experiments with different geometry parameters and particle systems. The results are presented in a universal form for a combination of dimensionless numbers.     

A coupled and interactive influence of operational parameters for optimizing power output of cleaner energy production systems under uncertain conditions

The mechanisms in proton‐exchange membrane fuel cells (PEMFCs) cannot be explicitly represented by a mathematical function because the PEMFC system is multi‐dimensional and complex and represents uncertainty in operation variables, which cannot be modeled by experiments or by trial‐and‐error approach. Therefore, this work proposes to study the coupled and interactive influence of stack current (SC), stack temperature (ST), oxygen excess ratio (OER), hydrogen excess ratio (HER), and inlet air humidity (IAH) for optimizing the power output of PEMFC. The data obtained from the experiments have been inserted into architecture of automated neural‐network search, which automates the selection of error function, activation function, uncertainties in inputs and number of hidden neurons in formulation of a robust and accurate model for power density as a function of five operational variables. Among the operational variables, the correlation coefficient between the SC and the output power is the highest, followed by OER, and the ST. However, for HER and IAH, the power output follows negative nonlinear relation. The optimization converged at 130^th iteration results in maximum power output of 3410 W for an optimum value of SC (51A), ST (59°C), OER (3:2), HER (1:10), and IAH (0.8).     

Geometry optimization and pressure analysis of a proton exchange membrane fuel cell stack

For proton exchange membrane fuel cells (PEMFCs), the distribution of reactant streams in the reactor is critical to their efficiency. This study aims to investigate the optimal design of the inlet/outlet flow channel in the fuel cell stack with different geometric dimensions of the tube and intermediate zones (IZ). The tube-to-IZ length ratio, the IZ width, and the tube diameter are adjusted to optimize the geometric dimensions for the highest pressure uniformity. Four different methods, including the Taguchi method, analysis of variance (ANOVA), neural network (NN), and multiple adaptive regression splines (MARS), are used in the analyses. The results indicate the tube diameter is the most impactive one among the three factors to improve the pressure uniformity. The analysis suggests that the optimal geometric design is the tube-to-IZ length ratio of 9, the IZ width of 14 mm, and the tube diameter of 9 mm with the pressure uniformity of 0.529. The relative errors of the predicted pressure uniformity values by NN and MARS under the optimal design are 1.62% and 3.89%, respectively. This reveals that NN and MARS can accurately predict the pressure uniformity, and are promising tools for the design of PEMFCs.