Analysis of coupled electron and mass transport in the gas diffusion layer of a PEM fuel cell

A numerical investigation of the coupled electrical conduction and mass diffusion in the cathodic GDL of a PEMFC is performed using 2D simulations. The current density on the GDL/catalyst layer interface, which constitutes one of the boundary conditions for the GDL domain and reflects the activation overpotential in the catalyst layer and the ohmic loss in the membrane, is solved iteratively using a novel numerical algorithm. A parametric study is performed to investigate the effects on current density distribution of various operating conditions such as oxygen concentration and membrane resistance, and of design factors such as GDL geometry, anisotropic transport properties, and deformation under the land area due to compression. The results show that the current density distribution under the land area can be dominated by either electron transport or mass transport, depending on the operating regime. The analysis of the in-plane current density gradients shows the contributions due to electrical conduction, oxygen diffusion and membrane resistance in an explicit form. The analysis also provides guidance for the scaling of the coupled transport problem.     

Numerical study on the compression effect of gas diffusion layer on PEMFC performance

A numerical method is developed to study the effect of the compression deformation of the gas diffusion layer (GDL) on the performance of the proton exchange membrane fuel cell (PEMFC). The GDL compression deformation, caused by the clamping force, plays an important role in controlling the performance of PEMFC since the compression deformation affects the contact resistance, the GDL porosity distribution, and the cross-section area of the gas channel. In the present paper, finite element method (FEM) is used to first analyze the ohmic contact resistance between the bipolar plate and the GDL, the GDL deformation, and the GDL porosity distribution. Then, finite volume method is used to analyze the transport of the reactants and products. We investigate the effects of the GDL compression deformation, the ohmic contact resistivity, the air relative humidity, and the thickness of the catalyst layer (CL) on the performance of the PEMFC. The numerical results show that the fuel cell performance decreases with increasing compression deformation if the contact resistance is negligible, but an optimal compression deformation exists if the contact resistance is considerable.     

Combined effect of channel to rib width ratio and gas diffusion layer deformation on high temperature – Polymer electrolyte membrane fuel cell performance

The present study investigates the combined influence of Channel to Rib Width (CRW) ratio and clamping pressure on the structure and performance of High Temperature-Polymer Electrolyte Membrane Fuel Cell (HT-PEMFC) using a three-dimensional numerical model developed previously. It also considers the impact of interfacial contact resistance between the Gas Diffusion Layer (GDL) and Bipolar Plate (BPP). The structural analysis of the single straight channel HT-PEMFC geometry shows that the von-Mises stress greatly increases in the GDL under the ribs as the CRW ratio increases resulting in considerably high deformation. The cell performance analysis depicts the significance of ohmic resistance and concentration polarization for different CRW ratios, particularly at higher operating current densities. However, in low to medium current density regions, the CRW ratio has little influence on cell performance. A substantial impact on the species, overpotential, and current distributions is observed. The findings also reveal that the CRW ratio significantly affects the temperature distribution in the cell.     

A numerical study of flow crossover between adjacent flow channels in a proton exchange membrane fuel cell with serpentine flow field

The focus of this paper is to study the flow crossover between two adjacent flow channels in a proton exchange membrane (PEM) fuel cell with serpentine flow field design in bipolar plates. The effect of gas diffusion layer (GDL) deformation on the flow crossover due to the compression in a fuel cell assembly process is particularly investigated. A three-dimensional structural mechanics model is created to study the GDL deformation under the assembly compression. A three-dimensional PEM fuel cell numerical model is developed in the aforementioned deformed domain to study the flow crossover between the adjacent channels in the presence of the GDL intrusion. The models are solved in COMSOL Multiphysics—a finite element-based commercial software package. The pressure, velocity, oxygen mass fraction and local current density distribution are presented. A parametric study is conducted to quantitatively investigate the effect of the GDL’s transport related parameters such as porosity and permeability on the flow crossover between the adjacent flow channels. The polarization curves are also examined with and without the assembly compression considered. It is found that the compression effect is evident in the high current density region. Without considering the assembly compression, the fuel cell model tends to over-predict the fuel cell’s performance. The proposed method to simulate the crossover with the deformed computational domain is more accurate in predicting the overall performance.     

Investigation of the effects of the anisotropy of gas-diffusion layers on heat and water transport in polymer electrolyte fuel cells

The aim of this work is to study the effects of gas-diffusion layer (GDL) anisotropy and the spatial variation of contact resistance between GDLs and catalyst layers (CLs) on water and heat transfer in polymer electrolyte fuel cells (PEFCs). A three-dimensional, two-phase, numerical PEFC model is employed to capture the transport phenomena inside the cell. The model is applied to a two-dimensional cross-sectional PEFC geometry with regard to the in-plane and through-plane directions. A parametric study is carried out to explore the effects of key parameters, such as through-plane and in-plane GDL thermal conductivities, operating current densities, and electronic and thermal contact resistances. The simulation results clearly demonstrate that GDL anisotropy and the spatial variation of GDL/CL contact resistance have a strong impact on thermal and two-phase transport characteristics in a PEFC by significantly altering the temperature, water and membrane current density distributions, as well as overall cell performance. This study contributes to the identification of optimum water and thermal management strategies of a PEFC based on realistic anisotropic GDL and contact-resistance variation inside a cell.     

Three-dimensional modeling of a PEMFC with serpentine flow field incorporating the impacts of electrode inhomogeneous compression deformation

The effects of compression deformation of gas diffusion layer (GDL) on the performance of a proton exchange membrane fuel cell (PEMFC) with serpentine flow field were numerically investigated by coupling two-dimensional GDL mechanical deformation model based on Finite Element Analysis and three-dimensional two-phase PEMFC model with incorporating the deformation impacts. Emphasis is located on exploring the influences of assembly pressure on the non-uniform geometric deformation and distributions of transport properties in the GDL, flow behaviors and local distributions of oxygen and current density, cell polarization curves and net power densities of the PEMFC. It was indicated that the non-uniform deformation of GDL results in inhomogeneous distributions of porosity and permeability in the GDL due to the presence of rib-channel pattern, and the transport properties in the under-rib region are greatly reduced with increasing the assembly pressure, consequently weakening the gas flow and oxygen transport in the under-rib region and increasing the non-uniformity of local current density distribution. As for the overall cell performance, however, attributed to the tradeoff between the adverse impacts of GDL compression on mass transport loss and positive effects on reducing ohmic loss, the overall cell performance is firstly increased and then decreased with increasing assembly pressure from 0 MPa to 5.0 MPa, and the maximum cell performance can be achieved at the assembly pressure of about 1.0 MPa for all cases studied. As compared with the case for zero assembly pressure, the maximum net power density of the cell can be improved by about 7.7%, 9.9%, 10.5% and 10.7% for the cathode stoichiometry ratios of 2.0, 3.0, 4.0 and 5.0@i_ref = 1 A·cm⁻², respectively. Practically, it is suggested that the assembly pressure is controlled in an appropriate range of 0.5 MPa–1.5 MPa such that the cell net power can be boosted and pressure head requirement for the pump can be maintained in a appropriate level.     

Correlation between anisotropic bending stiffness of GDL and land/channel width ratio of polymer electrolyte membrane fuel cells

A correlation between anisotropic bending stiffness of a gas diffusion layer (GDL) and land/channel width ratios of metallic bipolar plates (MBPs) in polymer electrolyte membrane fuel cells has been systematically investigated. I–V performances of the fuel cells with 90° GDLs, whose directions of higher stiffness are perpendicular to the direction of the major flow field, are generally higher than those with 0° GDLs, whose directions of higher stiffness are parallel with the direction of the major flow field. However, the differences of I–V performances and high-frequency resistance values between 0° and 90° GDL cells gradually decrease with increasing land/channel width ratio, because of the reduced anisotropic stiffness effects of the GDLs due to the better support by the MBPs with wider lands. The cross-sectional images of GDLs upon compression indicate that the 0° GDL appears to be more deformed and intruded into channel than the 90° GDL under the narrowest lands, whereas both 0° and 90° GDLs show very little intrusion and deformation under the widest lands. The results clearly explain why some MBPs (i.e., narrower lands) exhibit strong effects of GDL’s anisotropic stiffness on cell performances, whereas other MBPs (i.e., wider lands) do not experience such effects.     

Parameter sensitivity examination for a complete three-dimensional,two-phase,non-isothermal model of polymer electrolyte membrane fuel cell

Parameter sensitivity analysis is carried out for a complete three-dimensional, two-phase, non-isothermal model of polymer electrolyte membrane (PEM) fuel cell with a parallel flow field design. The model couples the two-phase flow of the multi-component reactants and liquid water, species transport, electrochemical reactions, proton and electron transport, and the electro-osmosis transport, back diffusion of water in the membrane, and energy transport. Twenty nine parameters, which are classified into the structural or transport parameters of porous layers (tortuosity, porosity, permeability, proton conductivity, electron conductivity, and thermal conductivity) as well as the electrochemical parameters (anodic and cathodic exchange current densities, anodic and cathodic transfer coefficients for anode and cathode reactions), are used to implement individual parameter investigation. The results show the parameters can be divided in to strongly sensitive, conditional sensitive and weak sensitive parameters according to its effect on the cell polarization curve. The optimization of parameters of cathode gas diffusion layer (GDL) and catalyst layer (CL) is more important to improve cell performance than that of anode GDL and CL because liquid water transport and removal affect significantly membrane hydration and reactant transport. Electrochemical parameters determine the activation potential and the slope of ohmic polarization hence these parameters can be used to fit experimental polarization curve more effectively than the other parameters.     

Effect of GDL permeability on water and thermal management in PEMFCs—II. Clamping force

In proton exchange membrane fuel cells (PEMFCs), the permeability of the gas diffusion layer (GDL) differs between the in-plane and through plane directions, and the overall permeability in the shoulder region is typically lower than that in the channel region due to the clamping force applied through the bipolar plates. Here, we conducted a numerical investigation of GDLs with different isotropic or anisotropic permeabilities in the channel and shoulder regions for PEMFCs. A three-dimensional, non-isothermal model was employed with a single straight channel. We found that the water and thermal management in PEMFCs depend on the permeability characteristics of the GDL, especially in the shoulder region. Moreover, the ohmic loss and cathode overpotential varied depending on the difference in isotropic permeability between the channel and shoulder regions. In the study on GDLs with anisotropic permeabilities in the channel and shoulder regions, however, we found that variations in the anisotropic permeabilities in the channel and shoulder regions, had little effect on the cathode overpotential at the shoulder region, but caused significant changes in ohmic loss as the ohmic loss depended on water and thermal management. In addition, we found that the cell temperature was much higher in GDLs with low anisotropic permeabilities due to hindering of the water removal process.     

Gas diffusion layer deformation and its effect on the transport characteristics and performance of proton exchange membrane fuel cell

Cell/stack assembly force can strongly affect the transport characteristics and performance of a proton exchange membrane fuel cell (PEMFC) through causing the structural deformation. In this study, a mathematical model has been developed to investigate the effect of the assembly force for different gas diffusion layers (GDL) and membranes. The results indicate that the predominant deformation of the cell structure occurs in the porous GDL due to its weak mechanical strength. Thicker GDLs result into lower water content in the GDL structure, and can sustain a larger assembly force without the risk of “electrode flooding”; while thinner GDLs have higher water content, can maintain the hydration required for the membrane, and yield a better cell performance with less sensitivity to the variations in the assembly force. Thinner membranes yield better cell performance, but the cell performance is more sensitive to the changes in the assembly force. A combination of thin GDL and membrane is beneficial for better cell performance with reasonable sensitivity to the assembly force. For thinner GDLs, an optimal assembly force exists beyond which the cell performance is reduced; and practical cell assembly force will limit the GDL thickness.     

Effects of a microporous layer on the performance degradation of proton exchange membrane fuel cells through repetitive freezing

The gas diffusion layer (GDL) covered with a microporous layer (MPL) is being widely used in proton exchange membrane fuel cells (PEMFCs). However, the effect of MPL on water transport is not so clear as yet; hence, many studies are still being carried out. In this study, the effect of MPL on the performance degradation of PEMFCs is investigated in repetitive freezing conditions. Two kinds of GDL differentiated by the existence of MPL are used in this experiment. Damage on the catalyst layer due to freezing takes place earlier when GDL with MPL is used. More water in the membrane and catalyst layer captured by MPL causes permanent damage on the catalyst layer faster. More detailed information about the degradation is obtained by electrochemical impedance spectroscopy (EIS). From the point of view that MPL reduces the ohmic resistance, it is effective until 40 freezing cycles, but has no more effect thereafter. On the other hand, from the point of view that MPL enhances mass transport, it delays the increase in the mass transport resistance.     

Effect of deformation on electrical properties of carbon fibers used in gas diffusion layer of proton exchange membrane fuel cells

In proton exchange membrane fuel cells, the stacks of anode, cathode, and membrane layers including gas diffusion layer (GDL) are held together by a compressive force applied through a bipolar plate. In this work, we studied the electrical properties of a carbon fiber of a GDL under deformation using four-point measurement methods inside a scanning electron microscope (SEM). We found out that through bending deformation the electrical resistivity of carbon fibers will be reduced. The drop in resistance during deformation may be the result of increasing conduction channels in the carbon fiber and parallel transport through them. Our finding offers a new insight on the effect of deformation on tuning the electrical properties of GDL materials.     

Effects of the electrical resistances of the GDL in a PEM fuel cell

In most PEM fuel cell models, the electrical resistance of the gas diffusion layers (GDL) is neglected under the assumptions that the GDL electrical conductivity is orders of magnitude higher than the ionic conductivity of the membrane. Recently some modeling efforts have taken the effects of electrical resistance of the GDL into consideration [H. Meng, C.Y. Wang, Electron transport in PEFCs, J. Electrochem. Soc. 151 (2004) A358–A367; B.R. Sivertsen, N. Djilali, CFD-based modeling of proton exchange membrane fuel cells, J. Power Sources 141 (2005) 65–78] and some of the results showed that under certain conditions, this effect was significant enough to alter the characteristics of current density distributions under the gas channels and the land areas. If these results are applicable to real-life fuel cells, the present design criteria and optimization procedures must be significantly changed to incorporate the effect of GDL electrical resistance. To examine this issue closely, a three-dimensional fuel cell model incorporating electron transport in the GDL is developed and employed to investigate the effect of electrical resistance through the GDL. In this model, the anisotropic nature of the GDL is taken into consideration by using different electrical conductivities in the through-plane and in-plane directions. The modeling results show that when realistic electrical conductivities for the GDL are used, the effect of the electrical resistance of GDL is slight and can be neglected for all industrial applications. It is believed that the over-estimations of the GDL resistance were mainly caused by neglecting the anisotropic nature of the GDL and/or lumping the contact resistance indiscriminately into the GDL, thus overestimating the electrical resistance of the GDL in the in-plane direction. Besides taking into consideration of the electrical resistance of GDL, the present model also take into consideration of the electron transport in the catalyst layers. When realistic values of electrical conductivities are used for both the GDL and catalyst layers, there is no significant change in the characteristics of current density distribution across the land and channel.     

A numerical investigation of the effects of GDL compression and intrusion in polymer electrolyte fuel cells (PEFCs)

The purpose of this work is to numerically investigate the effects of non-uniform compression of the gas diffusion layer (GDL) and GDL intrusion into a channel due to the channel/rib structure of the flow-field plate. The focus is placed on accurately predicting two-phase transport between the compressed GDL near the ribs and uncompressed GDL near the channels, and its associated effects on cell performance. In this paper, a GDL compression model is newly developed and incorporated into a comprehensive three-dimensional, two-phase PEFC model developed earlier. To assess solely the effects of GDL compression and intrusion, the new fuel cell model is applied to a simple single-straight channel fuel cell geometry. Numerical simulations with different levels of GDL compression and intrusion are carried out and simulation results reveal that the effects of GDL compression and intrusion considerably increase the non-uniformity, particularly, the in-plane gradient in liquid saturation, oxygen concentration, membrane water content, and current density profiles that in turn results in significant ohmic and concentration polarizations. The present three-dimensional GDL compression model yields realistic species profiles and cell performance that help to identify the optimal MEA, gasket, and flow channel designs in PEFCs.     

Determination of oxygen transport resistance in gas diffusion layer for polymer electrolyte fuel cells

Gas diffusion layer (GDL) plays an important role in the performance of membrane electrode assembly (MEA) in polymer electrolyte fuel cells. In this work, 2‐type MEAs were prepared by 2 different GDLs of 29 BC and 29‐WUT, and the performance were investigated using polarization curve methods. The performance of MEA with 29‐WUT was 120 mV higher than 29 BC at 1600 mA/cm². Electrochemical impedance spectroscopy (EIS) was applied to measure the mass transport resistance of 2‐type MEAs under normal running condition. The results of EIS showed that the mass transport resistance of 29 BC was 3.15 times higher than that of 29‐WUT at 1600 mA/cm². To clarify this phenomenon, limiting current methods were applied under diluting oxygen concentration, low humidity, and high flow rate conditions. The results of limiting current methods showed that both the total oxygen transport resistance and the molecular diffusion resistance in the GDL of 29 BC were larger than that of 29‐WUT due to the lower porosity of gas diffusion substrate in 29 BC . As a result, EIS can be well combined with limiting current methods to analyze oxygen transport resistance in GDLs of fuel cells.     

Non-uniform agglomerate cathode catalyst layer model on the performance of PEMFC with consideration of water effect

We focus on the effect of cathode catalyst layer physical structure on the cell performance of proton exchange membrane fuel cell (PEMFC). At low polarization, high inlet humidification predicts better cell performance because of the more active surface in the CL. As polarization is extended near the mass transfer limited regime, high humidification only renders a flooded electrode and inferior cell performance. Catalyst layer with better capillary water transport parameters performs better than that with inferior water repulsion capability. Permeation in the gas diffusion layer (GDL) is important for efficient oxygen diffusion in mass transfer influenced regime. On the other hand, the permeability in catalyst layer only has secondary effect.The distribution of material properties in the CL is studied for the MEA fabrication strategy. The CL is divided into three sub-layers with changing material properties. With water effect considered, better performance is obtained for higher porosity near the GDL, higher electrolyte fraction in the agglomerate near the membrane. The effect of agglomerate particle size differs in the ohmic and mass transfer controlled regimes. Larger agglomerate size near GDL is preferred in the ohmic limited regime, while smaller size near GDL performs better if operated at mass transfer controlled regime.     

Influence of clamping force on the performance of PEMFCs

The objective of the present paper is to investigate the effect of clamping force on the performance of proton exchange membrane fuel cell (PEMFC) with interdigitated gas distributors considering the interfacial contact resistance, the non-uniform porosity distribution of the gas diffusion layer (GDL) and the GDL deformation. The clamping force between the GDL and the bipolar plate is one of the important factors to affect the performance and efficiency of the fuel cell system. It directly affects the structure deformation of the GDL and the interfacial contact electrical resistance, and in turn influences the reactant transport and Ohmic overpotential in the GDL. Finite element method and finite volume method are used, respectively, to study the elastic deformation of the GDL and the mass transport of the reactants and products. It is found that there exists an optimal clamping force to obtain the highest power density for the PEMFC with the interdigitated gas distributors.     

EIS studies on electro-electrodialysis cell for concentration of hydriodic acid

EIS studies were carried out on an electro-electrodialytic cell used for concentration of hydriodic acid using platinum electrodes and nafion117 membrane. Different impedance spectra were obtained where the concentration of iodine was varied while the concentration of HI was kept fixed at 55 wt%. Equivalent circuit model was used to simulate the experimental data and it was found that the impedance of the cell without membrane can be modeled using a single Warburg element along with ohmic resistance in series. This indicates presence of only diffusion transport resistance at the electrode and absence of any non-electroneutral layer. The impedance spectra for cell with membrane can be modeled using a Warburg element and a CPE with capacitive character along with ohmic resistance in series. This indicates formation of a non-electroneutral (heterogeneous transport) layer at the membrane in addition to a diffusion transport layer. It was found that the ohmic resistance increased with increase in the concentration of iodine while the impedances due Warburg and heterogeneous transport layer decreased with increase in iodine concentration.     

Optimization of polytetrafluoroethylene content in cathode gas diffusion layer by the evaluation of compression effect on the performance of a proton exchange membrane fuel cell

This research investigates the optimal polytetrafluoroethylene (PTFE) content in the cathode gas diffusion layer (GDL) by evaluating the effect of compression on the performance of a proton exchange membrane (PEM) fuel cell. A special test fixture is designed to control the compression ratio, and thus the effect of compression on cell performance can be measured in situ. GDLs with and without a microporous layer (MPL) coating are considered. Electrochemical impedance spectroscopy (EIS) is used to diagnose the variations in ohmic resistance, charge transfer resistance and mass transport resistance with compression ratio. The results show that the optimal PTFE content, at which the maximum peak power density occurs, is about 5 wt% with a compression ratio of 30% for a GDL without an MPL coating. For a GDL with an MPL coating, the optimal PTFE content in the MPL is found to be 30% at a compression ratio of 30%.