Comparison of PEMFC performance with parallel serpentine and parallel serpentine-baffled flow fields under various operating and geometrical conditions; a parametric study

Optimal flow channel design of a fuel cell is crucial to further improve the performance of polymer electrolyte membrane fuel cell (PEMFC). In this work, a comprehensive parametric study was conducted to analyze the performance of a PEMFC with conventional parallel serpentine flow fields (PSFF) and parallel serpentine-baffled flow fields (PSBFF). A three-dimensional two-phase computational fluid dynamics model was used to numerically simulate the fuel cell performance. The effects of operating parameters such as pressure, temperature, and stoichiometric ratio, as well as the geometric parameters of channel height to channel width ratio and rib width to channel width ratio for both flow fields on fuel cell performance were investigated. The results show that as pressure, temperature, and stoichiometric ratio increase, cell performance increases for both flow fields, with a more substantial rate of improvement for the PSBFF design. A 16.1% improvement in cell performance at an operating pressure of 1 atm, a 19.9% improvement at a cell temperature of 70 °C, and a 16.1% improvement at a stoichiometric ratio of 2 were obtained when PSBFF was used instead of PSFF. By increasing the channel height and rib width, the cell performance for PSBFF remains almost constant due to the improved forced convection of the gas mixture and the reduction in concentration loss, while the cell performance for PSFF decreases significantly. At the largest channel height to channel width ratio of 1.5 and rib width to channel width ratio of 1.315 studied in this work, an improvement in cell performance of 53.3% and 58.5%, respectively, was achieved when PSBFF was used instead of PSFF. In addition, PSBFF was more effective in removing water from the porous zones than PSFF under all conditions.     

Three-dimensional analysis for effect of channel configuration on the performance of a small air-breathing proton exchange membrane fuel cell (PEMFC)

A coupled 3D mathematical model for the real geometry of an air-breathing proton exchange membrane (PEMFC) was developed and validated by experimental data. The free convection in the cathode side was included in the model. The concentration over-potential was considered as a function of mass transfer coefficient of oxygen in the catalyst layer. Governing equations possess the features that fluid dynamics, mass/heat transfer are coupled with the electrochemical reactions. The model was solved in a commercial software STAR-CD based on the finite-difference and finite-volume methods, and the electrochemical features and water transport in membrane are solved simultaneously through a user-specific subroutine. To investigate the effect of channel configuration on air-breathing fuel cell performance, calculations for three different widths of channels have been executed. Results show the best performance can be obtained in the cell with cathode channel width of 3 mm (open ratio of 75.9%).     

Three-dimensional modeling and experimental investigation for an air-breathing polymer electrolyte membrane fuel cell (PEMFC)

An air-breathing polymer electrolyte membrane fuel cell bears many advantages, which are important for portable-power applications. However, several barriers must be overcome before an air-breathing PEMFC achieve commercially wide-scale adoption. In this paper, with emphasis on improving the performance of air-breathing PEMFC, the simulation and experiment has been done simultaneously. Considering the natural convection in the cathode side, electrochemical reaction in the catalyst layer, water transport in the membrane, a coupled three-dimensional complex model has been developed in this work. The parameters which greatly affect the performance of an air-breathing PEMFC have been calculated for the base case such as the distribution of water and reactant, temperature and electrochemical performance. To validate the numerical result, the experiment test system have been designed to investigate the temperature distribution and cell performance. The results from this work show that the performance of air-breathing PEMFCs is strongly affected by natural convection feature. The concentration losses play a major role on the cell performance. The ambient relative humidity also has significant effect on the cell performance. The fields of water, temperature, velocity and electrochemical reaction have strong interaction on each others.     

An inverse geometry design problem for optimization of single serpentine flow field of PEM fuel cell

The cathode flow-field design of a proton exchange membrane fuel cell (PEMFC) determines its reactant transport rates to the catalyst layer and removal rates of liquid water from the cell. This study optimizes the cathode flow field for a single serpentine PEM fuel cell with 5 channels using the heights of channels 2–5 as search parameters. This work describes an optimization approach that integrates the simplified conjugated-gradient scheme and a three-dimensional, two-phase, non-isothermal fuel cell model. The proposed optimal serpentine design, which is composed of three tapered channels (channels 2–4) and a final diverging channel (channel 5), increases cell output power by 11.9% over that of a cell with straight channels. These tapered channels enhance main channel flow and sub-rib convection, both increasing the local oxygen transport rate and, hence, local electrical current density. A diverging, final channel is preferred, conversely, to minimize reactant leakage to the outlet. The proposed combined approach is effective in optimizing the cathode flow-field design for a single serpentine PEMFC. The role of sub-rib convection on cell performance is demonstrated.     

High performance PEMFC stack with open-cathode at ambient pressure and temperature conditions

An open-air cathode proton exchange membrane fuel cell (PEMFC) was developed. This paper presents a study of the effect of several critical operating conditions on the performance of an 8-cell stack. The studied operating conditions such as cell temperature, air flow rate and hydrogen pressure and flow rate were varied in order to identify situations that could arise when the PEMFC stack is used in low-power portable PEMFC applications. The stack uses an air fan in the edge of the cathode manifolds, combining high stoichiometric oxidant supply and stack cooling purposes. In comparison with natural convection air-breathing stacks, the air dual-function approach brings higher stack performances, at the expense of having a lower use of the total stack power output. Although improving the electrochemical reactions kinetics and decreasing the polarization effects, the increase of the stack temperature lead to membrane excessive dehydration (loss of sorbed water), increasing the ohmic resistance of the stack (lower performance).     

Influences of assembly pressure and flow channel size on performances of proton exchange membrane fuel cells based on a multi-model

In this work, assembly pressure and flow channel size on proton exchange membrane fuel cell performance are optimized by means of a multi-model. Based on stress-strain data of the SGL-22BB GDL obtained from its initial compression experiments, Young's modulus with different ranges of assembly pressure fits well through modeling. A mechanical model is established to analyze influences of assembly pressure on various gas diffusion layer parameters. Moreover, a CFD calculation model with different assembly pressures, channel width, and channel depth are established to calculate PEMFC performances. Furthermore, a BP neural network model is utilized to explore optimal combination of assembly pressure, channel width and channel depth. Finally, the CFD model is used to validate effect of size optimization on PEMFC performance. Results indicate that gap change of GDL below bipolar ribs is more remarkable than that below channels under action of the assembly pressure, making liquid water easily transported under high porosity, which is conducive to liquid water to the channels, reduces the accumulation of liquid water under the ribs, and enhances water removal in the PEMFC. Affected by the assembly force, change of GDL porosity affects its diffusion rate, permeability and other parameters, which is not conducive to mass transfer in GDL. Optimizing the depth and different dimensions through width of the flow field can effectively compensate for this effect. Therefore, the PEMFC performance can be enhanced through the comprehensive optimization of the assembly force, flow channel width and flow channel depth. The optimal parameter is obtained when assembly pressure, channel width and channel depth are set as 0.6 MPa, 0.8 mm, and 0.8 mm, respectively. The parameter optimization enhances the mass transfer, impedance, and electrochemical characteristics of PEMFC. Besides, it effectively enhances the quality transfer efficiency inside GDL, prevents flooding, and reduces concentration loss and ohmic loss.     

基于多模型的Z型流道燃料电池的性能优化

建立三维质子交换膜燃料单电池（PEMFC）数值模型,探究Z型流道PEMFC流道参数（角度、宽度、深度）、运行参数（温度、氢气湿度、氧气化学计量比）对燃料电池性能的影响,并建立多神经网络（MNN）模型,对上述参数进行优化。研究结果表明,最佳流道参数为角度-宽度-深度为25°-1.15 mm-0.85 mm,最佳运行参数为温度-湿度-化学计量比为349.15 K-0.60-4.5。通过对比优化前后的Z型流道PEMFC的性能可看出,优化后的Z型流道PEMFC在稳态特性及瞬态特性方面得到明显改善。     

Numerical study of optimized three-dimension novel Key-shaped flow field design for proton exchange membrane fuel cell

Key-shaped three-dimension (3D) flow field channel is designed to improve the performance and mass transfer of proton exchange membrane fuel cell (PEMFC). This study comprehensively analyses the impacts on the performance and mass transfer of the flow channel from multiple dimensions such as the size, shape, and placement of the blocks. In comparison with the conventional straight single flow field channel, the new channel with rectangular blocks can effectively improve performance by 30%. Semi-elliptical and quarter-elliptical blocks are designed to make forced convection and increase the diffusion area of oxygen. The results indicate that the flow velocity in the Z-axis direction can be increased to 0.08–0.2 m/s due to the narrow space formed by variable cross-sections. In conclusion, the Key-shaped design has a potential to improve the performance of mass transfer in the cathode channel, providing a new strategy for the development of flow field design in PEMFC field.     

Numerical investigation on the characteristics of mass transport and performance of PEMFC with baffle plates installed in the flow channel

A 3D numerical model of proton exchange membrane fuel cell (PEMFC) with the installation of baffle plates is developed. The majority of the conservation equations and physical parameters are implemented through the user defined functions (UDFs) in the FLUENT software. The characteristics of mass transport and performance of PEMFC are investigated. The results reveal that the baffle plate can enhance the mass transport efficiency and the performance of PEMFC. The baffle plate installed in the PEMFC flow channel increases the local gas velocity, which can promote the reactant gas transport and the liquid water removal in the porous electrode. As a result, the reactant gas concentration is larger in the porous electrode, which enhances the fuel cell performance for decreasing the over-potential of concentration. The fuel cell output power increases with the blockage ratio of the baffle plate. Considering the extra pumping power resulted from pressure loss caused by the baffle plate, the fuel cell with the blockage ratio of 0.8 is found to perform best in terms of the fuel cell net power generation. The fuel cell performance increases first with the baffle plate number, due to the better reactant distribution and water management, but decreases when the baffle plate number is too large, due to the excessive blockage for the reactant gas transport to the channel downstream. The PEMFC investigated with 5 baffle plates in the channel is found to be optimal. A channel design to achieve gradually increasing blockage ratios is also proposed, which exhibits better cell performance than the design with even blockage ratios.     

Experimental investigation on scaling and stacking up of proton exchange membrane fuel cells

The performance of a proton exchange membrane fuel cell (PEMFC) with various flow channel design (serpentine and interdigitated) with different landing to channel ratios (L:C = 1:1; 2:2) for an active area of 25 cm² and 70 cm², for single cell and two cells stack is studied and compared. The effect of back pressure on the PEMFC performance is also investigated. This study establishes a strong relation between back pressure and power output from a PEMFC. It was concluded that the interdigitated flow channel gives better results than the serpentine flow channel configuration for various landing to channel ratios. It was also found that power outputs do not proportionally increase with active area of the membrane electrode assembly (MEA). Similarly, stacking up studies with single cell and two cell stack shows that the two cell stack has reduced power densities when compared to that of a single cell. The effect of cooling channels with natural and forced convection by using induced draught fan on the performance of a PEMFC stack is also studied. Fuel distribution and temperature management are found to be the significant factors which determine the performance of a PEMFC stack.     

Coupling flow channel optimization and Bagging neural network to achieve performance prediction for proton exchange membrane fuel cells with varying imitated water-drop block channel

The proton exchange membrane fuel cell (PEMFC) flow channel structure obviously affects the reaction gas distribution and electrochemical reactions. In this study, the imitated water-drop block heights and widths within the channel are optimized for better PEMFC performance. A machine learning-based Bagging neural network is applied for the first time to predict PEMFC output performance based on different block structure parameters. First, the proposed imitated water-drop block height and width are optimized by changing parameters. Then, a database is established. Finally, after the Bagging model is validated, the performance is compared with the back-propagation (BP) neural network. Results indicate that the mass transfer and the electrochemical reaction are improved under the optimal width and height of imitated water-drop block for PEMFC. The Bagging prediction model uses less training data to obtain high-precision prediction results in 10 s. The performance prediction model can effectively improve the efficiency of channel optimization.     

Influence of structure dimensions on self-breathing micro fuel cells

In this paper a proton exchange membrane micro fuel cell (PEMFC) with a passive air breathing cathode and microstructured flow fields is studied comprehensively using a numerical model and experimental characterization. The design of the flow field structures is directly dependent on the fabrication technology. An optimization of structure dimensions is possible within the design space. A model is presented, which describes the influence of the aspect ratio of the channel width and the rib width of the micro flow field for a structure were no gas diffusion layers are incorporated. The fuel cell performance is limited by electrical losses in the electrode layer for large channel widths and by reactant transport for small channel widths.     

Unsteady three-dimensional numerical study of mass transfer in PEM fuel cell with spiral flow field

Bipolar plate design and its flow field shape have an important effect on the fuel cell performance. In this work, a FORTRAN program has been developed to investigate the effects of the channel width, the number of turns of the spiral channel and the flow direction on the reactants consumption in a proton exchange membrane fuel cell (PEMFC) with a spiral flow field design. The governing equations are discretized using the finite volume method in cylindrical coordinates. The results show that the channel-rib width ratio influences the cell performance; the higher ratio, the more important contact area between the channel and the GDL, the more reactants quantity seeped to the GDL and more uniform reactants distribution is. The increasing the spiral channel turns number improves the reactants distribution uniformity. The channel spiral shape engenders a centrifugal force which enhances the cell performances in the case when the reactants are injected from the external side of the spiral channel and ejected from its internal one.     

A three-dimensional full-cell CFD model used to investigate the effects of different flow channel designs on PEMFC performance

A three-dimensional “full-cell” computational fluid dynamics (CFD) model is proposed in this paper to investigate the effects of different flow channel designs on the performance of proton exchange membrane fuel cells (PEMFC). The flow channel designs selected in this work include the parallel and serpentine flow channels, single-path and multi-path flow channels, and uniform depth and step-wise depth flow channels. This model is validated by the experiments conducted in the fuel cell center of Yuan Ze University, showing that the present model can investigate the characteristics of flow channel for the PEMFC and assist in the optima designs of flow channels. The effects of different flow channel designs on the PEMFC performance obtained by the model predictions agree well with those obtained by experiments. Based on the simulation results, which are also confirmed by the experimental data, the parallel flow channel with the step-wise depth design significantly promotes the PEMFC performance. However, the performance of PEMFC with the serpentine flow channel is insensitive to these different depth designs. In addition, the distribution characteristics of fuel gases and current density for the PEMFC with different flow channels can be also reasonably captured by the present model.     

Numerical investigation into transient response of proton exchange membrane fuel cell with serpentine flow field

The transient response of a proton exchange membrane fuel cell (PEMFC) with a serpentine flow field design is investigated using a three‐dimensional numerical model. The simulations consider three different flow field designs with 7, 11, and 15 bends, respectively. For the flow field design with 11 bends, three different channel width ratios are considered, namely 25%, 50%, and 75%. The channel width ratio is defined as the ratio of the channel width to the total channel/rib width. The simulation results show that for all of the flow field designs, an overshoot in the local current density occurs when the voltage is reduced instantaneously from 0.7 to 0.5 V because of the high and uniform oxygen mass fraction. Conversely, a significant undershoot occurs when the voltage is increased instantaneously from 0.5 to 0.7 V because of the low and nonuniform oxygen mass fraction. The overshoot and undershoot phenomena are particularly evident in the PEMFC with a 15‐bend flow field. For the flow field design with 11 bends, the channel width ratio has little effect on the current density at an operating voltage of 0.7 V. However, at an operating voltage of 0.5 V, the oxygen concentration into the catalyst and diffusion layers increases with the increasing channel width ratio, which leads to higher current density. As a result, a more significant overshoot phenomenon is observed in the flow field with a width ratio of 75%. Copyright © 2012 John Wiley & Sons, Ltd.     

The effects of buoyancy on the performance of a PEM fuel cell with a wave-like gas flow channel design by numerical investigation

This study performs numerical simulations to investigate the effects of buoyancy on the gas flow characteristics, temperature distribution, electrochemical reaction efficiency and electrical performance of a proton exchange membrane fuel cell (PEMFC) with a novel wave-like gas flow channel design. In general, the simulation results show that compared to the straight geometry of a conventional gas flow channel, the wave-like configuration enhances the transport through the porous layer and improves the temperature distribution within the channel. As a result, the PEMFC has an improved fuel utilization efficiency and an enhanced heat transfer performance. It is found that the buoyancy effect increases the velocity of the reactant fuel gases in both the vertical and the horizontal directions. This increases the rate at which the oxygen gas is consumed in the fuel cell but improves the electrical performance of the PEMFC. The results show that compared to the conventional straight gas flow channel, the wave-like gas flow channel increases the output voltage and improves the maximum power density by approximately 39.5%.     

Effect of cathode separator structure on performance characteristics of free-breathing PEMFCs

The performance of free-breathing polymer electrolyte membrane fuel cells (PEMFCs) was studied experimentally and the effect of the cathode separator structure on the cell performance was investigated. Two types of cathode separators were used for a cell with an 18 cm² active area: an open type with parallel rectangular open-slits and a channel type with straight vertical channels with open ends. The polarization curves, cell impedance, and contact pressure distribution of the separators were measured with each type of cathode structure. The result showed that it is difficult to realize a uniform contact pressure across the cell layers for the open type separator, and this results in higher contact resistance and poorer cell performance than the channel type separator. The channel type separator can maintain a low contact resistance, and the cell performance is strongly affected by the natural convection inside the channel. Optimization of the channel design of the channel type separator achieves good performance and this type of separator is superior for a free-breathing PEMFC. A computational three-dimensional analysis for the free-breathing channel type PEMFC with the different channel depths was performed, and it identified the influence of natural convection.     

Numerical simulation and experimental study on the effect of symmetric and asymmetric bionic flow channels on PEMFC performance under gravity

In proton exchange membrane fuel cell (PEMFC), bionic flow field design is to apply the biological characteristics of nature to the structure design of flow field. The flow field designed by bionics can improve the water balance of the fuel cell and make the fuel distribute uniformly in the flow field. In order to study the PEMFC performance of symmetric and asymmetric bionic flow channel under gravity, the simulation and visualization experiments are used to study the bionic flow channel in different orientations. Under the influence of gravity, the distribution characteristics of liquid water are changed in the flow channel, and the difference of the transport process of liquid water in two different bionic flow channel under gravity is obtained. The results of the simulation and visualization experiments show that the gravity has a significant effect on the transport process of liquid water in the bionic flow channel, and the water transport process in the two types of bionic flow channel is obviously different. Meanwhile, the performance of the fuel cells with two bionic flow channel at different orientations is tested by experiments. The results show that gravity has a significant effect on the performance of PEMFC with bionic flow field. And there are significant differences between symmetrical and asymmetric bionic flow channel on PEMFC performance. The results of I–V curve show that when the PEMFC with asymmetric bionic flow channel has the best performance in the orientation of perpendicularity.     

Effects of channel and rib widths of flow field plates on the performance of a PEMFC

Effects of gas diffusion and electric conduction on the performance of a polymer electrolyte membrane fuel cell (PEMFC) were studied in an effort to optimize the channel configurations of flow field plates. The rib and channel widths of flow field plates were varied from 0.5 to 3 mm. The narrower the rib width, the performance of a cell becomes improved in the range investigated. From the results, gas diffusion seems to be a more important factor than electric conduction for the better cell performance.     

Performance evaluation of passive direct methanol fuel cell with methanol vapour supplied through a flow channel

This work examines the effect of fuel delivery configuration on the performance of a passive air-breathing direct methanol fuel cell (DMFC). The performance of a single cell is evaluated while the methanol vapour is supplied through a flow channel from a methanol reservoir connected to the anode. The oxygen is supplied from the ambient air to the cathode via natural convection. The fuel cell employs parallel channel configurations or open chamber configurations for methanol vapour feeding. The opening ratio of the flow channel and the flow channel configuration is changed. The opening ratio is defined as that between the area of the inlet port and the area of the outlet port. The chamber configuration is preferred for optimum fuel feeding. The best performance of the fuel cell is obtained when the opening ratio is 0.8 in the chamber configuration. Under these conditions, the peak power is 10.2 mW cm⁻² at room temperature and ambient pressure. Consequently, passive DMFCs using methanol vapour require sufficient methanol vapour feeding through the flow channel at the anode for best performance. The mediocre performance of a passive DMFC with a channel configuration is attributed to the low differential pressure and insufficient supply of methanol vapour.