Roughness effects of gas diffusion layers on droplet dynamics in PEMFC flow channels

Water management remains one of the major challenges in optimising the performance of PEMFCs, in which liquid accumulation and removal in gas diffusion layers (GDLs) and flow channels should be addressed. Here, effects of GDL surface roughness on the water droplet removal inside a PEMFC flow channel have been investigated using the Volume of Fluid method. Rough surfaces are generated according to realistic GDL properties by incorporating RMS roughness and roughness wavelength as the main characteristic parameters. Droplet dynamics including emergence, growth, detachment, and removal in flow channels with various airflow rates are simulated on rough substrates. The influences of airflow rate on droplet dynamics are also discussed by comparing the detachment time and droplet morphology. The liquid removal efficiency subject to different surface roughness parameters is evaluated by droplet detachment time and elongation, and regimes of detachment modes are identified based on the droplet breakup location and detachment ratio. The results suggest that rough surfaces with higher RMS roughness can facilitate the removal of liquid inside flow channel. Whilst surface roughness wavelength is found less significant to the liquid removal efficiency. The results here provide qualitative assessments on identifying the key surface characteristics controlling droplet motion in PEMFC channels.     

Numerical simulation of liquid water emerging and transport in the flow channel of PEMFC using the volume of fluid method

Three-dimensional numerical simulation of liquid water emerging from the gas diffusion layer (GDL) surface to the gas flow channel in the proton exchange membrane (PEM) fuel cell (PEMFC) is carried out using the volume of fluid (VOF) method. The effects of the water velocity in the GDL hole, the airflow velocity and the wettability of the channel surfaces on the water emerging process and transport in the flow channel are investigated. It is found that at low water velocity, the water detaches from the water hole, forming discrete water droplets on the GDL surface, and is transported downstream on the GDL surface until removed from the GDL surface by the U-turn part of the flow channel; whereas at high water velocity, the continuous water column impinges the hydrophilic channel surface counter to the GDL surface, being directly removed from the GDL surface. The airflow velocity affects water detachment and impact process in the channel corner, and water droplet breakup is observed under high airflow velocity. The channel surface wettability influences water droplet shape and its transport in the channel. Rather than forming corner water films at the U-turn for hydrophilic channel surface, water maintains the droplet shape and smoothly passes through the U-turn for hydrophobic channel surface. The importance of the U-turn to the water removal is also discussed. The U-turn promotes water removal from the GDL surface at low water velocity and water breakup at high airflow velocity.     

Investigating effect of different gas diffusion layers on water droplet characteristics for proton exchange membrane (PEM) fuel cells

In this work, advanced x-ray radiographic techniques available at the Canadian Light Source (CLS) were utilized to study water droplet dynamics in a serpentine flow channel mimicking a proton exchange membrane fuel cell (PEMFC). High spatial and temporal resolution coupled with high energy photons of an x-ray beam provided high-resolution images of water droplets. This technique solved the problem caused by the opaqueness of fuel cell materials including the gas diffusion layer by providing a unique way to study water droplet dynamics at different operating conditions. From the captured images, droplet emergence and formation on porous gas diffusion layers (GDLs) were analyzed. Three commercially available GDLs (Sigracet AA, Sigracet BA, and Sigracet BC) were used and droplet detachment height was found to decrease in the following order AA < BA < BC under the same flow condition. Increasing the superficial gas velocity was found to decrease the droplet detachment height for all GDLs tested. Average droplet cycle for various operating conditions was obtained. It was found that humidified air did not show a difference in droplet dimensions at detachment compared to dry air used at the inlet gas. However, it did show an impact on droplet cycle time, which might be due to condensation.     

Determination of effective water vapor diffusion coefficient in pemfc gas diffusion layers

The primary removal of product water in proton exchange membrane (PEM) fuel cells is through the cathode gas diffusion layer (GDL) which necessitates the understanding of vapor and liquid transport of water through porous media. In this investigation, the effect of microporous layer (MPL) coatings, GDL thickness, and polytetrafluorethylene (PTFE) loading on the effective water vapor diffusion coefficient is studied. MRC Grafil, SGL Sigracet, and Toray TGP-H GDL samples are tested experimentally with and without MPL coatings and varying PTFE loadings. A dynamic diffusion test cell is developed to produce a water vapor concentration gradient across the GDL and induce diffusion mass transfer. Tests are conducted at ambient temperature and flow rates of 500, 625, and 750 sccm. MPL coatings and increasing levels of PTFE content introduce significant resistance to diffusion while thickness has negligible effects.     

Experimental validation of a lumped model of single droplet deformation,oscillation and detachment on the GDL surface of a PEM fuel cell

Proton Exchange Membrane Fuel Cell (PEMFC) performance significantly depends on electrodes water content. Liquid water emerging from the Gas Diffusion Layer (GDL) micro-channels can form droplets, films or slugs in the Gas Flow Channel (GFC). In the regime of droplets formation, the interaction with the gas flow leads to an oscillating mechanisms that is fundamental to study the detachment from the GDL surface. In this work, a numerical model of a droplet growing on the GDL surface is developed to describe the interaction between droplet and gas flow. Therefore, a lumped force balance is enforced to determine the center of mass motion law. Oscillation frequencies during growth and at detachment are found as a function of droplet size. The model is also exploited to find the relationship between droplet critical detachment size and gas velocity. The numerical results are compared with the experimental data previously published by the authors as well as with other experimental results available in the literature. The matching between the numerical and experimental data is very good. The low computational burden and the conciseness of the proposed approach make the model suitable for applications such as control and optimization strategies development to enhance PEMFC performance. Additionally, the model can be exploited to implement monitoring and diagnostic algorithm as well.     

Fiber scale numerical investigations on water droplet dynamics on gas diffusion layers

The dynamics of water droplets on fiber layers are investigated by fiber-scale simulation using volume of fluid (VOF) method. The effects of fiber spaces, contact angles at fibers and numbers of layers on droplet dynamics are investigated. Force analysis for the pinned and moving droplets on fiber layers shows that the resistant forces from the wetted fibers at the edge positions rather than middle positions are the dominant force to control the droplet mobility. Force analysis for droplets on the dual-layers fiber layer are also conducted. The results show that the second layer contributes little to hinder the droplet directly due to the insignificant resistant force they provided. However, the second fiber layer enhances the total resistant force from the first layer. Furthermore a simplified model is used to compare with the fiber model. The results indicate that the simplified model can also be used to predict the droplet mobility once the contact angle is given.     

A droplet size dependent multiphase mixture model for two phase flow in PEMFCs

A droplet size dependent multiphase mixture model is developed in this paper, and the droplet size in the gas channel can be considered as a parameter in this multiphase mixture model, which includes the effect of gas diffusion layer (GDL) properties and the gas drag function and cannot be considered in the commonly used multiphase mixture model in the references. The three-dimensional two phase and non-isothermal simulation of the PEMFCs with a straight flow field is performed. The effect of droplet size on the liquid remove, the effect of liquid water on the heat transfer and the effect of gas flow pattern on the heat and mass transfer are mainly investigated. The simulation results show that the large droplet is hard to be dragged by the gas, so it produces large water saturation. The results of the heat transfer show that the liquid water hinders the heat transfer in the GDL and catalyst layer, so it produces the large relative high temperature area, and there are large temperature difference and water saturation in the PEMFCs operated with coflow pattern compared with counter flow pattern.     

Water distribution measurement for a PEMFC through neutron radiography

Neutron radiography has been used for in situ and non-destructive visualization and measurement technique for liquid water in a working proton exchange membrane fuel cell (PEMFC). In an attempt to differentiate water distribution in the anode side from that in the cathode side, a specially designed cell was machined and used for the experiment. The major difference between our design and traditional flow field design is the fact the anode channels and cathode channels were shifted by a channel width, so that the anode and cathode channels do not overlap in the majority of the active areas.

The neutron radiography experiments were performed at selected relative humidities, and stoichiometry values of cathode inlet. At each operating condition, the water distribution in anode/cathode gas diffusion layers (GDLs) was obtained. Image processing with four different spatial masks was applied to those images to differentiate liquid water in four different types of areas. Results indicate that the reactant gas relative humidity and stoichiometry significantly influence current density distribution and water distribution.     

Combined effects of microstructural characteristics on anisotropic transport properties of gas diffusion layers for PEMFCs

Gas diffusion layer (GDL) plays a key role in proton exchange membrane fuel cells, which provides multi-functions for gas transport, thermal-electrical conduction and mechanical support. Coupling manipulation of different microstructural characteristics could potentially improve transport properties of GDLs. This work proposes an approach to reconstruct heterogenous GDLs and conduct pore-scale modeling to evaluate the anisotropic transport properties. The models are reconstructed using X-ray computed tomography, stochastically reconstruction methods and morphological processing techniques, which consider different fiber diameter, GDL thickness and local porosity distribution type. Combined effects of microstructure characteristics on tortuosity, diffusivity, thermal-electrical conductivity and anisotropic ratios are investigated comprehensively. The results show that the diffusivity with fiber diameter of 7 μm is approximately 7% lower, and the conductivity is 8% higher than that of 9 μm. The anisotropic ratios of diffusivity, thermal conductivity and electrical conductivity range from 1.25 to 1.65, 5 to 20, and 20 to 55, respectively. Local porosity distribution of uniform-fluctuated type, fiber diameter of 7 μm and GDL thickness of 126 μm are suggested to balance diffusivity and thermal-electrical conductivity simultaneously. The methods and results can guide microstructure design of other porous electrodes with higher performance.     

Effects of cathode gas diffusion layer design on polymer electrolyte membrane fuel cell water management and performance

The effects of a microporous layer (MPL) on performance and water management of polymer electrolyte fuel cells are investigated. The presence of an MPL on the cathode side is found to slightly improve performance, although the voltage gain is less significant than that obtained by wetter reactants. The effect of the MPL on water management depends on the cathode inlet-gas humidity. Differences in water crossover rate are insignificant for wet cathode feed (RH = 75%), while they are significant for dry feed (RH = 25%). A model based on transport resistance of the MPL is proposed to explain the experimental trends observed. Modeling results suggest that the presence of the MPL on the cathode side causes a reduction of the water flux from the cathode catalyst layer to the flow channels, effectively promoting water back diffusion through the membrane. Higher cathode humidity reduces the driving force for water transport from the electrode to the gas channels, also reducing the importance of the water transport resistance due to the presence of the MPL.     

An integrated model of the water transport in nonuniform compressed gas diffusion layers for PEMFC

Water transport in gas diffusion layer (GDL) is a very important issue for high power density Proton Exchange Membrane Fuel Cell (PEMFC). During the GDL and bipolar plate (BPP) assembly process, the water transport behavior is greatly influenced by the nonuniform compression on the GDL, which leads to uneven distribution of the internal mass transport pores. In this study, an integrated model is developed to predict the water transport in nonuniform compressed GDL. Firstly, a GDL compression deformation model is built to obtain the relationship between the GDL deformation and assembly clamping force based on energy method. Then, a water transport model is established by considering the probability density function (PDF) of the pore size for the compressed GDL. The accuracy of the integrated model has been verified by comparing with the finite element method (FEM) and the computational fluid dynamics (CFD) simulation results. The influence of assembly clamping force, GDL thickness and channel geometry are analyzed based on the integrated model. Drainage pressure increases monotonically with the assembly clamping force and is divided into three stages. For the baseline case, 0.2 mm of GDL thickness and small rib-channel ratio is conducive to improving drainage capacity. It provides the guidance for matching of GDL/BPP assembly condition and performance prediction of PEMFC.     

Adoption of nano-materials for the micro-layer in gas diffusion layers of PEMFCs

Carbon nano-materials were applied to the gas diffusion layers of PEMFC. Gas diffusion layers consist of gas diffusion medium(carbon cloth or carbon paper) and micro-layers. Carbon blacks, such as Vulcan XC 72, have been widely used for the micro-layers. Main functions of gas diffusion layers are distribution of reactants to the active site of electrode, management of water supplied and/or generated and enhancement of electrical contact between the electrode and the bipolar plates. In this work, nano-fibers and nano-tubes are adopted to the micro-layer of gas diffusion layers. By applying nano-materials, thinner micro-layers can be fabricated. This newly made micro-layer showed higher gas permeability and good electric conductivity with similar degree of water management as well as enhanced performance.     

Impact of the anode operating conditions on the liquid water distribution in the cathode gas diffusion layer

Previous experimental results indicate that the humidification conditions at the anode have an impact on the liquid water distribution in the cathode gas diffusion layer. Numerical simulations are developed to reproduce and analyze this effect. Results consistent with the experimental results are first obtained by playing with the partition coefficients of an advanced pore network model computing the liquid water formation and transfer in the cathode gas diffusion layer (GDL) for a large range of operating conditions. Then, a model for the full anode – cathode assembly is developed by combining the pore network model of the cathode GDL and a 1D model describing the heat and water transfer in the various components of the anode-cathode assembly. This enables one to generalize the dry – wet regime diagram introduced in a previous work by incorporating the effect of the humidity condition at the anode.     

Water management studies in PEM fuel cells, part IV: Effects of channel surface wettability, geometry and orientation on the two-phase flow in parallel gas channels

In this study, the effects of channel surface wettability, cross-sectional geometry and orientation on the two-phase flow in parallel gas channels of proton exchange membrane fuel cells (PEMFCs) are investigated. Ex situ experiments were conducted in flow channels with three different surface wettability (hydrophilically coated, uncoated, and hydrophobically coated), three cross-sectional geometries (rectangular, sinusoidal and trapezoidal), and two orientations (vertical and horizontal). Flow pattern map, individual channel flow variation due to maldistribution, pressure drop and flow visualization images were used to analyze the two-phase flow characteristics. It is found that hydrophilically coated gas channels are advantageous over uncoated or slightly hydrophobic channels regarding uniform water and gas flow distribution and favoring film flow, the most desirable two-phase flow pattern in PEMFC gas channels. Sinusoidal channels favor film flow and have lower pressure drop than rectangular and trapezoidal channels, while the rectangular and trapezoidal channels behave similarly to each other. Vertical channel orientation is advantageous over horizontal orientation because the latter is more prone to slug flow, nonuniform liquid water distribution and instable operation.     

Innovative gas diffusion layers and their water removal characteristics in PEM fuel cell cathode

Liquid water transport is one of the key challenges regarding the water management in a proton exchange membrane (PEM) fuel cell. Conventional gas diffusion layers (GDLs) do not allow a well-organized liquid water flow from catalyst layer to gas flow channels. In this paper, three innovative GDLs with different micro-flow channels were proposed to solve liquid water flooding problems that conventional GDLs have. This paper also presents numerical investigations of air–water flow across the proposed innovative GDLs together with a serpentine gas flow channel on PEM fuel cell cathode by use of a commercial computational fluid dynamics (CFD) software package FLUENT. The results showed that different designs of GDLs will affect the liquid water flow patterns significantly, thus influencing the performance of PEM fuel cells. The detailed flow patterns of liquid water were shown. Several gas flow problems for the proposed different kinds of innovative GDLs were observed, and some useful suggestions were given through investigating the flow patterns inside the proposed GDLs.     

The impact of thermal conductivity and diffusion rates on water vapor transport through gas diffusion layers

Proper water management in a hydrogen-fueled polymer electrolyte membrane (PEM) fuel cell is critical for performance and durability. A mathematical model has been developed to elucidate the effect of thermal conductivity and water vapor diffusion coefficient in the gas diffusion layers (GDLs). The fraction of product water removed in the vapor phase through the GDL as a function of GDL properties/set of material and component parameters and operating conditions has been calculated. The current model enables identification of conditions wherein condensation occurs in each GDL component. The model predicts the temperature gradient across various components of a PEM fuel cell, providing insight into the overall mechanism of water transport in a given cell design. The water condensation conditions and transport mode in the GDL components depend on the combination of water vapor diffusion coefficients and thermal conductivities of the GDL components. Different types of GDLs and water transport scenarios are defined in this work, based on water condensation in the GDL and fraction of water that the GDL removes through the vapor phase, respectively.     

Influence of the surface microstructure of the fuel cell gas diffusion layer on the removal of liquid water

The effective removal of water on the gas diffusion layer (GDL) surface and low flow channel resistance are essential for the water management of proton exchange membrane fuel cells (PEMFCs). In this paper, a 3D two-phase volume of fluid (VOF) model is used to compare and analyze the influence of different GDL surface microstructures on the liquid hydrodynamic behavior and optimize the design of the sine wave microstructure. The results show that the surface microstructure of the GDL has a more significant impact on the water removal and flow resistance coefficient in the flow channel, and the sine wave microstructure has substantial advantages. The sine wave peak and period significantly influence the water removal and flow resistance coefficient. As the peak increases, the average relative change rate and the flow resistance coefficient also increase; the influence of the period is opposite to the peak, and the continuous decrease of the period will accelerate the water removal in the flow channel. The sine wave's height and width have little impact on water removal and the flow resistance coefficient. When the sine wave A = 75 μm, T = 1.5, H = 15 μm, and L = 25 μm, good flow channel water removal and low resistance are achieved. This work has particular guiding significance for removing liquid water on the GDL surface and obtaining low flow channel resistance.     

Study on the performance and characteristics of fuel cell coupling cathode channel with cooling channel

Water flooding in the cathode channel of the proton exchange membrane fuel cell (PEMFC), which reduce the current density output and affect fuel cell lifetime. Hence, to suppress water flooding, a novel channel is proposed in this study, that is to perforate hole between the cooling channel and cathode channel. A 3D numerical model is used to investigate the influence of the parameters including the hole's dimension, position, numbers, the operation conditions of the PEMFC and the slope angle (θ) of the incline cooling channel. The numerical results indicate that the optimal single hole parameters are 0.4 mm long, 0.5 mm wide and 20 mm position, which can maximum the current density output of the PEMFC. Increasing the hole numbers for novel channels can improve water removal. In addition, in comparison with the conventional channel with θ = 0.20° at 1.8 cathode stoichiometry, the H5 (novel channel with five holes) with θ = 0.20° decreases by 43.10% in the maximum water saturation of cathode channel, while increases by 12.54% in current density output. What's more, all the novel channel structure research hardly raises the pressure drop of channels.     

One-step to prepare high-performance gas diffusion layer (GDL) with three different functional layers for proton exchange membrane fuel cells (PEMFCs)

Gas diffusion layer (GDL) is one of the most important components of fuel cells. In order to improve the fuel cell performance, GDL has developed from single layer to dual layers, and then to multiple layers. However, dual or multi layers in GDL are usually prepared by layer-by-layer methods, which cost too much time, energy, and resources. In this work, we successfully developed a facile one-step method to prepare a GDL with three functional layers by utilizing the different sedimentation rates and filtration rates of short carbon fiber (CF) and carbon nanotube (CNT). The treatment temperature for this GDL is much lower than that of traditional method. The thickness of the GDL can be effectively controlled from as thin as 50 μm to more than 200 μm by simply adjusting the content of CF. The GDL with high flexibility is suitable to develop high performance flexible electronics. The fuel cell with the GDL has the maximum power density 1021 mW cm^?2, which shows 19% improvement comparing to the conventional one. Therefore, this work breaks the traditional concept that GDL for fuel cells only can be prepared by very complex and high-cost procedure.