Measurement of the water transport rate in a proton exchange membrane fuel cell and the influence of the gas diffusion layer

Water management in a PEM fuel cell significantly affects the fuel cell performance and durability. The gas diffusion layer (GDL) of a PEM fuel cell plays a critical role in the water management process. In this short communication, we report a simple method to measure the water transport rate across the GDL. Water rejection rates across a GDL at different cathode air-flow rates were measured. Based on the measurement results, the fuel cell operating conditions, such as current density, temperature, air stoichiometry and relative humidity, corresponding to membrane drying and flooding conditions were identified for the particular GDL used. This method can help researchers develop GDLs for a particular fuel cell design with specific operating conditions and optimize the operation conditions for the given PEM fuel cell components.     

The effect of operating parameters on water transport in PEM fuel cells

Water content in the membrane and the presence of liquid water in the catalyst layers (CL) and the gas diffusion layers (GDL) play a very important role in the performance of a PEM fuel cell. To study water transport in a PEM fuel cell, a two‐phase flow mathematical model is developed. This model couples the continuity equation, momentum conservative equation, species conservative equation, and water transport equation in the membrane. The modeling results of fuel cell performances agree well with measured experimental results. Then this model is used to simulate water transport and current density distribution in the cathode of a PEM fuel cell. The effects of operating pressure, cell temperature, and humidification temperatures on the net water transfer through the membrane, liquid water saturation, and current density distribution are studied. © 2006 Wiley Periodicals, Inc. Heat Trans Asian Res, 35(2): 89–100, 2006; Published online in Wiley InterScience ( www.interscience. wiley.com ). DOI 10.1002/htj.20107     

Characterization of flooding and two-phase flow in polymer electrolyte membrane fuel cell stacks

A partially flooded gas diffusion layer (GDL) model is proposed and solved simultaneously with a stack flow network model to estimate the operating conditions under which water flooding could be initiated in a polymer electrolyte membrane (PEM) fuel cell stack. The models were applied to the cathode side of a stack, which is more sensitive to the inception of GDL flooding and/or flow channel two-phase flow. The model can predict the stack performance in terms of pressure, species concentrations, GDL flooding and quality distributions in the flow fields as well as the geometrical specifications of the PEM fuel cell stack. The simulation results have revealed that under certain operating conditions, the GDL is fully flooded and the quality is lower than one for parts of the stack flow fields. Effects of current density, operating pressure, and level of inlet humidity on flooding are investigated.     

Experimental investigation of liquid water formation and transport in a transparent single-serpentine PEM fuel cell

Liquid water formation and transport were investigated by direct experimental visualization in an operational transparent single-serpentine PEM fuel cell. We examined the effectiveness of various gas diffusion layer (GDL) materials in removing water away from the cathode and through the flow field over a range of operating conditions. Complete polarization curves as well as time evolution studies after step changes in current draw were obtained with simultaneous liquid water visualization within the transparent cell. The level of cathode flow field flooding, under the same operating conditions and cell current, was recognized as a criterion for the water removal capacity of the GDL materials. When compared at the same current density (i.e. water production rate), higher amount of liquid water in the cathode channel indicated that water had been efficiently removed from the catalyst layer.

Visualization of the anode channel was used to investigate the influence of the microporous layer (MPL) on water transport. No liquid water was observed in the anode flow field unless cathode GDLs had an MPL. MPL on the cathode side creates a pressure barrier for water produced at the catalyst layer. Water is pushed across the membrane to the anode side, resulting in anode flow field flooding close to the H₂ exit.     

Effects of electrode wettabilities on liquid water behaviours in PEM fuel cell cathode

Liquid water transport is one of the key challenges for water management in a proton exchange membrane (PEM) fuel cell. Investigation of the air–water flow patterns inside fuel cell gas flow channels with gas diffusion layer (GDL) would provide valuable information that could be used in fuel cell design and optimization. This paper presents numerical investigations of air–water flow across an innovative GDL with catalyst layer and serpentine channel on PEM fuel cell cathode by use of a commercial Computational Fluid Dynamics (CFD) software package FLUENT. Different static contact angles (hydrophilic or hydrophobic) were applied to the electrode (GDL and catalyst layer). The results showed that different wettabilities of cathode electrode could affect liquid water flow patterns significantly, thus influencing on the performance of PEM fuel cells. The detailed flow patterns of liquid water were shown, several gas flow problems were observed, and some useful suggestions were given through investigating the flow patterns.     

Numerical studies of liquid water behaviors in PEM fuel cell cathode considering transport across different porous layers

In this paper, a two-phase two-dimensional PEM fuel cell model, which is capable of handling liquid water transport across different porous materials, is employed for parametric studies of liquid water transport and distribution in the cathode of a PEM fuel cell. Attention is paid particularly to the coupled effects of two-phase flow and heat transfer phenomena. The effects of key operation parameters, including the outside cell boundary temperature, the cathode gas humidification condition, and the cell operation current, on the liquid water behaviors and cell performance have been examined in detail. Numerical results elucidate that increasing the fuel cell temperature would not only enhance liquid water evaporation and thus decrease the liquid saturation inside the PEM fuel cell cathode, but also change the location where liquid water is condensed or evaporated. At a cell boundary temperature of 80 °C, liquid water inside the catalyst layer and gas diffusion media under the current-collecting land would flow laterally towards the gas channel and become evaporated along an interface separating the land and channel. As the cell boundary temperature increases, the maximum current density inside the membrane would shift laterally towards the current-collecting land, a phenomenon dictated by membrane hydration. Increasing the gas humidification condition in the cathode gas channel and/or increasing the operating current of the fuel cell could offset the temperature effect on liquid water transport and distribution.     

Three‐dimensional optimisation of a fuel gas channel of a proton exchange membrane fuel cell for maximum current density

Proton exchange membrane (PEM) fuel cells operated with hydrogen and air offer promising alternative to conventional fossil fuel sources for transport and stationary applications because of its high efficiency, low‐temperature operation, high power density, fast start‐up and potable power for mobile application. Power levels derivable from this class of fuel cell depend on the operating parameters. In this study, a three‐dimensional numerical optimisation of the effect of operating and design parameters of PEM fuel cell performance was developed. The model computational domain includes an anode flow channel, membrane electrode assembly and a cathode flow channel. The continuity, momentum, energy and species conservation equations describing the flow and species transport of the gas mixture in the coupled gas channels and the electrodes were numerically solved using a computational fluid dynamics code. The effects of several key parameters, including channel geometries (width and depth), flow orientation and gas diffusion layer (GDL) porosity on performance and species distribution in a typical fuel cell system have been studied. Numerical results of the effect of flow rate and GDL porosity on the flow channel optimal configurations for PEM fuel cell are reported. Simulations were carried out ranging from 0.6 to 1.6 mm for channel width, 0.5 to 3.0 mm for channel depth and 0.1 to 0.7 for the GDL porosity. Results were evaluated at 0.3 V operating cell voltage of the PEM fuel cell. The optimisation results show that the optimum dimension values for channel depth and channel width are 2.0 and 1.2 mm, respectively. In addition, the results indicate that effective design of fuel gas channel in combination with the reactant species flow rate and GDL porosity enhances the performance of the fuel cell. The numerical results computed agree well with experimental data in the literature. Consequently, the results obtained provide useful information for improving the design of fuel cells. Copyright © 2011 John Wiley & Sons, Ltd.     

Liquid water transport between graphite paper and a solid surface

We studied the interaction of a water droplet with a solid wall on a hydrophobic gas diffusion layer (GDL). Of particular interest is the stability of the droplet as a function of plate wetting properties and the potential for liquid entrapment in the GDL/land contact area. Such transport is of relevance to breakthrough dynamics and convective liquid droplet transport in polymer electrolyte membrane (PEM) fuel cell cathode gas channels. While a variety of complex coupled transport phenomena are present in the PEM fuel cell gas channel, we utilize a very simplified experimental model of the system where a droplet originally placed on a hydrophobic GDL is translated quasistatically across the GDL surface by a solid surface. Transport and entrapment are imaged using fluorescence microscopy. This work provides new insights into droplet behaviour at the GDL/land interface in a PEM fuel cell and suggests that hydrophobic land areas are preferable for mitigating the accumulation of liquid water under the land area of the gas flow channels.     

Measurement of liquid water content in cathode gas diffusion electrode of polymer electrolyte fuel cell

Water management in cathode gas diffusion electrode (GDE) of polymer electrolyte fuel cell (PEFC) is essential for high performance operation, because liquid water condensed in porous gas diffusion layer (GDL) and catalyst layer (CL) blocks oxygen transport to active reaction sites. In this study, the average liquid water content inside the cathode GDE of a low-temperature PEFC is experimentally and quantitatively estimated by the weight measurement, and the relationship between the water accumulation rate in the cathode GDE and the cell voltage is investigated. The liquid water behavior at the cathode is also visualized using an optical diagnostic, and the effects of operating conditions and GDL structures on the water transport in the cathode GDE are discussed. It is found that the liquid water content in the cathode GDE increases remarkably after starting the fuel cell operation due to the water production at the CL. At a high current density, the cell voltage drops suddenly after starting the operation in spite of a low water content in the cathode GDE. When the GDL thickness is increased, much water accumulates near the cathode CL and the fuel cell shuts down immediately after the operation. In the final section of this paper, the structure of cathode GDL that has several grooves for water removal is proposed to prevent water flooding and improve fuel cell performance. This groove structure is effective to promote the removal of the liquid water accumulated near the active catalyst sites.     

Experimental study on mitigating the cathode flooding at low temperature by adding hydrogen to the cathode reactant gas in PEM fuel cell

Severe flooding can be critical in a fuel cell vehicle operating at a high current density, and in a fuel cell vehicle at the initial stage of start up. It is often difficult to remove the condensed water from the cathode gas diffusion layer (GDL) of the fuel cell because of the surface tension between the water and the GDL. In this research, in order to remove the condensed water from the cathode GDL, a small amount of hydrogen was injected into the cathode reactant gases. The results showed that the hydrogen addition method successfully removed the liquid water from the cathode GDL. Water removal was verified for various hydrogen flow rates and hydrogen addition durations. Furthermore, the dew point temperature of the outlet gas at the cathode was observed to determine the amount of water removed from the cathode GDL. In addition, the water droplet in the cathode gas flow channel was visualized by using a transparent cell. Furthermore, degradation tests are also performed. Considering the degradation test, the hydrogen addition method is expected to be effective in mitigating cathode flooding.     

Humidity of reactant fuel on the cell performance of PEM fuel cell with baffle-blocked flow field designs

The objective of this work is to examine the effects of humidity of reactant fuel at the inlet on the detailed gas transport and cell performance of the PEM fuel cell with baffle-blocked flow field designs. It is expected that, due to the water management problem, the effects of inlet humidity of reactant fuel gases on both anode and cathode sides on the cell performance are considerable. In addition, the effects of baffle numbers on the detailed transport phenomena of the PEM fuel cell with baffle-blocked flow field are examined. Due to the blockage effects in the presence of the baffles, more fuel gas in the flow channel can be forced into the gas diffuser layer (GDL) and catalyst layer (CL) to enhance the chemical reactions and then augment the performance of the PEMFC systems. Effect of liquid water formation on the reactant gas transport is taken into account in the numerical modeling. Predictions show that the local transport of the reactant gas, the local current density generation and the cell performance can be enhanced by the presence of the baffles. Physical interpretation for the difference in the inlet relative humidity (RH) effects at high and low operating voltages is presented. Results reveal that, at low voltage conditions, the liquid water effect is especially significant and should be considered in the modeling. The cell performance can be enhanced at a higher inlet relative humidity, by which the occurrence of the mass transport loss can be delayed with the limiting current density raised considerably.     

Anode water removal and cathode gas diffusion layer flooding in a proton exchange membrane fuel cell

Anode water removal (AWR) is studied as a diagnostic tool to assess cathode gas diffusion layer (GDL) flooding in PEM fuel cells. This method uses a dry hydrogen stream to remove product water from the cathode, showing ideal fuel cell performance in the absence of GDL mass transfer limitations related to water. When cathode GDL flooding is limiting, the cell voltage increases as the hydrogen stoichiometry is increased. Several cathode GDLs were studied to determine the effect of microporous layer (MPL) and PTFE coating. The largest voltage gains occur with the use of cathode GDLs without an MPL since these GDLs are prone to higher liquid water saturation. Multiple GDLs are studied on the cathode side to exacerbate GDL flooding conditions to further confirm the mechanism of the AWR process. Increased temperature and lower cathode RH allow for greater overall water removal so the voltage improvement occurs faster, though this leads to quicker membrane dehydration.     

Performance and liquid water distribution in PEFCs with different anisotropic fiber directions of the GDL

To maintain the efficiency of proton exchange membrane fuel cells (PEFCs) without flooding, it is necessary to control the liquid water transport in the gas diffusion layer (GDL). This experimental study investigates the effects of the GDL fiber direction on the cell performance using an anisotropic GDL. The results of the experiments show that the efficiency of the cell is better when the fiber direction is perpendicular to the channel direction, and that the cells with perpendicular fibers are more tolerant to flooding than cells with fibers parallel to the channel direction. To determine the mechanism of the fiber direction effects, the liquid water behavior in the channels was observed through a glass window on the cathode side. The observations substantiate that the liquid water produced under the ribs is removed more smoothly with the perpendicular fiber direction. Additionally, the water inside the GDL was frozen to observe its distribution using a specially made cell broken into two pieces. The photographic results show that the amount of water under the ribs is larger than that under the channels using the parallel fiber direction GDL while the water distributions in these two places are almost equal level with the perpendicular fiber direction GDL. This freezing method confirmed the better liquid water removal ability and better reactant gas transportation in the GDL with the fiber direction perpendicular to the channel direction.     

Impact of channel geometry on two-phase flow in fuel cell microchannels

An important function of the gas delivery channels in PEM fuel cells is the evacuation of water at the cathode. The resulting two-phase flow impedes reactant transport and causes parasitic losses. There is a need for research on two-phase flow in channels in which the phase fraction varies along the flow direction as in operating fuel cells. This work studies two-phase flow in 60 cm long channels with distributed water injection through a porous GDL wall to examine the physics of flows relevant to fuel cells. Flow regime maps based on local gas and liquid flow rates are constructed for experimental conditions corresponding to current densities between 0.5 and 2 A cm⁻² and stoichiometric coefficients from 1 to 4. Flow structures transition along the length of the channel. Stratified flow occurs at high liquid flow rates, while intermittent slug flow occurs at low liquid flow rates. The prevalence of stratified flow in these serpentine channels is discussed in relation to water removal mechanisms in the cathode channels of PEM fuel cells. Corners facilitate formation of liquid films in the channel, but may reduce the water-evacuation capability. This analysis informs design guidelines for gas delivery microchannels for fuel cells.     

A comprehensive,consistent and systematic mathematical model of PEM fuel cells

This paper presents a comprehensive, consistent and systematic mathematical model for PEM fuel cells that can be used as the general formulation for the simulation and analysis of PEM fuel cells. As an illustration, the model is applied to an isothermal, steady state, two-dimensional PEM fuel cell. Water is assumed to be in either the gas phase or as a liquid phase in the pores of the polymer electrolyte. The model includes the transport of gas in the gas flow channels, electrode backing and catalyst layers; the transport of water and hydronium in the polymer electrolyte of the catalyst and polymer electrolyte layers; and the transport of electrical current in the solid phase. Water and ion transport in the polymer electrolyte was modeled using the generalized Stefan–Maxwell equations, based on non-equilibrium thermodynamics. Model simulations show that the bulk, convective gas velocity facilitates hydrogen transport from the gas flow channels to the anode catalyst layers, but inhibits oxygen transport. While some of the water required by the anode is supplied by the water produced in the cathode, the majority of water must be supplied by the anode gas phase, making operation with fully humidified reactants necessary. The length of the gas flow channel has a significant effect on the current production of the PEM fuel cell, with a longer channel length having a lower performance relative to a shorter channel length. This lower performance is caused by a greater variation in water content within the longer channel length.     

Liquid water visualization in PEM fuel cells: A review

Over the past few years, the importance of water management to the successful operation of polymer electrolyte membrane (PEM) fuel cells has stimulated an extensive research focus on liquid water transport and its effect on performance and durability. Empirical methods employed to investigate water transport in the fuel cell have the potential to provide useful feedback for developing empirical correlations and validating numerical models for fuel cell research and development. In this paper, a literature review is provided for the experimental techniques that have been applied to visualize liquid water in operating hydrogen PEM fuel cells and flow fields. The main hypotheses that have been proposed to describe liquid water transport in the gas diffusion layer (GDL) and current challenges will also be discussed.     

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.     

Numerical investigation of liquid water distribution in the cathode side of proton exchange membrane fuel cell and its effects on cell performance

A three-dimensional unsteady two-phase model for the cathode side of proton exchange membrane fuel cell (PEMFC) consisting of gas diffusion layer (GDL) with hybrid structural model is developed to investigate liquid water behaviors under different operating and geometrical conditions and to quantitatively evaluate effects of liquid water distribution on reactant transport and current density distribution. Simulation results reveal that liquid water transport processes and distributions are significantly affected by inlet air velocity, wall wettability and water inlet position, which in turn play a prominent role on local reactant transport and cause considerable disturbances of the current density. Liquid water film spreading on the gas channel (GC) top wall is identified as the most desirable flow pattern in the GC based on overall evaluations of current density magnitude, uniformity of current density distribution and pressure drop in the GC. Modification to GDL structure is proposed to promote the formation of the desirable flow pattern.     

Effect of capillary pressure on liquid water removal in the cathode gas diffusion layer of a polymer electrolyte fuel cell

In order to investigate the effect of capillary pressure on the transport of liquid water in the cathode gas diffusion layer (GDL) of a polymer electrolyte fuel cell, a one-dimensional steady-state mathematical model was developed, including the effect of temperature on the capillary pressure. Numerical results indicate that the liquid water saturation significantly increases with increases in the operating temperature of the fuel cell. An elevated operating temperature has an undesirable influence on the removal of liquid water inside the GDL. A reported peculiar phenomenon in which the flooding of the fuel cell under a high operating temperature and an over-saturated environment is more serious in a GDL combined with a micro-porous layer (MPL) than in a GDL without an MPL [Lim and Wang, Electrochim. Acta 49 (2004), 4149–4156] is explained based on the present analysis.     

A hybrid model of cathode of PEM fuel cell using the interdigitated gas distributor

A two-dimensional (2D), single- and two-phase, hybrid multi-component transport model is developed for the cathode of PEM fuel cell using interdigitated gas distributor. The continuity equation and Darcy's law are used to describe the flow of the reactant gas and production water. The production water is treated as vapor when the current density is small, and as two-phase while the current density is greater than the critical current density. The advection–diffusion equations are utilized to study species transport of multi-component mixture gas. The Butler–Volmer equation is prescribed for the domain in the catalyst layer. The predicted results of the hybrid model agree well with the available experimental data. The model is used to investigate the effects of operating conditions and the cathode structure parameters on the performance of the PEM fuel cell. It is observed that liquid water appears originally in the cathodic catalyst layer over outlet channel under intermediate current and tends to be distributed uniformly by the capillary force with the increase of the current. It is found that reduction of the width of outlet channel can enhance the performance of PEM fuel cell via the increase of the current density over this region, which has, seemingly, not been discussed in previous literatures.