Gas–liquid two-phase flow patterns in parallel channels for fuel cells

Two-phase flow in horizontal parallel channels has been experimentally investigated under fuel cell related operating conditions. Pronounced hysteresis is observed in the pressure drop versus flow characteristic curve when starting from either flooded or dry conditions. When gas is introduced into channels initially filled with water (flooded initial condition), both gas and liquid tend to flow predominantly in one channel at low gas or liquid flow velocities. As the gas flow velocity increases, even distribution of gas and liquid flow in both channels is observed, accompanied with a sudden decrease in the pressure drop. On the other hand, even gas and liquid flow distribution between both channels is found at comparatively lower gas flow velocities when starting with dry-gas flow conditions with liquid introduced into channels filled with gas (stratified flow regime). The flow regimes of this system are visualized in plots of the pressure drop against gas and liquid flow velocities. However, this phenomenon tends to vanish at high gas and liquid flow velocities, suggesting that high gas and liquid flow velocities are required to ensure even flow distribution in parallel channels. The hysteresis points appear at the same level of the pressure drop, reflecting intrinsic characteristics of the parallel channels used in this study. These results have important implications for PEM fuel cell operational strategies. In order to avoid reactant mal-distribution in parallel flow channels in the flow field in the two-phase flow regime, fuel cells should be operated at sufficiently high gas flow velocities.     

Three dimensional numerical simulation of gas-liquid two-phase flow patterns in a polymer-electrolyte membrane fuel cells gas flow channel

Water management in polymer-electrolyte membrane fuel cells (PEMFCs) has a major impact on fuel cell performance and durability. To investigate the two-phase flow patterns in PEMFC gas flow channels, the volume of fluid (VOF) method was employed to simulate the air-water flow in a 3D cuboid channel with a 1.0 mm × 1.0 mm square cross section and a 100 mm in length. The microstructure of gas diffusion layers (GDLs) was simplified by a number of representative opening pores on the 2D GDL surface. Water was injected from those pores to simulate water generation by the electrochemical reaction at the cathode side. Operating conditions and material properties were selected according to realistic fuel cell operating conditions. The water injection rate was also amplified 10 times, 100 times and 1000 times to study the flow pattern formation and transition in the channel. Simulation results show that, as the flow develops, the flow pattern evolves from corner droplet flow to top wall film flow, then annular flow, and finally slug flow. The total pressure drop increases exponentially with the increase in water volume fraction, which suggests that water accumulation should be avoided to reduce parasitic energy loss. The effect of material wettability was also studied by changing the contact angle of the GDL surface and channel walls, separately. It is shown that using a more hydrophobic GDL surface is helpful to expel water from the GDL surface, but increases the pressure drop. Using a more hydrophilic channel wall reduces the pressure drop, but increases the water residence time and water coverage of the GDL surface.     

Numerical study of two-phase flow patterns in the gas channel of PEM fuel cells with tapered flow field design

In this study the air–water two-phase flow in a tapered channel of a PEMFC was numerically simulated using the volume of fluid (VOF) method. In particular, a 3D mathematical model of the fuel cell flow channel was used to obtain a reliable evaluation of the fuel cell performance for different taper angles and different temperatures and to calculate the total amount of water produced. This information was then used as boundary conditions to simulate the two-phase flow in the cell channel through a 2D VOF model. Typical operating conditions were assigned and the numerical mesh was constructed to represent the real fuel cell configuration. The results show that tapering the channel downstream enhances the water removal due to increased airflow velocity. In the rectangular channel no film formation is noted with a marked predominance of slug flow. In contrast, as the taper angle is increased the predominant two-phase flow pattern is film flow. Finally many contact angles have been used to simulate the effect of the hydrophobicity of a GDL surface on the motion of the water. As the hydrophobicity of a GDL surface is decreased the presence of film is more evident even for less tapered channels.     

Boiling nucleation and two-phase flow patterns in forced liquid flow in microchannels

Using microfabrication techniques, a microscale platinum heater was fabricated on a Pyrex glass wafer and located in a shallow, but nearly trapezoidal microchannel with a hydraulic diameter of $D_{\mathrm{h}}$ = 56 microns fabricated on another glass wafer. Using a high-speed digital CCD video camera and microscope, the boiling nucleation temperature and two-phase flow patterns were observed and examined at different mass flow rates. The nucleation temperature was found to be reasonably close to the theoretical values as predicted by a 3D numerical heat transfer simulation with the measured bulk temperature of the microheater. The stability of the developed flow indicated three clearly distinguishable two-phase flow regimes: bubbly, wavy and annular. To avoid problems observed in the past, care was taken to ensure that the results were not influenced by the entrance and/or exit regions of the test section. The observed variations in the two-phase flow patterns were compared with the results of a model developed using a stability analysis of the liquid film.     

Modelling of stratified gas–liquid two-phase flow in horizontal circular pipes

This paper reports numerical and experimental investigation of stratified gas–liquid two-phase flow in horizontal circular pipes. The Reynolds averaged Navier–Stokes equations (RANS) with the k–ω turbulence model for a fully developed stratified gas–liquid two-phase flow are solved by using the finite element method. A smooth interface surface is assumed without considering the effects of the interfacial waves. The continuity of the shear stress across the interface is enforced with the continuity of the velocity being automatically satisfied by the variational formulation. For each given interface position and longitudinal pressure gradient, an inner iteration loop runs to solve the non-linear equations. The Newton–Raphson scheme is used to solve the transcendental equations by an outer iteration to determine the interface position and pressure gradient for a given pair of volumetric flow rates. Favorable comparison of the numerical results with available experimental results indicates that the k–ω model can be applied for the numerical simulation of stratified gas–liquid two-phase flow.     

Two-phase Flow Patterns in a Square Mini-channel

This paper presents a new set of experimental data of air-water flow patterns in a channel with a cross-section of 1×1 mm2. The ranges of the gas and liquid superficial velocities are 0.1-10 m/s and 0.2~7 m/s, respectively. Bubble, bubble-slug, slug, and frothy flows are observed. The present data are compared with other data in mini-channels reported in literature, and also compared with those in normal channel at microgravity, in which the Bond number has the same order of magnitude. The slug-frothy boundary is in consistent with each other, but for the bubble-slug transition, a much smaller value for the transition quality in the drift-flux model is obtained in the present study than those predicted by the empirical relations for the case of microgravity. It's shown that the mini-scale modeling may not be an effective way to anticipate the bubble-slug transition of two-phase flow at microgravity.     

Fundamental data on the gas–liquid two-phase flow in minichannels

We report on the results of investigations into the characteristics of an air–water isothermal two-phase flow in minichannels, that is, in capillary tubes with inner diameters of 1 mm, 2.4 mm, and 4.9 mm, also in capillary rectangular channels with an aspect ratio of 1 to 9. The directions of flow were vertical upward, horizontal and vertical downward. Based on the authors 15 years of fundamental research into the gas–liquid two-phase flows in circular tubes and rectangular channels, we summarized the characteristics of the flow phenomena in a minichannel with special attention on the flow patterns, the time varying holdup and the pressure loss. The effects of the tube diameters and aspect ratios of the channels on these flow parameters and the flow patterns were investigated. Also the correlations of the holdup and the frictional pressure drop were proposed.     

A heat-insulated permeable wall with suction in a compressible gas flow

The differential model of turbulence, supplemented with the transport equation for turbulent heat flux, is used to perform a numerical investigation of the boundary layer on a heat-insulated wall with suction in a compressible gas flow. It is shown that the laminarization of the initially turbulent boundary layer occurs under conditions of suction of gas, as is evidenced both by the behavior of integral and local characteristics of the flow and heat transfer and by the degeneracy of turbulence when the suction becomes asymptotic. In so doing, the temperature recovery factor is independent of Prandtl number and becomes equal to unity, i.e., the temperature of the heat-insulated wall becomes equal to the stagnation temperature of the outer flow.     

Unsteady steam condensation flow patterns inside a miniature tube

Unsteady steam condensation inside a single miniature tube has been studied. The visualization of different instantaneous and periodically two-phase flow is conducted for different experimental conditions. The two-phase flow characterization is obtained using the image processing. Annular, slug bubbly, spherical bubbly, and wavy flows are observed by varying the steam inlet pressure and cooling heat transfer. The cycle of the periodically flows are compared. It is shown that increasing the cooling heat flow rate reduces the number of the instabilities and the injected bubbles. The axial vapor velocity decreases during the waves growth. The local distribution of the condensate film thickness is analyzed. It is shown that the liquid film becomes thinner near the meniscus-like interface because of the surface tension effect. The reverse annular flow is observed at the end of each periodic flow when the bubbles leave the channel. It can be concluded from experimental results that the stratification effect is not significant during the condensation inside the miniature tube. The capillary pressure evolution is measured. The maximum values are obtained in the waves locations and near the meniscus of the annular flow.     

气液两相流相空间复杂网络非线性动力学特性分析

气液两相流动作为一个具有混沌特征的非线性动力学系统,其流型演化动力学特性尚未取得清楚的认识。以垂直上升管内空气-水两相流为研究对象,在实验获取气液两相流流型压差波动时间序列的基础上,将空气-水两相流的压差波动时间序列映射到流型相空间复杂网络对其非线性动力学特性进行了分析。通过分析发现在相空间不稳定周期轨的吸引特性作用下,不同流型的相空间复杂网络现呈出明显不同的网络结构,并且网络密度的演化趋势与流型的转化过程相吻合,较好地反映了垂直上升管内空气-水两相流的非线性动力学特性。     

Numerical simulation of bubbly two-phase flow in a narrow channel

An advanced numerical simulation method on fluid dynamics - lattice-Boltzmann (LB) method is employed to simulate the movement of Taylor bubbles in a narrow channel, and to investigate the flow regimes of two-phase flow in narrow channels under adiabatic conditions. The calculated average thickness of the fluid film between the Taylor bubble and the channel wall agree well with the classical analytical correlation developed by Bretherton. The numerical simulation of the behavior of the flow regime transition in a narrow channel shows that the body force has significant effect on the movement of bubbles with different sizes. Smaller body force always leads to the later coalescence of the bubbles, and decreases the flow regime transition time. The calculations show that the surface tension of the fluid has little effect on the flow regime transition behavior within the assumed range of the surface tension. The bubbly flow with different bubble sizes will gradually change into the slug flow regime. However, the bubbly flow regime with the same bubble size may be maintained if no perturbations on the bubble movement occur. The slug flow regime will not change if no phase change occurs at the two-phase interface.     

Numerical simulation of three-dimensional gas/liquid two-phase flow in a proton exchange membrane fuel cell

Investigation into the formation and transport of liquid water in proton exchange membrane fuel cells (PEMFCs) is the key to fuel cell water management. A three-dimensional gas/liquid two-phase flow and heat transfer model is developed based on the multiphase mixture theory. The reactant gas flow, diffusion, and chemical reaction as well as the liquid water transport and phase change process are modeled. Numerical simulations on liquid water distribution and its effects on the performance of a PEMFC are conducted. Results show that liquid water distributes mostly in the cathode, and predicted cell performance decreases quickly at high current density due to the obstruction of liquid water to oxygen diffusion. The simulation results agree well with experimental data. Translated from J Tsinghua Univ (Sci & Tech), 2006, 46(2): 252–256 [译自: 清华大学学报]     

Numerical simulation of two-phase flow in gas diffusion layer and gas channel of proton exchange membrane fuel cells

Liquid water within the cathode Gas Diffusion Layer (GDL) and Gas Channel (GC) of Proton Exchange Membrane Fuel Cells (PEMFCs) is strongly coupled to gas transport properties, thereby affecting the electrochemical conversion rates. In this study, the GDL and GC regions are utilized as the simulation domain, which differs from previous studies that only focused on any one of them. A Volume of Fluid (VOF) method is adopted to numerically investigate the two-phase flow (gas and liquid) behavior, e.g., water transport pattern evolution, water coverage ratio as well as local and total water saturation. To obtain GDL geometries, an in-house geometry-based method is developed for GDL reconstruction. Furthermore, to study the effect of GDL carbon fiber diameter, the same procedure is used to reconstruct three GDL structures by varying the carbon fiber diameter but keeping the porosity and geometric dimensions constant. The wall wettability is introduced with static contact angles at carbon fiber surfaces and channel walls. The results show that the GDL fiber microstructure has a significant impact on the two-phase flow patterns in the cathode field. Different stages of two-phase flow pattern evolution in both cathode domains are observed. The liquid water in the GDL experiences water invasion, spreading, and rising, followed by the droplet breakthrough in the GDL/GC interface. In the GC, the water droplets randomly experience accumulation, combination, attachment, and detachment. Due to the difference in surface wettability, the water coverage of the GDL/GC interface is smaller than that of the channel side and top walls. It is also found that the water saturation inside the GDL stabilizes after the water breakthrough, while local water saturation at the interface keeps irregular oscillations. Last but not the least, a water saturation balance requirement between the GDL and GC is observed. In terms of varying fiber diameter, a larger fiber diameter would result in less water saturation in the GDL but more water in the GC, in addition to faster water movement throughout the total domain.     

Flow boiling of liquid nitrogen in micro-tubes: Part I – The onset of nucleate boiling, two-phase flow instability and two-phase flow pressure drop

This paper is the first portion of a two-part study concerning the flow boiling of liquid nitrogen in the micro-tubes with the diameters of 0.531, 0.834, 1.042 and 1.931 mm. The contents mainly include the onset of nucleate boiling (ONB), two-phase flow instability and two-phase flow pressure drop. At ONB, mass flux drops suddenly while pressure drop increases, and apparent wall temperature hysteresis in the range of 1.0–5.0 K occurs. Modified Thom model can predict the wall superheat and heat flux at ONB. Moreover, stable long-period (50–60 s) and large-amplitude oscillations of mass flux, pressure drop and wall temperatures are observed at ONB for the 1.042 and 1.931 mm micro-tubes. Block phenomenon at ONB is also observed in the cases of high mass flux. The regions for the oscillations, block and stable flow boiling are classified. A physical model of vapor patch coalesced at the outlet is proposed to explain the ONB oscillations and block. Vapor generation caused by the flash evaporation is so large that it should be taken into account to precisely depict the variation of mass quality along the micro-tube. The adiabatic and diabatic two-phase flow pressure drop characteristics in micro-tubes are investigated and compared with four models including homogeneous model and three classical separated flow models. Contrary to the conventional channels, homogeneous model yields better prediction than three separated flow models. It can be explained by the fact that the density ratio of liquid to vapor for nitrogen is comparatively small, and the liquid and vapor phases may mix well in micro-tube at high mass flux due to small viscosity of liquid nitrogen, which leads to a more homogeneous flow. Part II of this study will focus on the heat transfer characteristics and critical heat flux (CHF) of flow boiling of liquid nitrogen in micro-tubes.     

Modeling of liquid water transport in a proton exchange membrane fuel cell gas flow channel with dynamic wettability

Liquid water transport in the gas flow channel is significantly important for the water removal and management in proton exchange membrane fuel cells. Previous numerical studies consider a single and constant static contact angle for the liquid water transport on the channel surface, which is insufficient to account for the dynamic wettability behavior of the flow. In this study, a dynamic wettability model is developed that incorporates the sliding angle and dynamic contact angles for the simulation of water transport in the flow channel. It is found that both the sliding and dynamic contact angles have significant impact on the characteristics of the water transport and dynamics in the flow channel. Water spreading on the channel surface is elliptic, and its minor and major axes oscillate out of phase with the droplet height. The pressure loss for the 2‐phase flow in the channel is directly related to this oscillation and deformation of the droplet shape. Flow channel surface with a small sliding angle facilitates the water transport and removal and reduces the associated pressure loss in the channel. The conventional static wettability model would overpredict droplet deformation and breakup as well as the pressure loss in the channel.     

Two-dimensional laminar fluid flow and heat transfer in a channel with a built-in heated square cylinder

A numerical investigation was conducted to analyze the unsteady flow field and heat transfer characteristics in a horizontal channel with a built-in heated square cylinder. Hydrodynamic behavior and heat transfer results are obtained by the solution of the complete Navier–Stokes and energy equations using a control volume finite element method (CVFEM) adapted to the staggered grid. The Computation was made for two channel blockage ratios (β=1/4 and 1/8), different Reynolds and Richardson numbers ranging from 62 to 200 and from 0 to 0.1 respectively at Pr=0.71. The flow is found to be unstable when the Richardson number crosses the critical value of 0.13. The results are presented to show the effects of the blockage ratio, the Reynolds and the Richardson numbers on the flow pattern and the heat transfer from the square cylinder. Heat transfer correlation are obtained through forced and mixed convection.     

Entropy generation in Poiseuille–Benard channel flow

The issue of entropy generation in Poiseuille–Benard channel flow is analyzed by solving numerically the mass, momentum and energy equations with the use of the classic Boussinesq incompressible approximation. The numerical scheme is based on Control Volume Finite Element Method with the SIMPLER algorithm for pressure–velocity coupling. Results are obtained for Rayleigh numbers Ra and irreversibility φ ranging from 10³ to 5×10⁴ and from 10⁻⁴ to 10 respectively. Variations of entropy generation and the Bejan number as a function of Ra and φ are studied. The limit value φ_l for which entropy generation due to heat transfer is equal to entropy due to fluid friction is evaluated. It has been found that φ_l is a decreasing function of the Rayleigh number Ra. φ_l varies from 0.0015 to 0.096 when Ra decrease from 5×10⁴ to 10³. Stream lines and entropy generation maps are plotted at six times over one period at Ra =10⁴ and φ=10⁻³. It has been found that the maximum entropy generation is localized at areas where heat exchanged between the walls and the flow is maximum. No significant entropy production is seen in the main flow.     

Dynamic behaviour of liquid water emerging from a GDL pore into a PEMFC gas flow channel

A numerical investigation of the dynamic behaviour of liquid water entering a polymer electrolyte membrane fuel cell (PEMFC) channel through a GDL pore is reported. Two-dimensional, transient simulations employing the volume of fluid (VOF) method are performed to explicitly track the liquid–gas interface, and to gain understanding into the dynamics of a water droplet subjected to air flow in the bulk of the gas channel. The modeled domain consists of a straight channel with air flowing from one side and water entering the domain from a pore at the bottom wall of the channel. The channel dimensions, flow conditions and surface properties are chosen to be representative of typical conditions in a PEMFC. A series of parametric studies, including the effects of channel size, pore size, and the coalescence of droplets are performed with a particular focus on the effect of geometrical structure. The simulation results and analysis of the time evolution of flow patterns show that the height of the channel as well as the width of the pore have significant impacts on the deformation and detachment of the water droplet. Simulations performed for droplets emerging from two pores with the same size into the channel show that coalescence of two water droplets can accelerate the deformation rate and motion of the droplets in the microchannel. Accounting for the initial connection of a droplet to a pore was found to yield critical air inlet velocities for droplet detachment that are significantly different from previous studies that considered an initially stagnant droplet sitting on the surface. The predicted critical air velocity is found to be sensitive to the geometry of the pore, with higher values obtained when the curvature associated with the GDL fibres is taken into account. The critical velocity is also found to decrease with increasing droplet size and decreasing GDL pore diameter.     

Three-dimension simulation of two-phase flows in a thin gas flow channel of PEM fuel cell using a volume of fluid method

This study investigates the two-phase flow in a thin gas flow channel of PEM fuel cells and wall contact angle's impact using the volume of fluid (VOF) method with tracked two-phase interface. The VOF results are compared with experimental data, theoretical solution and analytical data in terms of flow pattern, pressure drop and water fraction. Stable film flow is predicted, as observed experimentally, for the contact angle ranging from 5° to 40° including varying contact angles at different walls of a channel. The contact angle is found to have small impact on the gas pressure drop for the stratified flow regime, but it determines the meniscus of the two-phase interface, which affects the optical detection of the liquid thickness in experiment. The work is important to study of two-phase flow dynamics, multichannel design, experimental design and control of two-phase flows in thin gas flow channels for PEM fuel cells.     

Visualization of the unburned gas flow field ahead of an accelerating flame in an obstructed square channel

The effect of blockage ratio on the early phase of the flame acceleration process was investigated in an obstructed square cross-section channel. Flame acceleration was promoted by an array of top-and bottom-surface mounted obstacles that were distributed along the entire channel length at an equal spacing corresponding to one channel height. It was determined that flame acceleration is more pronounced for higher blockage obstacles during the initial stage of flame acceleration up to a flame velocity below the speed of sound of the reactants. The progression of the flame shape and flame area was determined by constructing a series of three-dimensional flame surface models using synchronized orthogonal schlieren images. A novel schlieren based photographic technique was used to visualize the unburned gas flow field ahead of the flame front. A small amount of helium gas is injected into the channel before ignition, and the evolution of the helium diluted unburned gas pocket is tracked simultaneously with the flame front. Using this technique the formation of a vortex downstream of each obstacle was observed. The size of the vortex increases with time until it reaches the channel wall and completely spans the distance between adjacent obstacles. A shear layer develops separating the core flow from the recirculation zone between the obstacles. The evolution of oscillations in centerline flame velocity is discussed in the context of the development of these flow structures in the unburned gas.