Experimental investigation on the heat and water transfer enhancement in a membrane-based air-to-air humidifier at insulation condition

In the present study, a membrane-based air-to-air planar humidifier (MAPH) with baffle-blocked flow channels and a common MAPH are fabricated, tested and compared. These MAPHs are well thermal insulated from their surroundings. Polyoxymethylene (POM) plates with some unique properties such as large tensile and flexural strength, high chemical resistance and high stiffness are used to create channels at dry and humid sides of MAPHs. The obtained findings revealed that the higher heat and water transfer rates and smaller dew point approach temperature (DPAT) in entire tested flow rates occurs in baffle-blocked MAPH. To evaluate the MAPH performance with considering the pressure drop, a dimensionless parameter, performance evaluation criteria (PEC), is introduced. At flow rates less than 1 m³/h, PEC is less than 1, indicating a decline in MAPH performance with considering the pressure drop. In baffle-blocked MAPH using water trap in the inlet of dry side leads to the performance deterioration. Additionally, the increased relative humidity (RH) of humid side inlet causes an increase in DPAT, consequently, the performance deterioration.     

Modeling and experimental validation of H2 gas bubble humidifier for a 50 kW stationary PEMFC system

Ensuring uniform membrane hydration in a PEMFC (Proton Exchange Membrane Fuel Cell) is important for its performance and durability. In this study, a bubble humidifier for humidifying hydrogen in a 50 kW PEMFC pilot plant was designed, built, and modeled. Initial tests, carried out by humidifying air, show that a dew point temperature of higher than 59 °C is attained when operating the PEMFC plant at nominal power at 65 °C. The model simulation results show good agreement with experimental data and the model is used for studying humidifier performance at other conditions. Steady state simulation results suggest that by increasing the heating water flow rate, the humidifier outlet dew point temperature can be increased by several degrees because of improved heat transfer. Finally, dynamic simulation results suggest that the humidity of the hydrogen can be controlled by manipulating the heat supply to the humidifier.     

Two dimensional dynamic modeling of a shell-and-tube water-to-gas membrane humidifier for proton exchange membrane fuel cell

Water management is a crucial factor in determining the performance of proton exchange membrane fuel cell (PEMFC) for automotive application. The shell-and-tube water-to-gas membrane humidifier is useful for humidifying the PEMFC due to its good performance. Shell-and-tube water-to-gas membrane humidifiers have liquid water on one side of the tube wall and a dry gas on the other. In order to investigate humidifier performance, a two-dimensional dynamic model of a shell-and-tube water-to-gas membrane humidifier is developed. The model is discretized into three control volumes – shell, tube and membrane – in the cross-sectional direction to resolve the temperature and species concentration of the humidifier. For validation, the dew point temperature of the simulation result is compared with that of experimental data and shows good agreement with only a slight difference. The distribution of humidification characteristics can be captured using the discretization along the air-flow direction. The humidification performance of two different flow configurations, counter and parallel, are compared under various operating conditions and geometric parameters. Finally, the dynamic response of the humidifier at the step-change of various air flow rates is investigated. These results suggest that the model can be used to optimize the inlet flow humidity of a PEMFC.     

Design of an air humidifier for a 5 kW proton exchange membrane fuel cell stack operated at elevated temperatures

Air humidification is a crucial issue for superior performance of proton exchange membrane fuel cell (PEM fuel cell) stacks. In this work, an air humidifier is proposed for a 5 kW PEM fuel cell stack working at elevated temperatures, e.g., 90–95 °C. The high temperature coolant exiting the stack is utilized to pre-heat the air in the heat exchanging tubes of the humidifier, and the heated air is humidified with deionized water supplied by a nozzle fixed in a top cavity. Both the tubes and the nozzle are properly designed to ensure sufficient heat transfer and superior atomization. Humidification performance is evaluated under different operation conditions. The nozzle is able to inject well-atomized water with uniform droplet diameter. With the variation of inlet air flow rate, the relative humidity (RH) of the outlet air increases at the beginning, then decreases gradually due to the attenuation of dew point (DP) temperature. However, the humidification performance can be improved when higher temperature deionized water is injected or high temperature coolant is supplied. At a coolant temperature of 95 °C, the outlet air DP temperature is maintained over 80 °C with 25 °C injection water. Moreover, better humidification performance is achieved when the injection water flow rate is controlled according to the working conditions of the stack.     

Experimental study of gas humidification with injectors for automotive PEM fuel cell systems

A scaled gas humidification system using injectors for PEM fuel cell vehicles was developed and the humidification performance was evaluated under various operating conditions. The humidification system consists of an injector, a duplex enthalpy mixer and a water management apparatus. A dew point meter of the chilled mirror type was used to measure the humidity of the air and the hydrogen. Humidification performance was evaluated by measuring the dew point temperature of the humidified gases. Humidification performance was observed to be critically affected by the temperature of injected water and the gas flow rate in this study. The dew point of the humidified gas rose when the temperature of injected water increased, however, it dropped when the gas flow rate was increased. Experimental results show that the outlet temperature was 58.4 °C, dew point temperature of the humidified air reached 54.0 °C when the injection water temperature was 69.5 °C with the room temperature air flow rate of 200 L min⁻¹. Inlet gas temperature also affected the humidification performance and response time. In addition, a 50 cm² PEM fuel cell was tested to verify the effectiveness of the devised humidifier. When operated at 65 °C, the fuel cell showed an operating voltage of 0.5 V at a current density of 600 mA cm⁻².     

An experimental study and model validation of a membrane humidifier for PEM fuel cell humidification control

This paper presents an experimental study and model validation of an external membrane humidifier for PEM fuel cell humidification control. Membrane humidification behavior was investigated with steady-state and dynamic tests. Steady-state test results show that the membrane vapor transfer rate increases significantly with water channel temperature, air channel temperature, and air flow rate. Water channel pressure has little effect on the vapor transfer rate and thus can be neglected in the system modeling. Dynamic test results reveal that the membrane humidifier has a non-minimum phase (NMP) behavior, which presents extra challenges for control system design. Based on the test data, a new water vapor transfer coefficient for Nafion membrane was obtained. This coefficient increases exponentially with the membrane temperature. The test results were also used to validate a thermodynamic model for membrane humidification. It is shown that the model prediction agrees well with the experimental results. The validated model provides an important tool for external humidifier design and fuel cell humidification control.     

Analysis of the water and thermal management in proton exchange membrane fuel cell systems

Water and thermal management is essential to the performance of proton exchange membrane (PEM) fuel cell system. The key components in water and thermal management system, namely the fuel cell stack, radiator, condenser and membrane humidifier are all modeled analytically in this paper. Combined with a steady-state, one-dimensional, isothermal fuel cell model, a simple channel-groove pressure drop model is included in the stack analysis. Two compact heat exchangers, radiator and condenser are sized and rated to maintain the heat and material balance. The influence of non-condensable gas is also considered in the calculation of the condenser. Based on the proposed methodology, the effects of two important operating parameters, namely the air stoichiometric ratio and the cathode outlet pressure, and three kinds of anode humidification, namely recycling humidification, membrane humidification and recycling combining membrane humidification are analyzed. The methodology in this article is helpful to the design of water and thermal management system in fuel cell systems.     

Three-dimensional CFD modeling of a planar membrane humidifier for PEM fuel cell systems

A three-dimensional numerical model is developed to investigate and compare the performance of humidifiers with counter-flow and parallel-flow configurations. This model has a set of coupled equations including conservations of mass, momentum, species and energy. The results indicate that in counter-flow humidifier, water and heat transfer is more than that of the parallel-flow that leads to a higher dew point at dry side outlet, consequently, a better humidifier performance. An increase in temperature and a decrease in mass flow rate at dry side inlet lead to a better humidifier performance. However at the low flow rates the humidifier performance does not change a lot by preheating the inlet dry gas. An increase in relative humidity at dry side inlet does not offer any advantage.     

Comprehensive investigation of membrane sorption and CFD modeling of a tube membrane humidifier with experimental validation

The humidification of PEM fuel cells is critical for their performance and efficiency and for ensuring a long durability. In most PEM fuel cell systems for mobile applications membrane humidifiers are used to humidify the fresh air. In this process, the water contained in the cathode exhaust gas is used to increase the humidity of the supply air. Despite the simple design of membrane humidifiers, the simulation of the water transfer is difficult and so far there exist hardly any precise models to calculate the absorption and desorption processes. Common approaches that use the Sherwood number to determine the sorption rates cannot account for the influence of the local water content of the membrane. This ultimately leads to an inaccurate simulation of humidifier behavior, as these models cannot consider the fact that desorption is nearly ten times faster than absorption.In this study, an empirical formula for an accurate determination of the sorption rate is derived based on experimental data. This function accounts for the different absorption and desorption rates by finding a sorption rate coefficient as a function of the local membrane water content, temperature, pressure and flow velocity.Furthermore, a CFD model is derived from the geometry of a commercially available membrane humidifier, which is also investigated on a test bench. Using the experimental data, the CFD model is validated and it is shown that the developed sorption rate formula leads to good agreements between simulations and experiments at steady-state operating points of the humidifier.     

燃料电池空气系统增湿器建模与仿真

建立气-气增湿器的数学理论模型,并基于Amesim软件建立燃料电池增湿器及空气系统仿真模型,从燃料电池系统层面分析干湿侧不同温度、压力、水含量等输入条件下的干侧出口空气的湿度变化情况,并采用水转移率（water vapor transfer rate,WVTR）对增湿器增湿性能进行评价,结果表明此模型可进行前期验证,能较好地预测汽车运行过程中增湿器的动态响应特性。     

Analysis of turbulent flow and heat transfer over a double forward facing step with obstacles

A numerical study has been conducted to analyze the turbulent forced convection heat transfer for double forward facing step flow with obstacles. Obstacles have rectangular cross-sectional area with different aspect ratio that is located before each step. The numerical solutions of continuity, momentum and energy equations were solved by using a commercial code which uses finite volume techniques. The effect of turbulence was modeled by using a k–ε model. The effects of step height, obstacle aspect ratio and Reynolds number on the flow and heat transfer are investigated. The obtained results show that the rate of heat transfer is enhanced as aspect ratio of obstacle increases and this trend is affected by the step height. Also the results verified that the pressure drop decreases as obstacle aspect ratio increases.     

Water and pressure effects on a single PEM fuel cell

A fuel cell is a promising energy conversion system that will eventually become the first-choice for producing power because of its clean or zero-emission nature. A steady-state, two-dimensional mathematical model with pressure and phase change effects for a single PEM fuel cell was developed to illustrate the inlet humidification and pressure effects on proton exchange membrane (PEM) fuel cell performance. This model considers the transport of species along the channel as well as water transfer through the membrane. It can be used to predict trends of the following parameters along the fuel cell channels: mole number of liquid water and water vapor, pressure, temperature, density, viscosity, velocity, saturation pressure, pressure drop, vapor mole fraction, volume flow rate, required pumping power and current density.     

Experimental verification of a membrane humidifier model based on the effectiveness method

Experiments conducted on a commercial fuel cell humidifier determined that the water recovery ratio is the best performance metric because it considers the water supplied to the humidifier. Data from a porous polymer membrane with a hydrophilic additive were analyzed under a heat and mass transfer model. The membrane showed low water uptake profiles at relative humidities below 80 percent, and a steep increase in water uptake above threshold.The experiments were conducted with samples of the porous membrane in a single cell humidifier at isothermal conditions at temperatures of 25, 50, and 75 °C. The water recovery ratio for the porous membrane decreased with increasing flow rate.The model was verified experimentally and its predictions agreed with the measured data.     

Heat transfer enhancement in micro-channels caused by vortex promoters

This paper presents a systematic numerical study of the effects of heat transfer and pressure drop produced by vortex promoters of various shapes in a 2D, laminar flow in a micro-channel. The liquid is assumed to be water, with temperature dependent viscosity and thermal conductivity. It is intended to obtain useful design criteria of micro-cooling systems, taking into account that practical solutions should be both thermally efficient and not expensive in terms of the pumping power. Three reference cross sections, namely circular/elliptical, rectangular, and triangular, at various aspect ratios are considered. The effect of the blockage ratio, the Reynolds number, and the relative position and orientation of the obstacle are also studied. Some design guidelines based on two figures of merit (related to thermal efficiency and pressure drop, respectively), which could be used in an engineering environment are provided.     

Effect of operating parameters on dynamic response of water-to-gas membrane humidifier for proton exchange membrane fuel cell vehicle

An analytic multi-dimensional dynamic model of a membrane type humidifier has been developed for the study of transient responses of the humidifier under proton exchange membrane fuel cell vehicle operating conditions. The dynamic responses of heat and mass transfer and fluid flow in a membrane humidifier are mathematically formulated and modeled with a newly developed pseudo-multi-dimensional concept. The model is used to analyze the performance of the humidifier under various operating conditions and the dynamic response of the humidifier under transient operating conditions. The simulation results show that, in the case of the water-to-gas type membrane humidifier modeled in this study, the time constant of water diffusion in the membrane is less than 1 s. Thus, the delay of the response of the humidifier induced by the vapor diffusion in the membrane is not significant in vehicle operation. However, it is also found that the dynamic behavior is mainly due to the thermal resistance and heat capacity of the membrane humidifier.     

Experimental study on performance of membrane humidifiers with different configurations and operating conditions for PEM fuel cells

In this study on humidifiers for polymer electrolyte membrane (PEM) fuel cell application, the experimental outcome of two air-to-air planar membrane humidifiers with three different internal flow patterns including cross, parallel and counter flows are investigated under isothermal and insulated boundary conditions. At all temperatures and flow rates, the conditions of higher performance, corresponding to highest water recovery ratio (WRR) and lowest dew point approach temperatures (DPAT), are encountered in the counter flow case, in contrary to the cross flow configuration. The insulation condition with dry inlet temperature at 30 °C and wet inlet temperature at 60 °C has a higher WRR index compared to isothermal condition at 60 °C but is lower than isothermal condition at 30 °C. The DPAT in humidifier with insulation condition is approximately equal to that obtained in isothermal condition at 60 °C but is much higher than what results in isothermal condition at 30 °C. It can be deduced that the temperature of the wet side inlet plays a key role in the humidifier performance.     

Three-dimensional thermal analysis of heat sinks with circular cooling micro-channels

The pressure drop and thermal characteristics of heat sinks with circular micro-channels are investigated using the continuum model consisting of the conventional Navier-Stokes equations and the energy conservation equation. Developing flow (both hydrodynamically and thermally) is assumed in the fluid region and three-dimensional conjugate heat transfer is assumed in the solid region. Thermal results based on this approach are shown to be in good agreement with existing experimental data. Effects of various geometrical parameters, material properties, and Reynolds number on the thermal performance of the sink were investigated. A comparison between circular and rectangular channels at the same Reynolds number and hydraulic diameter showed that sinks with rectangular channels have lower thermal resistance, while sinks with circular channels dissipate more heat per unit pumping power.     

膜加湿器热质交换过程的理论分析

膜加湿器是保证质子交换膜燃料电池(PEMFC)正常高效运行的重要组成部分.以燃料电池的板式膜加湿器为研究对象,根据热质交换原理对膜加湿器的传热传质过程进行了理论计算,分析了空气质量流量、膜内加湿侧进口温度和膜内加湿侧进口湿度对传热传质过程的影响.在传热方面:当空气质量流量不同时,随着膜内加湿侧进口温度的变化,膜内的热流量变化趋势不一致;当膜内加湿侧进口相对湿度为95%时,随着空气质量流量的变化,膜内热流量变化不大.在传质方面:当加湿侧进口相对湿度不变时,膜中水传输速率随着空气质量流量的增大而减小;当空气质量流量不变时,膜中水传输速率随着加湿侧进口相对湿度的增大而增大.     

Design methodology for membrane-based plate-and-frame fuel cell humidifiers

Currently, polymer electrolyte membrane fuel cells require some method of humidification to operate effectively. External gas-to-gas membrane-based humidifiers can provide an efficient method to recycle exhaust heat and product water from the fuel cell stack. This work describes a design methodology involving a series of design equations for plate-and-frame membrane humidifiers. Humidifiers of different flow channel geometries were created with a rapid prototyping technique. These humidifier units were tested at different operating conditions in an attempt to validate the design equations. The ratio between the residence time of gas in the humidifier over the diffusion time of water from the surface of the membrane into the channel can be used as a design parameter. This ratio was shown to offer a good starting point for humidifier design, and a target range between 2.0 and 4.0 was identified (with a nominal desired value of 3.0). A humidifier design procedure and suggestions are presented based on this parameter and the packaging requirements of the humidifier in a fuel cell system. This algorithm was validated by creating a further prototype humidifier.     

An experimental study on the bubble humidification method of polymer electrolyte membrane fuel cells

A necessary requirement for polymer electrolyte membrane fuel cell (PEMFC) performance is providing sufficient water content in the membrane. The bubble humidifier is the simplest and inexpensive method for PEMFC humidification. In this study, a prototype of bubble humidifier is designed, fabricated, and tested. The effects of water temperature in the reservoir, water level inside the reservoir and inlet air flow on the humidifier performance are investigated. The results show that the outlet air relative humidity decreases (about 6% - 11%) with an increase in the inlet air flow rate from 1 m³ h^?1 to 3 m³ h^?1 at four different water temperatures. The increase in the water temperature and water level inside the reservoir lead to the better humidifier performance. At the water temperature of 20^°C, increasing water level from 5 cm to 7.5 cm has a significant effect on humidifier performance but increasing water level from 7.5 cm to 15 cm does not offer any advantage.