Numerical study of thermal stresses in high-temperature proton exchange membrane fuel cell (HT-PEMFC)

The purpose of this work is to numerically examine the thermal stress distributions in a high-temperature proton exchange membrane fuel cell (HT-PEMFC) based on a phosphoric acid doped polybenzimidazole (PBI) membrane. A fluid structure interaction (FSI) method is adopted to simulate the expansion/compression that arises in various components of a membrane electrode assembly (MEA) during the HT-PEMFC assembly processes, as well as during cell operations. First, three-dimensional (3-D) finite element method (FEM) simulations are conducted to predict the cell deformation during cell clamping. Then, a nonisothermal computational fluid dynamic (CFD)-based HT-PEMFC model developed in a previous study [1] is applied to the deformed cell geometry to estimate the key species and temperature distributions inside the cell. Finally, the temperature distributions obtained from these CFD simulations are employed as the input load for 3-D FEM simulations. The present numerical study provides a fundamental understanding of the stress–temperature interaction during HT-PEMFC operations and demonstrates that the coupled FEM/CFD HT-PEMFC model presented in this paper can be used as a useful tool for optimizing HT-PEMFC clamping and operating conditions.     

3D non-isothermal dynamic simulation of high temperature proton exchange membrane fuel cell in the start-up process

High temperature proton exchange membrane fuel cell (HT-PEMFC) with phosphoric acid doped polybenzimidazole (PBI) electrolyte shows multiple advantages over conventional PEMFC working at below 373 K, such as faster electrochemical kinetics, simpler water management, higher carbon monoxide tolerance. However, starting HT-PEMFC from room temperature to the optimal operating temperature range (433.15 K–453.15 K) is still a serious challenge. In present work, the start-up strategy is proposed and evaluated and a three-dimensional non-isothermal dynamic model is developed to investigate start-up time and temperature distribution during the start-up process. The HT-PEMFC is preheated by gas to 393.15 K, followed by discharging a current from the cell for electrochemical heat generation. Firstly, different current loads are applied when the average temperature of membrane reaches 393.15 K. Then, the start-up time and temperature distribution of co-flow and counter-flow are compared at different current loads. Finally, the effect of inlet velocity and temperature on the start-up process are explored in the case of counter-flow. Numerical results clearly show that applied current load is necessary to reduce start-up time and just 0.1 A/cm² current load can reduce startup time by 45%. It is also found that co-flow takes 18.8% less time than counter-flow to heat membrane temperature to 393.15 K, but the maximum temperature difference of membrane is 39% higher than the counter-flow. Increasing the inlet gas flow velocity and temperature can shorten the start-up time but increases the temperature difference of the membrane.     

A facile method of asymmetric ether-containing polybenzimidazole membrane for high temperature proton exchange membrane fuel cell

A facile method has been suggested for the preparation of poly [2,2′-(p-oxydiphenylene)-5,5′-benzimidazole] (OPBI) membrane that comprises of dense and porous layers for high temperature proton exchange membrane fuel cells (HT-PEMFCs). The porosity as well as the asymmetry of the membrane is formed by the use of component solvent at steadily increasing temperatures. This approach needs not to use any porogen, whereas the resultant asymmetric OPBI membrane indicates an improved phosphoric acid (PA) doping level together with mechanical strength. For instance, the PA doping level of the asymmetric OPBI membrane is almost twice as much as that of the homogenous dense OPBI membrane. The conductivity of asymmetric OPBI arrived at 0.072 S cm^?1 at 180 °C. The membrane electrode assembly (MEA) based on the asymmetric OPBI demonstrated an exceptional fuel cell functionality with a peak power density of 393 mW cm^?2 at 160 °C under anhydrous conditions.     

Reconstruction and optimization of catalyst layer of high temperature proton exchange membrane fuel cell

Catalyst layer determines the performance and cost of high temperature proton exchange membrane fuel cell. However, a fundamental understanding and optimization of its microstructure is hindered by the characterization limitation. In this study, the micro model and macro model are integrated to examine the effects of ionomer/carbon (I/C) ratio, Pt/C ratio and Pt loading on the microstructure and cell performance. As many Pt particles are partly coved by the ionomer, assuming all catalyst are covered by ionomer is inappropriate. Both Pt/C ratio and I/C ratio can significantly affect the compositions and microstructure of CL. The increase of Pt loading increases the cell performance, but the increment is small at a high platinum loading. However, the performance cost increases linearly with the increasing platinum loading. Thus, both cell performance and performance cost must be taken into consideration when designing CL of high temperature proton exchange membrane fuel cell.     

Numerical modeling and investigation of gas crossover effects in high temperature proton exchange membrane (PEM) fuel cells

A gas crossover model is developed for a high temperature proton exchange membrane fuel cell (HT-PEMFC) with a phosphoric acid-doped polybenzimidazole membrane. The model considers dissolution of reactants into electrolyte phase in the catalyst layers and subsequent crossover of reactant gases through the membrane. Furthermore, the model accounts for a mixed potential on the cathode side resulting from hydrogen crossover and hydrogen/oxygen catalytic combustion on the anode side due to oxygen crossover, which were overlooked in the HT-PEMFC modeling works in the literature. Numerical simulations are carried out to investigate the effects of gas crossover on HT-PEMFC performance by varying three critical parameters, i.e. operating current density, operating temperature and gas crossover diffusivity to approximate the membrane degradation. The numerical results indicate that the effect of gas crossover on HT-PEMFC performance is insignificant in a fresh membrane. However, as the membrane is degraded and hence gas crossover diffusivities are raised, the model predicts non-uniform reactant and current density distributions as well as lower cell performance. In addition, the thermal analysis demonstrates that the amount of heat generated due to hydrogen/oxygen catalytic combustion is not appreciable compared to total waste heat released during HT-PEMFC operations.     

A review of high-temperature proton exchange membrane fuel cell (HT-PEMFC) system

This paper provides information encompassing the recent discovery of the High Temperature Proton Exchange Membrane Fuel Cell (HT-PEMFC) focusing on systems requirement. To have a reliable power production and higher durability level, a proper system must be applied in both normal and especially in transient operations. To date many issues of HT-PEMFC especially in durability and performance still unsolved. This article is written to provide clear information about the research undergo and must be the focus in order to produce an efficient performance. Information about the advantages towards Low Temperature Proton Exchange Membrane Fuel Cell (LT-PEMFC), the main components, and the mode of operation also discussed. In-depth research needs to be conducted into the innovative design and development of HT-PEMFC components and its system since these are the key factors for optimum performance.     

Parameter study of high-temperature proton exchange membrane fuel cell using data-driven models

In this paper, a numerical model of high-temperature proton exchange membrane fuel cell (HT-PEMFC) was developed, in which the thermal and electrical properties were treated as temperature dependent. Based on the numerical simulation, the needed training data was acquired and used for the development of data-driven model via the artificial neural network (ANN) algorithm. The developed data-driven model was then used to predict the performance of HT-PEMFC. The simulation results indicated that the deviation of ANN prediction was less than 2.48% compared with numerical simulation. The effects of various influential factors, such as the geometry size of the gas flow channel, the thickness of the membrane and the operating temperature, could be predicted easily by using the ANN model. The ANN model prediction results showed that the more compact fuel cell and the higher operating temperature improved the performance of HT-PEMFC. The proposed ANN model and the parameters study will contribute to the further design and operation of HT-PEMFC.     

Numerical studies on an air-breathing proton exchange membrane (PEM) fuel cell stack

Air-breathing proton exchange membrane (PEM) fuel cells provide for fully or partially passive operation and have gained much interest in the past decade, as part of the efforts to reduce the system complexity. This paper presents a detailed physics-based numerical analysis of the transport and electrochemical phenomena involved in the operation of a stack consisting of an array of vertically oriented air-breathing fuel cells. A comprehensive two-dimensional, nonisothermal, multi-component numerical model with pressurized hydrogen supply at the anode and natural convection air supply at the cathode is developed and validated with experimental data. Systematic parametric studies are performed to investigate the effects of cell dimensions, inter-cell spacing and the gap between the array and the substrate on the performance of the stack. Temperature and species distributions and flow patterns are presented to elucidate the coupled multiphysics phenomena. The analysis is used to determine optimum stack designs based on constraints on desired performance and overall stack size.     

Water transport study in a high temperature proton exchange membrane fuel cell stack

A study of water transport in a high temperature phosphoric acid doped polybenzimidazole (PBI) membrane fuel cell stack is reported. Tests with different stoichiometries of dry cathode and different humidity levels of anode are performed. It is found that water transport across the membrane electrode assembly (MEA) is noteworthy and that water vapor partial pressure on the anode outlet is almost always higher than on the cathode outlet, even when using dry hydrogen. The water transport is a strong function of current density but it also depends on stoichiometry and humidity level. In a series of tests with dry nitrogen on one side and humid nitrogen on the other side, the membrane's water permeability coefficient is determined to be 2.4 × 10⁻¹³ mol s⁻¹ cm⁻¹ Pa⁻¹ at 160 °C which is more than an order of magnitude higher than the values previously reported in the literature. Also, the results indicate that the permeability coefficient might be relative humidity dependent and could even be somewhat higher than the value reported here, but further investigation is needed. The experimental findings are reproduced and explained with a 2D steady state computational fluid dynamics (CFD) model. Internal water transport profiles across the membrane and along the gas flow channels are presented and discussed.     

Polybenzimidazole containing ether units as electrolyte for high temperature proton exchange membrane fuel cells

A rapid method to synthesize poly[2,2′-(p-oxydiphenylene)-5,5′-benzimidazole] (OPBI) through a solution polycondensation under microwave irradiation is explored. Synthesis parameters affecting the molecular weight (M_w) of OPBI, including the mass ratio of solvent to P₂O₅, the monomer concentration, and reaction time, are optimized. The main characteristics of OPBI are studied, and the corresponding membrane is prepared through a solvent casting process. A series of sulfuric acid doped OPBI (H₂SO₄/OPBI) hybrid membranes with different acid doping levels (ADLs) are developed. The effects of H₂SO₄ on microstructure, ADL and electrochemical properties of these membranes are explored. Herein, the hybrid membrane shows high proton conductivity (190 mS cm⁻¹) at elevated temperature (160 °C) and anhydrous conditions, high ADL (18.73 mol of H₂SO₄ for OPBI per repeat unit, i.e., ADL = 18.73 mol PRU⁻¹) and excellent dimensional stability (40.3%). All these properties demonstrated that H₂SO₄/OPBI hybrid membrane can be used as an alternative membrane for high temperature proton exchange membrane fuel cells (HT-PEMFCs).     

Utilizing coke oven gases as a fuel for a cogeneration system based on high temperature proton exchange membrane fuel cell; energy,exergy and economic assessment

Based on a high temperature proton exchange membrane fuel cell (HT-PEMFC), a cogeneration system is proposed to produce heat and power. The system includes a coke oven gas steam reformer, a water gas shift reactor, and an afterburner. The system is analyzed in detail considering the energy, exergy and economic viewpoints. The analyses reveal the importance of HT-PEMFC in the system and according to the results, 9.03 kW power is generated with energy and exergy efficiencies of 88.2% and 26.2%, respectively and the total product unit cost is calculated as 91.8 $/GJ. Through a parametric study the effects on system performance are studied of such variables as the current density, fuel cell and reformer operating temperatures, and cathode stoichiometric ratio. It is found that an increase in the fuel cell temperature and/or a decrease in the reformer temperature enhance the exergy efficiency. The exergy efficiency is also maximized at the cathode stoichiometric ratio of 2.4. By performing a two-objective optimization using genetic algorithm, the best operating point is determined at which the exergy efficiency is (32.86%) and the total product unit cost is (78.68 $/GJ).     

Experimental investigation on influences of methanol reformate impurities in performances of high temperature proton exchange membrane fuel cells

Even though the methanol reformate can be fed into the high temperature proton exchange membrane fuel cell, the influences of different reformate components on the fuel cell are still unclear. This work investigates the effects of CO, CO₂, H₂O, and CH₃OH in the fuel gas on the fuel cell performances. The distribution of relaxation times and equivalent circuit model are employed for analysis. The results show the increase of anodic charge and mass transfer resistances are main factors of CO poisoning which results in 77 mV overpotential. The maximum overpotential difference between CO₂ and Ar is only 4 mV, which means the dilution effect of CO₂ is similar to Ar. H₂O decreases the Ohmic and anodic charge transfer resistances and reducing the overpotential by 10 mV. CH₃OH below 3% has slight positive effect on the fuel cell performance. However, 5% CH₃OH results in high overpotential of 36 mV.     

Feasibility of ultra-low Pt loading electrodes for high temperature proton exchange membrane fuel cells based in phosphoric acid-doped membrane

Factors as the Pt/C ratio of the catalyst, the binder content of the electrode and the catalyst deposition method were studied within the scope of ultra-low Pt loading electrodes for high temperature proton exchange membrane fuel cells (HT-PEMFCs). The Pt/C ratio of the catalyst allowed to tune the thickness of the catalytic layer and so to minimize the detrimental effect of the phosphoric acid flooding. A membrane electrode assembly (MEA) with 0.05 mg_Ptcm⁻² at anode and 0.1 mg_Ptcm⁻² at cathode (0.150 mg_Ptcm⁻² in total) attained a peak power density of 346 mW cm⁻². It was proven that including a binder in the catalytic layer of ultra-low Pt loading electrodes lowers its performance. Electrospraying-based MEAs with ultra-low Pt loaded electrodes (0.1 mg_Ptcm⁻²) rendered the best (peak power density of 400 mW cm⁻²) compared to conventional methods (spraying or ultrasonic spraying) but with the penalty of a low catalyst deposition rate.     

Sliding-mode-based temperature regulation of a proton exchange membrane fuel cell test bench

The temperature regulation of a cooling system of a PEMFC (Proton Exchange Membrane Fuel Cell) test bench is studied in this paper. Because of the unique configuration which is dedicated for cold start experiments, the operation at nominal temperature is unstable with a simple PI controller. A sliding-based control strategy is applied to suppress the temperature fluctuation. Firstly the structure of the cooling system is demonstrated and the cause of temperature fluctuation is analyzed. Then, a physics-based model of the cooling system is proposed on the Matlab/Simulink platform and validated with experimental data. Based on the model, a Sliding-mode controller with Extended Kalman Filter (EKF) is designed to regulate the temperature. The simulation results showed that the controlled system performed satisfactorily. Furthermore, when applied to the real system, the controller's real-time performance fulfills the test bench criterion. Experimental data show that the coolant temperature at the outlet of the fuel cell stack is kept in a range within ±1 °C, disregarding the heat generated at various working condition.     

Analysis and optimization of high temperature proton exchange membrane (HT-PEM) fuel cell based on surrogate model

The stoichiometric ratio and flow channel geometry play a vital role in the performance of high temperature proton exchange membrane (HT-PEM) fuel cells. Because of the high cost of experiments or simulations, most analyses and optimization of the stoichiometric ratio and flow channel geometry are limited to several points in the entire design domain. In this study, an analysis and optimization method for HT-PEM fuel cells based on the surrogate model was proposed. Surrogate models were constructed using some of the available budgets of samples to analyze and optimize the entire design domain. With this method, it was indicated that the effect of the cathode stoichiometric ratio is more significant to the cell performance than the anode stoichiometric ratio and there are significant nonlinear interactions among the flow channel geometry parameters. At the fixed operating voltage, the flow channel geometry with the maximum current density and that with the maximum real power were obtained. Compared with the base design, the designs obtained by the surrogate model improve the current density and real power by 10.54% and 3.93%, respectively. Thus, this analysis and optimization method is demonstrated to be helpful and deserves attention in future research.     

A simple transient model for a high temperature PEM fuel cell impedance

We develop a pseudo two-dimensional, isothermal transient model for a high temperature proton exchange membrane fuel cell. It takes into account the dynamic change of oxygen concentration in the cathode gas diffusion layer and in the cathode channel. The model can be used to simulate and analyze electrochemical impedance spectra of the cell in both potentiostatic and galvanostatic modes, current interrupt results and step changes in the cell current or potential. The model is validated by fitting experimental data.     

Modeling and off-design performance of a 1 kWe HT-PEMFC (high temperature-proton exchange membrane fuel cell)-based residential micro-CHP (combined-heat-and-power) system for Danish single-family households

A novel proposal for the modeling and operation of a micro-CHP (combined-heat-and-power) residential system based on HT-PEMFC (High Temperature-Proton Exchange Membrane Fuel Cell) technology is described and analyzed to investigate its commercialization prospects. An HT-PEMFC operates at elevated temperatures, as compared to Nafion-based PEMFCs and therefore can be a significant candidate for cogeneration residential systems. The proposed system can provide electric power, hot water, and space heating for a typical Danish single-family household. A complete fuel processing subsystem, with all necessary BOP (balance-of-plant) components, is modeled and coupled to the fuel cell stack subsystem. The micro-CHP system is simulated in LabVIEW™ environment to provide the ability of Data Acquisition of actual components and thereby more realistic design in the future. A part-load study has been conducted to indicate performance characteristics at off-design conditions. The system is sized to provide realistic dimensioning of the actual system.     

Performance improvement of air-breathing proton exchange membrane fuel cell stacks by thermal management

Air-breathing is known as a way to reduce the weight, volume, and the cost of PEMFCs. In this study, the thermal management of the high-powered air-breathing PEMFC stacks by applying different cathode flow channel configurations is carried out to improve the stack performance. In order to verify the thermal management results, numerical simulation is also performed. The research results show that a combination of the 50% and 58.3% opening ratios in the air-breathing stack reduces the stack temperature and enhances the temperature distribution uniformity, leading to a better and more stable stack performance. In addition, it is found that the stack performance is significantly improved under the assisted-air-breathing condition. Moreover, the simulation results and the experimental data are basically consistent. It is suggested to adopt the average temperature over the cross-sectional flow region from simulation as fitting the simulation results and the measured data.     

Numerical investigation of transport component design effect on a proton exchange membrane fuel cell

A numerical investigation of the transport phenomena and performance of a proton exchange membrane fuel cell (PEMFC) with various design parameters of the transport component is presented. A three-dimensional fuel cell model, incorporating conservations of species, momentum, as well as current transport, is used. The Bulter–Volmer equation that describes the electrochemical reaction in the catalyst layer is introduced; the activation overpotential connects the solid phase potential field to that of the electrolyte phase. Through cell performance simulation with various channel aspect ratios and gas diffusion layer (GDL) thicknesses, a slender channel is found suitable for cells operating at moderate reaction rate, and a flat channel produces more current at low cell voltage. Plots of transverse oxygen concentration and phase potential variation indicate that these oppositely affect the local current density pattern. The relative strengths of these two factors depend on the transport component position and geometry, as well as on the cell operating conditions. Consequently, the curves of cell output current density demonstrate that the optimal GDL thickness increases as the cell voltage decreases. However, at the lowest considered cell voltage of 0.14 V, optimal thickness decreases as that of a thick GDL. The oxygen deficiency caused by long traveling length and clogging effect of liquid water reverses this relationship.