Effects of serpentine flow field with outlet channel contraction on cell performance of proton exchange membrane fuel cells

A serpentine flow field with outlet channels having modified heights or lengths was designed to improve reactant utilization and liquid water removal in proton exchange membrane (PEM) fuel cells. A three-dimensional full-cell model was developed to analyze the effects of the contraction ratios of height and length on the cell performance. Liquid water formation, that influences the transport phenomena and cell performance, was included in the model. The predictions show that the reductions of the outlet channel flow areas increase the reactant velocities in these regions, which enhance reactant transport, reactant utilization and liquid water removal; therefore, the cell performance is improved compared with the conventional serpentine flow field. The predictions also show that the cell performance is improved by increments in the length of the reduced flow area, besides greater decrements in the outlet flow area. If the power losses due to pressure drops are not considered, the cell performance with the contracted outlet channel flow areas continues to improve as the outlet flow areas are reduced and the lengths of the reduced flow areas are increased. When the pressure losses are also taken into account, the optimal performance is obtained at a height contraction ratio of 0.4 and a length contraction ratio of 0.4 in the present design.     

Predicting current density distribution of proton exchange membrane fuel cells with different flow field designs

In a proton exchange membrane fuel cell (PEMFC), flow field design is an important factor that influences the distributions of current density and water accumulation. The segmented model developed in prior study is used to investigate the effect of flow field patterns on current density distribution. This model predicts the distributed characteristics of water content in the membrane, relative humidity in the flow channels, and water accumulation in the gas diffusion layers (GDLs).Three single cells with different flow field patterns are designed and fabricated. These three flow field designs are simulated using the segmented model and the predicted results are compared and validated by experimental data. This segmented model can be used to predict the effect of flow field patterns on water and current distributions before they are machined.     

Novel serpentine-baffle flow field design for proton exchange membrane fuel cells

An appropriate flow field in the bipolar plates of a fuel cell can effectively enhance the reactant transport rates and liquid water removal efficiency, improving cell performance. This paper proposes a novel serpentine-baffle flow field (SBFF) design to improve the cell performance compared to that for a conventional serpentine flow field (SFF). A three-dimensional model is used to analyze the reactant and product transport and the electrochemical reactions in the cell. The results show that at high operating voltages, the conventional design and the baffled design have the same performance, because the electrochemical rate is low and only a small amount of oxygen is consumed, so the oxygen transport rates for both designs are sufficient to maintain the reaction rates. However, at low operating voltages, the baffled design shows better performance than the conventional design. Analyses of the local transport phenomena in the cell indicate that the baffled design induces larger pressure differences between adjacent flow channels over the entire electrode surface than does the conventional design, enhancing under-rib convection through the electrode porous layer. The under-rib convection increases the mass transport rates of the reactants and products to and from the catalyst layer and reduces the amount of liquid water trapped in the porous electrode. The baffled design increases the limiting current density and improves the cell performance relative to conventional design.     

The conception of in-plate adverse-flow flow field for a proton exchange membrane fuel cell

To improve species concentration and current density distribution uniformity of a proton exchange membrane (PEM) fuel cell, an in-plate adverse-flow (IPAF) flow field is developed. Its utility is conceptually examined through three-dimensional numerical simulation comparison between three typical fuel and air flow combinations out of those it can support. Under isothermal condition and constant velocity reactant feeding mode, as the simulation results indicate, there is no significant cell performance improvement by the new flow filed unless in mass transport limited region, while the species concentration and current density distribution uniformities are substantially improved. As data analysis supports, there are two mechanisms in the new flow field that are responsible for the distribution uniformity improvement: the along-channel offset effect and the across-rib transport effect, and their respective pure contributions to the improvement are well discerned.     

Nature inspired flow field designs for proton exchange membrane fuel cell

Nature inspired flow field designs for proton exchange membrane fuel cells (PEMFCs) are a relatively recent development in the technology evolution. These novel designs have the potential to show dramatic performance improvements by effective distribution of reactant gases without water flooding. Optimization of a flow field requires balancing gas distribution, water management, electron transport, pressure drop and manufacturing simplicity. Computational fluid dynamics (CFD) simulation studies are a useful tool for evaluating nature inspired flow field designs; however, the predictions should be used with caution until validated by an experimental study. Nature inspired flow field designs can be generated using formal mathematical algorithms or by making heuristic modifications to existing natural structures. This paper reviews the current state of nature inspired PEMFC flow field designs and discusses the challenges in evaluating these designs.     

Optimization of blocked channel design for a proton exchange membrane fuel cell by coupled genetic algorithm and three-dimensional CFD modeling

Installing blocks in cathode flow field can effectively enhance the transfer of oxygen from channel to the reaction sites of catalyst layer, thus boosting the performance of the fuel cell. In this work, an optimization methodology combined with genetic algorithm and three-dimensional fuel cell modeling is developed to optimize the design of partially blocked channel for a proton exchange membrane fuel cell (PEMFC) with parallel flow field. In the optimization, the heights of the blocks are assumed to be linearly increased and two parameters (i.e., height of the first block and the height increase between adjacent blocks) are considered. The impact of the optimized design of the blocked channel on cell performance is analyzed, and the effects of the optimized blocked channel designs with increasing-height and uniform-height block height distributions were also compared in detail. With this optimization methodology, the optimal height distribution of the blocks in the channel can be obtained for various block numbers. With varying the block numbers, the cell voltage and net cell power are firstly improved until the maximal values reached and then lowered. The maximal net cell power is reached for the block number of 16. As compared with the flow channel without adding blocks, the net power of the PEMFC can be enhanced by about 10.9%. For pressure drop behavior, with the optimized block height distribution, the total pressure drop in cathode flow field can be maintained in similar level with varying block numbers from 4 to 20. Considering both the net power and pressure drop, the optimized blocked channels with adding 8 to 16 blocks are recommended in this study. Besides, it is indicated that the performance of the optimized block design with increasing-height is higher than that of the optimized block design with uniform-height.     

Effects of chlorides on the performance of proton exchange membrane fuel cells

This paper investigates the effects of cathode gases containing chloride ions on the proton exchange membrane fuel cell (PEMFC) performance. Chloride solutions are vaporized using an ultrasonic oscillator and mixed with oxygen/air. The salt concentration of the mixed gas in the cathode is set by varying the concentration of the chloride solution. Five-hour tests show that an increase in the concentration of sodium chloride did not significantly affect the cell performance of the PEMFC. It is found that variations in the concentration of chloride do not show significant influence on the cell performance at low current density operating condition. However, for high current density operating conditions and high calcium chloride concentrations, the chloride ion appears to have a considerable effect on cell performance. Experimental results of 108-h tests indicate that the fuel cell operating with air containing calcium chloride has a performance decay rate of 3.446 mV h⁻¹ under the operating condition of current density at 1 A/cm². From the measurements of the I-V polarization curves, it appears that the presence of calcium chloride in the cathode fuel gas affects the cell performance more than sodium chloride does.     

Experimental study of commercial size proton exchange membrane fuel cell performance

Commercial sized (16 × 16 cm² active surface area) proton exchange membrane (PEM) fuel cells with serpentine flow chambers are fabricated. The GORE-TEX® PRIMEA 5621 was used with a 35-μm-thick PEM with an anode catalyst layer with 0.45 mg cm⁻² Pt and cathode catalyst layer with 0.6 mg cm⁻² Pt and Ru or GORE-TEX® PRIMEA 57 was used with an 18-μm-thick PEM with an anode catalyst layer at 0.2 mg cm⁻² Pt and cathode catalyst layer at 0.4 mg cm⁻² of Pt and Ru. At the specified cell and humidification temperatures, the thin PRIMEA 57 membrane yields better cell performance than the thick PRIMEA 5621 membrane, since hydration of the former is more easily maintained with the limited amount of produced water. Sufficient humidification at both the cathode and anode sides is essential to achieve high cell performance with a thick membrane, like the PRIMEA 5621. The optimal cell temperature to produce the best cell performance with PRIMEA 5621 is close to the humidification temperature. For PRIMEA 57, however, optimal cell temperature exceeds the humidification temperature.     

Mass transfer in proton exchange membrane fuel cells with baffled flow channels and a porous‐blocked baffled flow channel design

In proton exchange membrane fuel cells, baffled flow channels enhance the reactant transfer from flow channels to gas diffusion layers. However, the reactant transfer depends on both the diffusive transfer and convective transfer, and how the baffles in flow channels affect them is still unknown. Therefore, in this work, a two‐dimensional, two‐phase, nonisothermal, and steady‐state model of proton exchange membrane fuel cells is developed, and these two transfer processes from flow channels to gas diffusion layers are comparatively studied. Simulation results show that first of all, the reactant transfer from flow channels to gas diffusion layers mainly depends on the diffusive transfer. Therefore, if the desire is to enhance the mass transfer from flow channels to gas diffusion layers, the diffusive mass transfer should be enhanced firstly. Being guided by this goal, a porous‐blocked baffled flow channel is developed. This flow channel design can further enhance the reactant transfer from flow channels to gas diffusion layers, and the cell performance can be improved. Moreover, when the porosities of porous blocks at the front place of flow channels are lower, the cell power is also increased but the pumping power can be reduced a lot.     

Development of a proton exchange membrane fuel cell cogeneration system

A proton exchange membrane fuel cell (PEMFC) cogeneration system that provides high-quality electricity and hot water has been developed. A specially designed thermal management system together with a microcontroller embedded with appropriate control algorithm is integrated into a PEM fuel cell system. The thermal management system does not only control the fuel cell operation temperature but also recover the heat dissipated by FC stack. The dynamic behaviors of thermal and electrical characteristics are presented to verify the stability of the fuel cell cogeneration system. In addition, the reliability of the fuel cell cogeneration system is proved by one-day demonstration that deals with the daily power demand in a typical family. Finally, the effects of external loads on the efficiencies of the fuel cell cogeneration system are examined. Results reveal that the maximum system efficiency was as high as 81% when combining heat and power.     

Optimizing the relative humidity to improve the stability of a proton exchange membrane by segmented fuel cell technology

The segmented fuel cell technology was applied to investigate the effects of the humidification conditions on the internal locally resolved performance and the stability of the fuel cell system. It was found at certain operating conditions, the time-dependent oscillation of current at potentio-static state appeared. The appearance of positive spikes of current indicated a temporary improved performance, while the negative current spikes indicated a temporary decreased performance. The periodic build-up and removal of liquid water in the cell caused unstable cell performance. Through the analyses of the evolution of the locally resolved current density distributions, the reasons for the positive or the negative spikes of current peaks with respect to a stationary value were found, which might be due to the drying-out of the membrane or the flooding of the membrane. The contour of the current density mapping differed to each other at the period of current peaks up or down, which might be due to different effect of the drying-out or flooding on the membrane. Through optimizing the relative humidity of anode (RHa) or cathode (RHc) of the fuel cell, the oscillation of the current disappeared and the performance of the cell became stable. RHc affects the performance of fuel cell much more obviously than RHa. The stability of the fuel cell system is also dependent on the imposed voltage. With the cell voltage decreased, the amplitude and the frequency of positive spikes of current increased.     

An experimental study for optimizing the energy efficiency of a proton exchange membrane fuel cell with an open-cathode

To develop an operating strategy for maximizing the energy efficiency of open-cathode proton exchange membrane fuel cells (OCPEMFCs), the present study investigates the effect of the fan speed on the stack performance and energy efficiency using a commercially available OCPEMFC system. The temperature, voltage, and current of the stack are monitored, and the energy efficiency is calculated at various stack power levels. The results of the system with a lab-developed controller are compared with the commercial system with a built-in controller. It is found that the fan speed should be minimum to reduce the auxiliary power consumption and that the stack should be efficiently heated to enhance the electrochemical reaction. In addition, it is noticed that the stack performance dramatically drops when the stack temperature is above 75 °C, due to the membrane dehydration. Overall, the results show that the stack temperature is an important indicator for controlling the fan speed for optimization of energy efficiency, and for stack powers of 50, 60, 70, and 80 W, the peak values of energy efficiencies are 38.0%, 38.3%, 38.5%, and 38.3% at the duty cycles of 0.2, 0.2, 0.25, and 0.3, respectively, which are 28–38% higher than the commercially available OCPEMFC system.     

Parametric analysis of the proton exchange membrane fuel cell performance using design of experiments

Proton exchange membrane fuel cell (PEMFC) performance depends on different fuel cell operating temperatures, humidification temperatures, operating pressures, flow rates, and various combinations of these parameters. This study employed the method of the design of experiments (DOE) to obtain the optimal combination of the six primary operating parameters (fuel cell operating temperatures, operating pressures, anode and cathode humidification temperatures, anode and cathode stoichiometric flow ratios). In the first stage, this study adopted a 2^k−2 fractional factorial design of the DOE to determine whether these factors have significant effects on a response and the interactions between various parameters. Second, the L₂₇(3¹³) orthogonal array of the Taguchi method is utilized to determine the optimal combination of factors for a fuel cell. Based on this study, the operating pressure, the operating temperature, and the interactions between operating temperature and operating pressure have a significant effect on the fuel cell performance. Among them, the operating pressure is the most important contributor. When the operating pressure increases, it should simultaneously lower the effects of other factors. While both the operating temperature and pressure increase simultaneously with that, the other factors are at appropriate conditions, it is possible to improve the fuel cell performance.     

Three-dimensional two-phase flow model of proton exchange membrane fuel cell with parallel gas distributors

A non-isothermal, steady-state, three-dimensional (3D), two-phase, multicomponent transport model is developed for proton exchange membrane (PEM) fuel cell with parallel gas distributors. A key feature of this work is that a detailed membrane model is developed for the liquid water transport with a two-mode water transfer condition, accounting for the non-equilibrium humidification of membrane with the replacement of an equilibrium assumption. Another key feature is that water transport processes inside electrodes are coupled and the balance of water flux is insured between anode and cathode during the modeling. The model is validated by the comparison of predicted cell polarization curve with experimental data. The simulation is performed for water vapor concentration field of reactant gases, water content distribution in the membrane, liquid water velocity field and liquid water saturation distribution inside the cathode. The net water flux and net water transport coefficient values are obtained at different current densities in this work, which are seldom discussed in other modeling works. The temperature distribution inside the cell is also simulated by this model.     

Coolant induced variable temperature flow field for improved performance of proton exchange membrane fuel cells

The objective of the coolant induced variable temperature flow field concept is to maintain high membrane water content along the entire flow field without external humidification and without occurrence of liquid water inside the cell at higher currents. This is achieved by imposing a temperature gradient in the cathode downstream direction in such manner that the product water is just sufficient to maintain close to 100% relative humidity along the entire flow field. The concept must be feasible for stack applications and flexible to enable efficient operation under significantly different operating conditions. The concept is investigated via interactive combination of computational fluid dynamics modeling and experimental validation for two membranes, namely Nafion^® 212 and Nafion^® 115. Additional calculations are also carried out for a five-cell stack with Nafion^® 212 membranes. The results of the computational fluid dynamics model are compared with the experimental data. Calculated and measured current density and relative humidity distributions along the cell give insight in the membrane water content and membrane water flux. With the coolant induced variable temperature flow field concept it is possible to achieve close to 100% relative humidity along the entire flow field without the requirement for external humidification, and to minimize the occurrence of liquid water inside the cell, resulting in improved performance of the cell in comparison with commonly used isothermal operation.     

Parallel serpentine-baffle flow field design for water management in a proton exchange membrane fuel cell

In a proton exchange membrane fuel cell (PEMFC) water management is one of the critical issues to be addressed. Although the membrane requires humidification for high proton conductivity, water in excess decreases the cell performance by flooding. In this paper an improved strategy for water management in a fuel cell operating with low water content is proposed using a parallel serpentine-baffle flow field plate (PSBFFP) design compared to the parallel serpentine flow field plate (PSFFP). The water management in a fuel cell is closely connected to the temperature control in the fuel cell and gases humidifier. The PSBFFP and the PSFFP were evaluated comparatively under three different humidity conditions and their influence on the PEMFC prototype performance was monitored by determining the current density–voltage and current density–power curves. Under low humidification conditions the PEMFC prototype presented better performance when fitted with the PSBFFP since it retains water in the flow field channels.     

Dynamic performance for a kW-grade air-cooled proton exchange membrane fuel cell stack

In this study, a kW-grade air-cooled proton exchange membrane fuel cell (PEMFC) stack with a dead-end anode (DEA) operation is designed and manufactured. The gravity-assisted drainage principle is applied for the stack to design the wettability of gas diffusion layers (GDLs) and the anode channel geometry, which can help the liquid water that diffuses to the anode to drain out of the anode porous electrode and move down the anode channel outlets. As a result, the stack can stably operate in a long purge interval of 268 s and in a short purge time of 2 s. In addition, using this design, only four small-power fans are employed to pump air to the cathode to provide oxygen for the electrochemical reaction and cool the stack. With a constant load current of 30, 45, or 60 A, the stack output voltage is experimentally tested at various cathode air flow rates (CAFRs). The local temperatures (60 measurement points) inside the stack and the pressure differences across anode channels are also monitored to understand heat dissipation and the back diffusion of liquid water. In a wide range of operating conditions, the designed stack possesses superior and stable voltage output characteristics with relatively uniform temperature distributions. The measured maximum output power is 3.83 kW, and the parasitic powers of fans are only 80～112 W.     

Planar current collector design and fabrication for proton exchange membrane fuel cell

This paper proposes a novel planar type lightweight current collector for proton exchange membrane fuel cells (PEMFC) designed for low power portable applications. The proposed lightweight current collector, which is composed of a substrate, electrical conduction layer and corrosion resistance layer, combines the conventional metal sheet/mesh for current collecting and substrate together to reduce the possible distortion during operation caused by the mismatch due to large different mechanical properties between components. The current collector adopts FR-4 as the substrate material. The electrical conduction layer is made via coating a copper thin film using a thermo-evaporation layer. The corrosion resistance layer is made via coating a graphene thin film using spin coating and a vacuum oven process. Fabricated current collector sheet resistance measurements are conducted. The complete current collectors are assembled into a single cell PEMFC with both forced convection air-breathing cathode and self-air-breathing cathode. The related performance and stability experiments were conducted to investigate the feasibility for further applications.     

Improving two-phase mass transportation under Non-Darcy flow effect in orientated-type flow channels of proton exchange membrane fuel cells

Orientated-type flow channels of proton exchange membrane fuel cells cause non-Darcy effect occurring in flow regions. Therefore, the species transportation is affected by inertial effect. However, how the inertial force affects convection and diffusion of different species has not been discussed before. Thus, a modified two-dimensional, non-isothermal, two-phase and steady state model considering non-Darcy effect is employed in this study, and reactants and products transportations through diffusion and convection under inertial effects are quantitatively analyzed for the first time. Simulation results reveal that the convective transportation of reactants increases more under the influence of inertial force; water vapor transportation through convection increases the water content in porous regions. At the same time, liquid water expels more rapidly from gas diffusion layers under baffle regions, and enlarging baffle volumes increases the regions where the liquid water is rapidly removed under the inertial effect.