Investigation of bio-inspired flow channel designs for bipolar plates in proton exchange membrane fuel cells

Proton exchange membrane (PEM) fuel cell performance is directly related to the flow channel design on bipolar plates. Power gains can be found by varying the type, size, or arrangement of channels. The objective of this paper is to present two new flow channel patterns: a leaf design and a lung design. These bio-inspired designs combine the advantages of the existing serpentine and interdigitated patterns with inspiration from patterns found in nature. Both numerical simulation and experimental testing have been conducted to investigate the effects of two new flow channel patterns on fuel cell performance. From the numerical simulation, it was found that there is a lower pressure drop from the inlet to outlet in the leaf or lung design than the existing serpentine or interdigitated flow patterns. The flow diffusion to the gas diffusion layer was found be to more uniform for the new flow channel patterns. A 25 cm² fuel cell was assembled and tested for four different flow channels: leaf, lung, serpentine and interdigitated. The polarization curve has been obtained under different operating conditions. It was found that the fuel cell with either leaf or lung design performs better than the convectional flow channel design under the same operating conditions. Both the leaf and lung design show improvements over previous designs by up to 30% in peak power density.     

Graphene as corrosion protection for metal foam flow distributor in proton exchange membrane fuel cells

In this study, graphene was grown on nickel foam by chemical vapor deposition method. The morphology and crystallization of graphene films were characterized by scanning electron microscopy and Raman spectroscopy. Graphene-coated nickel foams have been used as flow distributor in a single PEM fuel cell, and the current density of the cell reached 1000 mA/cm² at 0.6 V. Tafel analysis indicates that graphene-coated samples showed greatly lower corrosion current density (nine times) than the uncoated ones. The contact angle was 35% larger than uncoated sample. These results clearly show that graphene-coated metal foams significantly enhances electrical conductivity and hydrophobicity.     

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.     

Heat transport characteristics of flow fields in proton exchange membrane fuel cells

Since the electrochemical reaction at electrodes of PEMFC is a form of exothermic reaction, three-dimensional non-isothermal numerical simulation was developed including the energy equation with all heat source terms such as reversible heat generation and irreversible heat release attributed to ohmic and activation polarization. The results show that the maximum temperature is observed at the cathode because of reaction heat from water formation reaction and temperature at the electrolyte along channel increases due to accumulative heat addition and heat is mainly generated by irreversible loss at a low voltage and by water formation loss at a low current density.     

Performance prediction of proton exchange membrane fuel cells using a three-dimensional model

In this study a steady-state three-dimensional computational fluid dynamics (CFD) model of a proton exchange membrane fuel cell is developed and presented for a single cell. A complete set of conservation equations of mass, momentum, species, energy transport, and charge is considered with proper account of electrochemical kinetics based on Butler–Volmer equation. The catalyst layer structure is considered to be agglomerate. This model enables us to investigate the flow field, current distribution, and cell voltage over the fuel cell which includes the anode and cathode collector plates, gas channels, catalyst layers, gas diffusion layers, and the membrane. The numerical solution is based on a finite-volume method in a single solution domain. In this investigation a CFD code was used as the core solver for the transport equations, while mathematical models for the main physical and electrochemical phenomena were devised into the solver using user-developed subroutines. Three-dimensional results of the flow structure, species concentrations and current distribution are presented for bipolar plates with square cross section of straight flow channels. A polarization curve is obtained for the fuel cell under consideration. A comparison between the polarization curves obtained from the current study and the corresponding available experimental data is presented and a reasonable agreement is obtained. Such CFD model can be used as a tool in the development and optimization of PEM fuel cells.     

A novel intersectant flow field of metal bipolar plate for proton exchange membrane fuel cell

A novel intersectant flow field of metal bipolar plate for proton exchange membrane fuel cell (PEMFC) was proposed. The bionics, fractal theory, and Murray's law were employed to design the novel flow field to decrease the drag force for the reaction medium and product. Computational fluid dynamics method was employed to investigate the performance of the novel flow field. The performance of traditional serpentine flow field was compared with the said one to calibrate the efficiency of the novel design of flow field. A test system of PEMFC was assembled to validate the reliability of the numerical simulation. The metal bipolar plates with the intersectant flow field were fabricated by electro discharge machining for the test. The surface treatment of the bipolar plate was conducted. Results showed that the novel flow field exhibited some advantages than the serpentine flow field in terms of the uniform distribution of reaction medium and exhausting of reaction product. The polarization curve also released that the novel flow field owned the higher power and current density. The experimental results certified the accuracy of numerical simulation and validated the advantage of the novel flow field in promoting the efficiency of PEMFC. Copyright © 2017 John Wiley & Sons, Ltd.     

Entropy generation analysis of a proton exchange membrane fuel cell (PEMFC) with a fermat spiral as a flow distributor

The present paper aims at investigating the main sources of irreversibility in a Proton Exchange Membrane Fuel Cell (PEMFC) using a Fermat spiral as flow distributor and also to direct possible improvements in its design. The numerical analysis is based on a finite volume technique with a SIMPLE algorithm as numerical procedure. In order to have a more complete and rigorous analysis a new dimensionless parameter is proposed here. The parameter represents the ratio of the entropy generation due to mass transfer to the total entropy generation is proposed here. Results demonstrate that the main sources of irreversibility in a fuel cell are the concentration losses for the most part of the operational domain, whereas the heat transfer effect is not dominant.     

Performances prediction study for proton exchange membrane fuel cells

In this work, we propose to study the influence of the membrane physical properties on the performance of a single PEM cell through the polarization curve. A thermal approach describing the main heat transfer aspects was also discussed. For this study, we have developed and used a simulation tool called Performances Prediction Fuel Cell tool (2PFC tool) based on simplified charge, mass and even heat transfer equations. This tool aims to visualize the main evolutions in the heart of a single cell, and the results should help users to understand the variation of some operating conditions and component properties on the output cell voltage by offering a variety of sensitivity parameter studies. For this sensitivity analysis, three separated simulations are launched. The first simulation regards the effect of the resistive losses and charge transfer coefficient on the cell voltage. The second simulation concerns the influence of the water content of the membrane and the cell operating temperature on it proton conductivity. The last simulation takes in consideration the effect of water activity variation on the proton membrane conductivity, and the results proved the direct and strong relation of the charge transfer coefficient and of the water content of the membrane on the output cell voltage. In the thermal approach part, we have proposed to study the temperature distribution between two cathodes with the presence of an implemented cooling channel.     

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.     

Comparison of water management between two bipolar plate flow-field geometries in proton exchange membrane fuel cells at low-density current range

This experimental research studies some aspects of water formation and management in polymer electrolyte membrane fuel cells (PEMFCs). To this end, two different single cells of 49 cm² active area have been tested, the first one with a serpentine-parallel geometry and the second with a cascade-type flow-field topology. In order to visualize the processes, flow-field channels have been machined on transparent plastic. Experiments have consisted in both image acquisition using a CCD camera, and simultaneous measurements of pressure drop in both hydrogen and oxygen gas flow paths. It has been observed that with the cascade-type flow-field geometry, water produced in the cathode does not flood the gas flow channels and, consequently, can be drained in an easy way. On the other hand, it has also been verified that saturated condition for the hydrogen gas flow at the anode side produces water condensation and channel flooding for the serpentine-parallel flow-field topology. Time fluctuations in the pressure drop of the gas flow have been detected and are associated to some transient process inherent to water formation and management.     

Simultaneous measurement of current and temperature distributions in a proton exchange membrane fuel cell

Using a specially designed current distribution measurement gasket in anode and thin thermocouples between the catalyst layer and gas diffusion layer (GDL) in cathode, in-plane current and temperature distributions in a proton exchange membrane fuel cell (PEMFC) have been simultaneously measured. Such simultaneous measurements are realized in a commercially available experimental PEMFC. Experiments have been conducted under different air flow rates, different hydrogen flow rates and different operating voltages, and measurement results show that there is a very good correlation between local temperature rise and local current density. Such correlations can be explained and agree well with basic thermodynamic analysis. Measurement results also show that significant difference exists between the temperatures at cathode catalyst layer/GDL interface and that in the center of cathode endplate, which is often taken as the cell operating temperature. Compared with separate measurement of local current density or temperature, simultaneous measurements of both can reveal additional information on reaction irreversibility and various transport phenomena in fuel cells.     

Different flow fields,operation modes and designs for proton exchange membrane fuel cells with dead-ended anode

Water and nitrogen can accumulate in the anode channel in proton exchange membrane fuel cells (PEMFCs) with dead-ended anode (DEA) and can affect cell performance significantly. In this paper, the cell performance characteristics in DEA PEMFCs with three different anode flow fields under two operating modes are studied through measuring the cell voltages and local current densities. The effect of the anode exit reservoir is also studied for the three different anode flow fields. The experimental results show that the interdigitated flow field has the most stable cell performance under both constant pressure and pressure swing supply modes. Parallel and serpentine flow fields lead to very non-uniform local current distributions under constant pressure supply mode and experience severe fluctuations and spikes in local current densities under pressure swing supply mode. The results also show that anode pressure swing supply mode can achieve more stable cell performance than anode constant pressure supply mode for parallel and serpentine anode flow fields. The anode exit reservoir can significantly improve cell performance stability for parallel and serpentine flow fields, but has no significant effect on interdigitated flow fields. Besides, the results further show that PEMFCs with DEA can maintain very stable operation with anode serpentine flow field and an anode exit reservoir under pressure swing operation.     

An improved model for predicting electrical contact resistance between bipolar plate and gas diffusion layer in proton exchange membrane fuel cells

Electrical contact resistance between bipolar plates (BPPs) and gas diffusion layers (GDLs) in PEM fuel cells has attracted much attention since it is one significant part of the total contact resistance which plays an important role in fuel cell performance. This paper extends a previous model by Zhou et al. [Y. Zhou, G. Lin, A.J. Shih, S.J. Hu, J. Power Sources 163 (2007) 777–783] on the prediction of electrical contact resistance within PEM fuel cells. The original microscale numerical model was based on the Hertz solution for individual elastic contacts, assuming that contact bodies, GDL carbon fibers and BPP asperities are isotropic elastic half-spaces. The new model features a more practical contact by taking into account the bending behavior of carbon fibers as well as their anisotropic properties. The microscale single contact process is solved numerically using the finite element method (FEM). The relationship between the contact pressure and the electrical resistance at the GDL/BPP interface is derived by multiple regression models. Comparisons of the original model by Zhou et al. and the new model with experimental data show that the original model slightly overestimates the electrical contact resistance, whereas a better agreement with experimental data is observed using the new model.     

Thermal and electrochemical durability of carbonaceous composites used as a bipolar plate of proton exchange membrane fuel cell

Thermal and electrochemical durability of carbonaceous composite plates, which are made from graphite powders and a resin for use as bipolar plates of PEMFC (proton exchange membrane fuel cell), were investigated. The thermal durability was investigated by TG (thermal gravimetry) coupled with DTA (differential thermal analysis) technique under air up to 600 °C. A weight loss was significant over 300 °C, but the hydrophobicity was decreased after heated at 80 °C for 192 h.The electrochemical durability was investigated in 10 μmol dm⁻³ of hydrochloric acid solution under nitrogen or oxygen atmosphere by means of potential holding test from 0.8 to 1.5 V against RHE (reversible hydrogen electrode) at 80 °C. During the potential holding tests, CO₂ production due to the corrosion was quantified by a GC (gas-chromatography) and the production was detectable above 1.3 V irrespective with atmosphere; on the other hand, it was clarified from the contact angle measurements that the hydrophobicity was changed below 1.3 V. The results of this study showed that the carbonaceous composite plates were electrochemically degraded under PEMFC condition and were seriously degraded in URFC (unitized regenerative fuel cell) condition.     

Numerical investigation of the performance of symmetric flow distributors as flow channels for PEM fuel cells

This work reports on the performance of a single PEM fuel cell using symmetric flow patterns as gas delivery channels. Three flow patterns, two symmetric and one serpentine, are taken from the literature on cooling of electronics and they are implemented in a computational model as gas flow channels in the anode and cathode side of a PEMFC. A commercial CFD code was used to solve the physics involved in a fuel cell namely: the flow field, the mass conservation, the energy conservation, the species transport, and the electric/ionic fields under the assumptions of steady state and single phase. An important feature of the current modeling efforts is the analysis of the main irreversibilities at different current densities showing the main energy dissipation phenomena in each cell design. Also, the hydraulic performance of the flow patterns was studied by evaluating the pressure drop and pumping power. The first part of this work reveals the advantages of using a serpentine pattern over the base symmetric distributors. The second part is an optimization of the symmetric patterns using the entropy minimization criteria. Such an optimization led to the creation of a flow structure that promotes an improved performance from the point of view of power generation, uniformity of current density, and low pumping power.     

Flow distribution in parallel-channel plate for proton exchange membrane fuel cells

Parallel channel flow field with manifold openings is widely used in Proton exchange membrane fuel cells (PEMFCs) because of its low-pressure drop and easiness of manufacture. This research presents a hydrodynamic model to describe the airflow distribution, and the predicted pressure differences are validated by experiments. We also investigate the influences of the flow rate, the geometry of header and the length ratio of manifold opening to header region on the airflow distribution. Therefore, the optimal strategy is proposed based on an overall consideration of uniformity and configuration in the fuel-cell plate for application.     

Formability improvement in multi-stage stamping of ultra-thin metallic bipolar plate for proton exchange membrane fuel cell

Multi-stage stamping process is the promising technology to fabricate the metallic bipolar plate (BPP) for proton exchange membrane (PEM) fuel cell. In the present study, a novel die design in the pre-forming stage is proposed and its effect on the formability of ultra-thin metallic BPP is verified by the finite element (FE) simulations of micro- and macro-scale BPP channels. It reveals that the multi-stage forming with the proposed die approach significantly improve the formability of ultra-thin BPP. As a result, the more uniform thickness distribution and considerable reduction of springback are beneficial to the fabrication of high quality metallic BPP. Furthermore, the relatively high reaction efficiency (～79.4%) of fuel cell stacks can be predicted, indicating the high fuel consumption. These findings demonstrate the feasibility and efficiency of the proposed die design in the fabrication of ultra-thin metallic BPP based on the perspectives of both the formability and energy efficiency.     

Design of experiment study of the parameters that affect performance of three flow plate configurations of a proton exchange membrane fuel cell

Low temperature hydrogen fuel cells are electrochemical devices which offer a promising alternative to traditional power sources. Fuel cells produce electricity with a reaction of the fuel (hydrogen) and air. Fuel cells have the advantage of being clean; only producing water and heat as by products. The efficiency of a fuel cell varies depending on the type; SOFC with CHP for example, can have a system efficiency of up to 65%.     

Measurements of serpentine channel flow characteristics for a proton exchange membrane fuel cell

Flow characteristics at Re = 660–3000 in a serpentine channel are measured. A scale-up model whose channel hydraulic diameter is 50 times as large as that for a proton exchange membrane fuel cell (PEMFC) is used for the measurements. The flow conditions correspond to operating conditions for PEMFCs of 25–40 cm² at current density of 1–3 A/cm² when the fuel utilisation ratio is 0.75 and air is used for the O₂ supply. Two different porous media are used to simulate the gas diffusion layer (GDL). The results suggest that although the leakage flow rate is rather insensitive to the total flow rate, it increases significantly depending on the increase of the GDL permeability. Increasing the flow rate or the permeability enhances the sectional secondary flows and is expected to enhance mass transfer on the GDL. It is confirmed that the flow becomes turbulent around the bend even at Re = 660.     

Anticorrosion properties of Ta-coated 316L stainless steel as bipolar plate material in proton exchange membrane fuel cells

In order to reduce the cost, volume and weight of the bipolar plates used in the proton exchange membrane fuel cells (PEMFC), more attention is being paid to metallic materials, among which 316L stainless steel (SS316L) is quite attractive. In this study, metallic Ta is deposited on SS316L using physical vapor deposition (PVD) to enhance the corrosion resistance of the bipolar plates. Simulative working environment of PEMFC is applied for testing the corrosion property of uncoated and Ta-coated SS316L. X-ray diffraction (XRD), scanning electron microscopy (SEM) and electrochemical methods (potentiodynamic and potentiostatic polarization) are also used for analyzing characteristics of uncoated and Ta-coated SS316L. Results show that, Ta-coated SS316L has significantly better anticorrosion property than that of uncoated SS316L, with corrosion current densities of uncoated SS316L being 44.61 μA cm⁻² versus 9.25 μA cm⁻² for Ta-coated SS316L, a decrease of about 5 times. Moreover, corrosion current densities of Ta-coated SS316L in both simulative anode (purged with H₂) and cathode (purged with air) conditions are smaller than those of uncoated SS316L.