Experimental investigation of the effect of channel length on performance and water accumulation in a PEMFC parallel flow field

Longer channels within serpentine flow fields are highly effective at removing liquid water slugs and have little water accumulation; however, the long flow path causes a large pressure drop across the cell. This results in both a significant concentration gradient between the inlet and outlet, and high pumping losses. Parallel flow fields have a shorter flow path and smaller pressure drop between the inlet and outlet. This low pressure drop and multiple routes for reactants in parallel channels allows for significant formation of liquid water slugs and water accumulation. To investigate these differences, a polymer electrolyte membrane fuel cell parallel flow field with the ability to modify the length of the channels was designed, fabricated, and tested. Polarization curves and the performance, water accumulation, and pressure drop were measured during 15 min of 0.5 A cm⁻² steady-state operation. An analysis of variance was performed to determine if the channel length had a significant effect on performance. It was found that the longer 25 cm channels had significantly higher and more stable performance than the shorter 5 cm channels with an 18% and an 87% higher maximum power density and maximum current density, respectively. Channel lengths which result in a pressure drop, across the flow field, slightly larger than that required to expel liquid water slugs were found to have minimal water accumulation and high performance, while requiring minimal parasitic pumping power.     

Effect of inserting obstacles in flow field on a membrane humidifier performance for PEMFC application: A CFD model

In this study, the numerical models are developed to investigate the influence of obstacle shape and number on performance of a planar porous membrane humidifier for proton exchange membrane fuel cell (PEMFC) application. Dew point of dry side outlet and water transfer rate are applied as evaluation parameters of the performance regardless of pressure drop. A dimensionless number named performance evaluation criteria (PEC) is calculated for all models. The higher value of PEC indicates the higher heat transfer rate with lower pressure drop. In humidifier with one rectangular obstacle compared with the simple humidifier, water transfer rate increases by 7.28%. The highest values of water transfer rate, dew point and PEC, also the greatest values of pressure drop are in humidifiers with rectangular, triangular and circular obstacles, in that order. When there is restriction in securing pumping power in fuel cell system, circular obstacle is the best choice. With considering the pressure drop, using one obstacle does not offer any advantage because the PEC is less than one (0.898). At least two obstacles are needed to have PEC number greater than one, consequently an efficient performance. An increment in number of obstacles causes an increment in water transfer rate, dew point and PEC.     

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.     

Liquid water transport in parallel serpentine channels with manifolds on cathode side of a PEM fuel cell stack

Water management in a proton exchange membrane (PEM) fuel cell stack has been a challenging issue on the road to commercialization. This paper presents a numerical investigation of air–water flow in parallel serpentine channels on cathode side of a PEM fuel cell stack by use of the commercial Computational Fluid Dynamics (CFD) software package FLUENT. Different air–water flow behaviours inside the serpentine flow channels with inlet and outlet manifolds were discussed. The results showed that there were significant variations of water distribution and pressure drop in different cells at different times. The “collecting-and-separating effect” due to the serpentine shape of the gas flow channels, the pressure drop change due to the water distribution inside the inlet and outlet manifolds were observed. Several gas flow problems of this type of parallel serpentine channels were identified and useful suggestions were given through investigating the flow patterns inside the channels and manifolds.     

Detailed analysis of polymer electrolyte membrane fuel cell with enhanced cross‐flow split serpentine flow field design

Most generally used flow channel designs in polymer electrolyte membrane fuel cells (PEMFCs) are serpentine flow designs as single channels or as multiple channels due to their advantages over parallel flow field designs. But these flow fields have inherent problems of high pressure drop, improper reactant distribution, and poor water management, especially near the U‐bends. The problem of inadequate water evacuation and improper reactant distribution become more severe and these designs become worse at higher current loads (low voltages). In the current work, a detailed performance study of enhanced cross‐flow split serpentine flow field (ECSSFF) design for PEMFC has been conducted using a three‐dimensional (3‐D) multiphase computational fluid dynamic (CFD) model. ECSSFF design is used for cathode part of the cell and parallel flow field on anode part of the cell. The performance of PEMFC with ECSSFF has been compared with the performance of triple serpentine flow design on cathode side by keeping all other parameters and anode side flow field design similar. The performance is evaluated in terms of their polarization curves. A parametric study is carried out by varying operating conditions, viz, cell temperature and inlet humidity on air and fuel side. The ECSSFF has shown superior performance over the triple serpentine design under all these conditions.     

Experimental investigations on liquid water removal from the gas diffusion layer by reactant flow in a PEM fuel cell

The cross flow from channel to channel through gas diffusion layer (GDL) under the land could play an important role for water removal in proton exchange membrane (PEM) fuel cells. In this study, characteristics of liquid water removal from GDL have been investigated experimentally, through measuring unsteady pressure drop in a cell which has the GDL initially wet with liquid water. The thickness of GDL is carefully controlled by inserting various thicknesses of metal shims between the plates. It has been found that severe compression of GDL could result in excessive pressure drop from channel inlet to channel outlet. Removing liquid water from GDL by cross flow is difficult for GDL with high compression levels and for low inlet air flow rates. However, effective water removal can still be achieved at high compression levels of GDL if the inlet air flow rate is high. Based on different compressed GDL thicknesses, different GDL porosities and permeabilities were calculated and their effects on the characteristics of liquid water removal from GDL were evaluated. Visualization of liquid water transport has been conducted by using transparent flow channel, and liquid water removal from GDL under the land was observed for all the tested inlet air flow rates, which confirms that cross flow is practically effective to remove the liquid water accumulated in GDL under the land area.     

Numerical simulation of effect of catalyst wire-mesh pressure drop characteristics on flow distribution in catalytic parallel plate steam reformer

Steam reforming of hydrocarbons using a catalytic plate-type-heat-exchanger (CPHE) reformer is an attractive method of producing hydrogen for a fuel cell-based micro combined-heat-and-power system. In this study the flow distribution in a CPHE reformer, which uses a coated wire-mesh catalyst, is considered to investigate the effect of catalyst wire-mesh pressure drop characteristics on flow distribution in the CPHE reformer. Flow distribution in a CPHE reformer is rarely uniform due to inlet and exhaust manifold design. Poorly-designed manifolds may lead to severe flow maldistribution, flow reversal in some of the CPHE reformer channels and increased overall pressure drop. Excessive flow maldistribution can significantly reduce the CPHE reformer performance. Detailed three-dimensional models are used to investigate the flow distribution at three different catalyst wire-mesh pressure drop coefficients and at five different flow rates. Experiments are performed on a single CPHE reformer channel to evaluate the pressure drop characteristics of the catalyst wire-mesh in the current CPHE reformer design. The results are used in the numerical model where the catalyst zone is simulated as domains with momentum source to account for the pressure drop. The numerical model is verified experimentally, numerical and experimental results are found to be in good agreement. The study shows that severe flow maldistribution exists in the current reformer stack. At nominal load some channels in the CPHE reformer receive up to four times the average mass flow, while other channels have reversed flow. Flow maldistribution and flow reversal can be improved significantly by increasing the pressure drop characteristics of the catalyst wire-mesh.     

Numerical investigation of the impact of two-phase flow maldistribution on PEM fuel cell performance

Flow maldistribution usually happens in PEM fuel cells when using common inlet and exit headers to supply reactant gases to multiple channels. As a result, some channels are flooded with more water and have less air flow while other channels are filled with less water but have excessive air flow. To investigate the impact of two-phase flow maldistribution on PEM fuel cell performance, a Volume of Fluid (VOF) model coupled with a 1D MEA model was employed to simulate two parallel channels. The slug flow pattern is mainly observed in the flow channels under different flow maldistribution conditions, and it significantly increases the gas diffusion layer (GDL) surface water coverage over the whole range of simulated current densities, which directly leads to poor fuel cell performance. Therefore, it is recommended that liquid and gas flow maldistribution in parallel channels should be avoided if possible over the whole range of operation. Increasing the gas stoichiometric flow ratio is not an effective method to mitigate the gas flow maldistribution, but adding a gas inlet resistance to the flow channel is effective in mitigating maldistribution. With a carefully selected value of the flow resistance coefficient, both the fuel cell performance and the gas flow distribution can be significantly improved without causing too much extra pressure drop.     

Experimental validation of two-phase pressure drop multiplier as a diagnostic tool for characterizing PEM fuel cell performance

Water management is a key area of interest in improving the performance of Proton Exchange Membrane fuel cells. Cell flooding and membrane dehydration are two extreme conditions arising from poor water management. Pressure drop has been recognized as a good diagnostic tool to determine the presence of liquid water in the reactant channels. Presence of liquid water in the channels increases the mass transport resistances and therefore reduces the cell performance, which is quantified by the cell voltage at a set current density. Since the two-phase pressure drop multiplier is uniquely related to the water content in the channel, it serves as a good diagnostic tool for directly predicting the cell performance. Experiments are carried out to establish the relationship between the pressure drop multiplier and cell voltage at different operating conditions. Cell temperature was varied from 30 °C to 80 °C and the inlet RH was varied from 0 to 95%. At the lower temperatures, a two-phase multiplier below 1.5 reduces flooding in the flow field. However, at the higher temperatures, a two-phase flow multiplier above 1.2 is preferred as it indicates the membrane remains hydrated for improved performance from the cell. The two-phase pressure drop multiplier has been successfully demonstrated as a diagnostic tool to predict cell flooding and membrane dehydration.     

Experimental Investigation of Heat Transfer and Resistance Characteristics of a Finned Oval-Tube Heat Exchanger With Different Air Inlet Angles

The air inlet flow direction is not orthogonal to the heat exchanger surface in many cases. To study the performance of the heat transfer and pressure drop of a heat exchanger with different air inlet angles, this paper shows the experimental system about a finned oval-tube heat exchanger inclined toward the air incoming flow direction. The heat transfer and pressure drop characteristics of four air inlet angles (90°, 60°, 45°, and 30°) are studied separately for the Reynolds number ranging from 1300 to 13000 in this study. The experimental correlations of Nusselt number and resistance coefficient of the air side are acquired. The results show that the overall heat transfer coefficients become smaller and smaller with the decrease of the air inlet angles, while the pressure drops have significant changes. The heat transfer performances of the heat exchanger under the three inclined air inlet angles are worse than that at 90°. Among the three inclined angles, the performance at 45° is the best under identical mass flow rate criterion and at low Reynolds number under identical pressure drop criterion; that at 60° is the best at large Reynolds under identical pressure drop criterion. Finally, some conclusions are attained about the effects of the air inlet angles on the heat transfer and pressure drop performance of the finned oval-tube heat exchanger.     

Application of artificial neural network method for performance prediction of a gas cooler in a CO2 heat pump

The objective of this work is to train an artificial neural network (ANN) to predict the performance of gas cooler in carbon dioxide transcritical air-conditioning system. The designed ANN was trained by performance test data under varying conditions. The deviations between the ANN predicted and measured data are basically less than ±5%. The well-trained ANN is then used to predict the effects of the five input parameters individually. The predicted results show that for the heat transfer and CO₂ pressure drop the most effective factor is the inlet air velocity, then come the inlet CO₂ pressure and temperature. The inlet mass flow rate can enhance heat transfer with a much larger CO₂ pressure drop penalty. The most unfavorable factor is the increase in the inlet air temperature, leading to the deterioration of heat transfer and severely increase in CO₂ pressure drop.     

Thermodynamic optimization for an open cycle of an externally fired micro gas turbine (EFmGT). Part 1: Thermodynamic modelling

The principle of optimally tuning the air flow rate and subsequent distribution of pressure drops is applied to optimize the performance of a thermodynamic model for an open regenerative cycle of an externally fired micro gas turbine power plant with pressure drop irreversibilities by using finite-time thermodynamics and considering the size constraints of the real plant. There are eight flow resistances encountered by the working fluid stream for the cycle model. Two of these, the friction through the blades and vanes of the compressor and the turbine, are related to the isentropic efficiencies. The remaining flow resistances are always present because of the changes in flow cross-section at the compressor inlet and outlet, the turbine inlet and outlet and the regenerator hot/cold-side inlet and outlet. These resistances associated with the flow through various cross-sectional areas are derived as functions of the compressor inlet relative pressure drop, and control the air flow rate and the net power output and thermal efficiency. The analytical formulae for the power output, efficiency and other coefficients are derived, which indicate that the thermodynamic performance for an open regenerative cycle of an externally fired micro gas turbine power plant can be optimized by adjusting the mass flow rate (or the distribution of pressure losses along the flow path). It is shown that there are optimal air mass flow rates (or the distribution of pressure losses along the flow path) which maximize the net power output.     

折弯弓形折流板换热器流动换热性能研究

为了提高折流板换热器的换热性能,改变了折流板换热器的折弯夹角和折流板间距,利用ANSYS Fluent对换热器壳程流体流动与换热过程进行模拟,分析了不同折流板折弯夹角α (110°,135°,170°和180°)、折流板间距（250,300和350 mm)和雷诺数（10 000,20 000和50 000）对换热器壳程压力、速度和温度的影响。结果表明：增大雷诺数对改善流动死区有很大的作用,雷诺数为50 000时的流动死区相对于雷诺数为10 000时面积减小较大;随着夹角α的减小,折流板背流侧的流动死区面积逐渐减小、换热器的表面传热系数和进出口压降力越大,夹角α为110°时出口温度最小、进出口压降最大,夹角α为135°时PEC最大且换热器综合性能最优;折流板间距增大,压力变化梯度减小,压差变化幅度减小,壳程出口温度变化不成正比关系,间距为300 mm时出口温度最低。     

Mechanism and influence factor analysis of heat transfer deterioration of transcritical methane

A three-dimensional simulation, of transcritical flow, and heat transfer of methane, under asymmetric heating conditions, were performed. The simulation results demonstrated that the drastic changes in density at the pseudo critical temperature lead to an M-type velocity distribution, which plays a dominant role in the deterioration of heat transfer. The specific heat affects the location of the deterioration, while the thermal conductivity and viscosity affect only the wall temperature magnitude, whereas they do not affect the occurrence and location of heat transfer deterioration. The M-type velocity gradually disappears with the inlet mass flow rate increasing, indicating that heat transfer deterioration was eliminated. In addition, there is a critical inlet pressure of 10 MPa. When the inlet pressure is less than critical inlet pressure, heat transfer is improved with the inlet pressure's increase. However, when the inlet pressure is higher than critical inlet pressure, with inlet pressure increasing further, the decrease in the peak specific heat value will weaken the heat absorption capacity of methane, making the deterioration more severe. The deterioration of heat transfer will be improved by increasing the wall roughness, while the pressure drop will also be increased. The optimal wall roughness of 7 μm can be selected by using the thermal performance factor.     

Two-phase flow and maldistribution in gas channels of a polymer electrolyte fuel cell

Liquid water transport in a polymer electrolyte fuel cell (PEFC) is a major issue for automotive applications. Mist flow with tiny droplets suspended in gas has been commonly assumed for channel flow while two-phase flow has been modeled in other cell components. However, experimental studies have found that two-phase flow in the channels has a profound effect on PEFC performance, stability and durability. Therefore, a complete two-phase flow model is developed in this work for PEFC including two-phase flow in both anode and cathode channels. The model is validated against experimental data of the wetted area ratio and pressure drop in the cathode side. Due to the intrusion of soft gas diffusion layer (GDL) material in the channels, flow resistance is higher in some channels than in others. The resulting flow maldistribution among PEFC channels is of great concern because non-uniform distributions of fuel and oxidizer result in non-uniform reaction rates and thus adversely affect PEFC performance and durability. The two-phase flow maldistribution among the parallel channels in an operating PEFC is explored in detail.     

Void Fraction Variations in a Fractal-Like Branching Microchannel Network

Based on predictions of lower pressure drop penalties in fractal-like branching channels compared to parallel channels, an experimental investigation of two-phase void fraction variations was performed. The flow network, mimicking flow networks found in nature, was designed with a self-similar bifurcating channel configuration and etched 150 μ m into a 38.1 mm diameter silicon disk. A Pyrex® cover was anodically bonded to the silicon disk to allow for flow visualization. The length and width scale ratios between channels on either side of a bifurcation are fixed. The channel widths range in size from 100 μ m to 400 μm over a total channel length of approximately 17 mm. Experimental results of flow boiling are presented for a heater energy input power of 66 W and an inlet water flow rate of 45 g/min at a fixed inlet fluid temperature of 88°C. High-speed, high-resolution imaging was used to visualize the flow and quantify void fraction values in several channels within a branching structure. Both time-averaged and instantaneous two-dimensional void fraction data are presented, showing a correlation between channels at the same bifurcation level and between channels at different bifurcation levels.     

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.     

Dry gas operation of proton exchange membrane fuel cells with parallel channels: Non-porous versus porous plates

We present a study of proton exchange membrane (PEM) fuel cells with parallel channel flow fields for the cathode, dry inlet gases, and ambient pressure at the outlets. The study compares the performance of two designs: a standard, non-porous graphite cathode plate design and a porous hydrophilic carbon plate version. The experimental study of the non-porous plate is a control case and highlights the significant challenges of operation with dry gases and non-porous, parallel channel cathodes. These challenges include significant transients in power density and severe performance loss due to flooding and electrolyte dry-out. Our experimental study shows that the porous plate yields significant improvements in performance and robustness of operation. We hypothesize that the porous plate distributes water throughout the cell area by capillary action; including pumping water upstream to normally dry inlet regions. The porous plate reduces membrane resistance and air pressure drop. Further, IR-free polarization curves confirm operation free of flooding. With an air stoichiometric ratio of 1.3, we obtain a maximum power density of 0.40 W cm⁻², which is 3.5 times greater than that achieved with the non-porous plate at the same operating condition.     

Numerical simulation of the power-based efficiency in vanadium redox flow battery with different serpentine channel size

We present numerical investigations on the power-based efficiency of vanadium redox flow battery (VRFB). A three-dimensional numerical model is developed to capture the complexities of electrochemical reactions and fluid dynamics when considering different serpentine channel sizes and electrolyte flow rates. It is shown that the reduced channel size and increased electrolyte flow rate improve the electrochemical performance of the VRFB due to the enhanced distribution of molar centration at the electrodes. Nonetheless, the channel size reduction and increased electrolyte flow rate also increases pressure drop between inlet and outlet of the serpentine channels for negative and positive sides. In this, we calculate the power-based efficiency by considering the generated power of VRFB and power loss due to overpotentials, ohmic loss, and required pump power. The maximum power-based efficiency of 96.6% is calculated with the channel size of 1.9 mm at 60 mL min⁻¹, while it is 95.5% with 9.6 mm in channel size at 100 mL min⁻¹. The proposed numerical approach can be useful to determine the channel size with optimized electrolyte flow rate and maximum VRFB efficiency.     

Anode analysis and modelling hydrodynamic behaviour of the multiphase flow field in circular PEM water electrolyzer

A numerical study of the behaviour of the multiphase flow of an anode-porous transport layer of an aqueous electrolyzer with a proton-exchange membrane (PEM) of an aqueous electrolyzer is presented. A mixture model was used to study the flow behaviour in a circular-shaped anode box to determine the efficient design of a PEM water electrolyzer. As a result of the simulation, it was found that the model pressure drop profiles obtained by computational fluid dynamics (CFD) are in good agreement with the corresponding experimental data. In addition, the performance profile was predicted considering various PEM water electrolyzer cell improvement factors compared to the Bassline model. The results of the behaviour of two-phase flows with different velocity, pressure and volume fraction profiles, as well as with porous regions in the centre, are presented, which showed a key difference in the flow profile for various inlet and outlet flow configurations. In addition, the flow volume fraction behaviour was obtained at higher and lower water and oxygen rates. Three-dimensional (3D) modelling predicted flow characteristics for three different cell configurations. In this article, we also run simulations over a wide range of flow rates. The main results of the numerical study were discussed to shed light on the design of a high-performance PEM water electrolyzer.