An experimental and numerical investigation on the cross flow through gas diffusion layer in a PEM fuel cell with a serpentine flow channel

A serpentine flow channel is one of the most common and practical channel layouts for a polymer electrolyte membrane (PEM) fuel cell since it ensures the removal of water produced in a cell with acceptable parasitic load. During the reactant flows along the flow channel, it can also leak or cross to neighboring channel via the porous gas diffusion layer due to the high pressure gradient caused by the short distance. Such a cross flow leads to a larger effective flow area altering reactant flow in the flow channel so that the resultant pressure and flow distributions are substantially different from that without considering cross flow, even though this cross flow has largely been ignored in previous studies. In this work, a numerical and experimental study has been carried out to investigate the cross flow in a PEM fuel cell. Experimental measurements revealed that the pressure drop in a PEM fuel cell is significantly lower than that without cross flow. Three-dimensional numerical simulation has been performed for wide ranges of flow rate, permeability and thickness of gas diffusion layer to analyze the effects of those parameters on the resultant cross flow and the pressure drop of the reactant streams. Considerable amount of cross flow through gas diffusion layer has been found in flow simulation and its effect on pressure drop becomes more significant as the permeability and the thickness of gas diffusion layer are increased. The effects of this phenomenon are also crucial for effective water removal from the porous electrode structure and for estimating pumping energy requirement in a PEM fuel cell, it cannot be neglected for the analysis, simulation, design, operation and performance optimization of practical PEM fuel cells.     

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.     

An analytical analysis on the cross flow in a PEM fuel cell with serpentine flow channel

A serpentine flow channel can be considered as neighboring channels connected in series, and is one of the most common and practical channel layouts for polymer electrolyte membrane (PEM) fuel cells, as it ensures the removal of liquid water produced in a cell with good performance and acceptable parasitic load. During the reactant flows along the flow channel, it can also leak or cross directly to the neighboring channel via the porous gas diffusion layer (GDL) due to the high‐pressure gradient caused by the short distance. Such a cross flow leads to a larger effective flow area resulting in a substantially lower amount of pressure drop in an actual PEM fuel cell compared with the case without cross flow. In this study, an analytical solution is obtained for the cross flow in a PEM fuel cell with a serpentine flow channel based on the assumption that the velocity of cross flow is linearly distributed in the GDL between two successive U‐turns. The analytical solution predicts the amount of pressure drop and the average volume flow rate in the flow channel and the GDL. The solution is validated over a wide range of the thickness and permeability of the GDL by comparing the results with experimental measurements and 3‐D numerical simulations in literature. Excellent agreement is obtained for the permeability less than 10^?9 m², which covers the typical permeability values of the GDLs in actual PEM fuel cells. The solution presents an accurate and efficient estimation for cross flow providing a useful tool for the design and optimization of PEM fuel cells with serpentine flow channels. Copyright © 2010 John Wiley & Sons, Ltd.     

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.     

Study of novel flow channels influence on the performance of direct methanol fuel cell

The existing flow channels like parallel and gird channels have been modified for better fuel distribution in order to boost the performance of direct methanol fuel cell. The main objective of the work is to achieve minimized pressure drop in the flow channel, uniform distribution of methanol, reduced water accumulation, and better oxygen supply. A 3D mathematical model with serpentine channel is simulated for the cell temperature of 80 °C, 0.5 M methanol concentration. The study resulted in 40 mW/cm² of power density and 190 mA/cm² of current density at the operating voltage of 0.25 V. Further, the numerical study is carried out for modified flow channels to discuss their merits and demerits on anode and cathode side. The anode serpentine channel is unmatched by the modified zigzag and pin channels by ensuring the better methanol distribution under the ribs and increased the fuel consumption. But the cathode serpentine channel is lacking in water management. The modified channels at anode offered reduced pressure drop, still uniform reactant distribution is found impossible. The modified channels at cathode outperform the serpentine channel by reducing the effect of water accumulation, and uniform oxygen supply. So the serpentine channel is retained for methanol supply, and modified channel is chosen for cathode reactant supply. In comparison to cell with only serpentine channel, the serpentine anode channel combined with cathode zigzag and pin channel enhanced power density by 17.8% and 10.2% respectively. The results revealed that the zigzag and pin channel are very effective in mitigating water accumulation and ensuring better oxygen supply at the cathode.     

A flow channel design procedure for PEM fuel cells with effective water removal

Proper water management in polymer electrolyte membrane (PEM) fuel cells is critical to achieve the potential of PEM fuel cells. Membrane electrolyte requires full hydration in order to function as proton conductor, often achieved by fully humidifying the anode and cathode reactant gas streams. On the other hand, water is also produced in the cell due to electrochemical reaction. The combined effect is that liquid water forms in the cell structure and water flooding deteriorates the cell performance significantly. In the present study, a design procedure has been developed for flow channels on bipolar plates that can effectively remove water from the PEM fuel cells. The main design philosophy is based on the determination of an appropriate pressure drop along the flow channel so that all the liquid water in the cell is evaporated and removed from, or carried out of, the cell by the gas stream in the flow channel. At the same time, the gas stream in the flow channel is maintained fully saturated in order to prevent membrane electrolyte dehydration. Sample flow channels have been designed, manufactured and tested for five different cell sizes of 50, 100, 200, 300 and 441 cm². Similar cell performance has been measured for these five significantly different cell sizes, indicating that scaling of the PEM fuel cells is possible if liquid water flooding or membrane dehydration can be avoided during the cell operation. It is observed that no liquid water flows out of the cell at the anode and cathode channel exits for the present designed cells during the performance tests, and virtually no liquid water content in the cell structure has been measured by the neutron imaging technique. These measurements indicate that the present design procedure can provide flow channels that can effectively remove water in the PEM fuel cell structure.     

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.     

In-situ measurements of GDL effective permeability and under-land cross-flow in a PEM fuel cell

When reactant gases flow along a channel in serpentine flow field of a proton exchange membrane (PEM) fuel cell, there is a pressure difference between the adjacent channels and it produces an under-land cross-flow (or under-rib convection) from the higher pressure side to the lower pressure side through the gas diffusion layer (GDL). A unique experimental setup is developed for in-situ measurement of this cross-flow and the GDL effective permeability at the cathode side of a PEM fuel cell under dry and realistic humidified gas conditions. The non-Darcy effect, defined as a function of the Forchheimer number is studied and compared for both 1 mm and 2 mm land widths and both dry and humidified air conditions. Finally, a dimensional analysis is performed and the non-dimensional cross-flowrate is shown to increases linearly with the increase of the non-dimensional pressure difference.     

Novel serpentine-baffle flow field design for proton exchange membrane fuel cells

An appropriate flow field in the bipolar plates of a fuel cell can effectively enhance the reactant transport rates and liquid water removal efficiency, improving cell performance. This paper proposes a novel serpentine-baffle flow field (SBFF) design to improve the cell performance compared to that for a conventional serpentine flow field (SFF). A three-dimensional model is used to analyze the reactant and product transport and the electrochemical reactions in the cell. The results show that at high operating voltages, the conventional design and the baffled design have the same performance, because the electrochemical rate is low and only a small amount of oxygen is consumed, so the oxygen transport rates for both designs are sufficient to maintain the reaction rates. However, at low operating voltages, the baffled design shows better performance than the conventional design. Analyses of the local transport phenomena in the cell indicate that the baffled design induces larger pressure differences between adjacent flow channels over the entire electrode surface than does the conventional design, enhancing under-rib convection through the electrode porous layer. The under-rib convection increases the mass transport rates of the reactants and products to and from the catalyst layer and reduces the amount of liquid water trapped in the porous electrode. The baffled design increases the limiting current density and improves the cell performance relative to conventional design.     

Development of bipolar plates with different flow channel configurations for fuel cells

Bipolar plates include separate gas flow channels for anode and cathode electrodes of a fuel cell. These gases flow channels supply reactant gasses as well as remove products from the cathode side of the fuel cell. Fluid flow, heat and mass transport processes in these channels have significant effect on fuel cell performance, particularly to the mass transport losses. The design of the bipolar plates should minimize plate thickness for low volume and mass. Additionally, contact faces should provide a high degree of surface uniformity for low thermal and electrical contact resistances. Finally, the flow fields should provide for efficient heat and mass transport processes with reduced pressure drops. In this study, bipolar plates with different serpentine flow channel configurations are analyzed using computational fluid dynamics modeling. Flow characteristics including variation of pressure in the flow channel across the bipolar plate are presented. Pressure drop characteristics for different flow channel designs are compared. Results show that with increased number of parallel channels and smaller sizes, a more effective contact surface area along with decreased pressured drop can be achieved. Correlations of such entrance region coefficients will be useful for the PEM fuel cell simulation model to evaluate the affects of the bipolar plate design on mass transfer loss and hence on the total current and power density of the fuel cell.     

Experimental investigation on PEM fuel cell using serpentine with tapered flow channels

The performance comparison of various flow fields for practical application can be better understood when loading the cell at a lower voltage region for an operational duration of more than an hour. In this paper, the performance of serpentine and serpentine with tapered channels are compared by loading the Polymer Electrolyte Membrane (PEM) fuel cell at a constant voltage of 0.5 V for an operational duration of 5 h. Purging with nitrogen at the inlets is done to recover the drop in current over the period of operation and flush out water. The presence of tapered flow fields in a serpentine flow channel shows an improvement of 15% in the current obtained due to better reactant gas transport in the gas diffusion layer. The performance of both flow fields were studied with polarization and power density curve obtained after 5 h of testing. Further, to confirm the performance improvement at lower voltage region, impedance study is done and obtained Nyquist plot confirms the better transport phenomenon of reactant gases to catalyst site and better removal of water in Gas Diffusion Layer (GDL).     

Detailed analysis of polymer electrolyte membrane fuel cell with enhanced cross‐flow split serpentine flow field design

Most generally used flow channel designs in polymer electrolyte membrane fuel cells (PEMFCs) are serpentine flow designs as single channels or as multiple channels due to their advantages over parallel flow field designs. But these flow fields have inherent problems of high pressure drop, improper reactant distribution, and poor water management, especially near the U‐bends. The problem of inadequate water evacuation and improper reactant distribution become more severe and these designs become worse at higher current loads (low voltages). In the current work, a detailed performance study of enhanced cross‐flow split serpentine flow field (ECSSFF) design for PEMFC has been conducted using a three‐dimensional (3‐D) multiphase computational fluid dynamic (CFD) model. ECSSFF design is used for cathode part of the cell and parallel flow field on anode part of the cell. The performance of PEMFC with ECSSFF has been compared with the performance of triple serpentine flow design on cathode side by keeping all other parameters and anode side flow field design similar. The performance is evaluated in terms of their polarization curves. A parametric study is carried out by varying operating conditions, viz, cell temperature and inlet humidity on air and fuel side. The ECSSFF has shown superior performance over the triple serpentine design under all these conditions.     

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

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

Determination of the optimal active area for proton exchange membrane fuel cells with parallel,interdigitated or serpentine designs

Effects of active area size on steady-state characteristics of a working PEM fuel cell, including local current densities, local oxygen transport rates, and liquid water transport were studied by applying a three-dimensional, two-phase PEM fuel cell model. The PEM fuel cells were with parallel, interdigitated, and serpentine flow channel design. At high operating voltages, the size effects on cell performance are not noticeable owing to the occurrence of oxygen supply limit. The electrochemical reaction rates are high at low operating voltages, producing large quantity of water, whose removal capability is significantly affected by flow channel design. The cells with long parallel flow field experience easy water accumulation, thereby presenting low oxygen transport rate and low current density. The cells with interdigitated and serpentine flow fields generate forced convection stream to improve reactant transport and liquid water removal, thereby leading to enhanced cell performance and different size effect from the parallel flow cells. Increase in active area significantly improves performance for serpentine cells, but only has limited effect on that of interdigitated cells. Size effects of pressure drop over the PEM cells were also discussed.     

Liquid water transport in parallel serpentine channels with manifolds on cathode side of a PEM fuel cell stack

Water management in a proton exchange membrane (PEM) fuel cell stack has been a challenging issue on the road to commercialization. This paper presents a numerical investigation of air–water flow in parallel serpentine channels on cathode side of a PEM fuel cell stack by use of the commercial Computational Fluid Dynamics (CFD) software package FLUENT. Different air–water flow behaviours inside the serpentine flow channels with inlet and outlet manifolds were discussed. The results showed that there were significant variations of water distribution and pressure drop in different cells at different times. The “collecting-and-separating effect” due to the serpentine shape of the gas flow channels, the pressure drop change due to the water distribution inside the inlet and outlet manifolds were observed. Several gas flow problems of this type of parallel serpentine channels were identified and useful suggestions were given through investigating the flow patterns inside the channels and manifolds.     

Numerical evaluation of a PEM fuel cell with conventional flow fields adapted to tubular plates

In this research a 3D numerical study on a PEM fuel cell model with tubular plates is presented. The study is focused on the performance evaluation of three flow fields with cylindrical geometry (serpentine, interdigitated and straight channels) in a fuel cell. These designs are proposed not only with the aim to reduce the pressure losses that conventional designs exhibit with rectangular flow fields but also to improve the mass transport processes that take place in the fuel cell cathode. A commercial computational fluid dynamics (CFD) code was used to solve the numerical model. From the numerical solution of the fluid mechanics equations and the electrochemical model of Butler-Volmer different analysis of pressure losses, species concentration, current density, temperature and ionic conductivity were carried out. The results were obtained at the flow channels and the catalyst layers as well as in the gas diffusion layers and the membrane interfaces. Numerical results showed that cylindrical channel configurations reduced the pressure losses in the cell due to the gradual reduction of the angle at the flow path and the twist of the channel, thus facilitating the expulsion of liquid water from the gas diffusion layers and in turn promoting a high oxygen concentration at the triple phase boundary of the catalyst layers. Moreover, numerical results were compared to polarization curves and the literature data reported for similar designs. These results demonstrated that conventional flow field designs applied to conventional tubular plates have some advantages over the rectangular designs, such as uniform pressure and current density distributions among others, therefore they could be considered for fuel cell designs in portable applications.     

Experimental study on the two phase flow behavior in PEM fuel cell parallel channels with porous media inserts

In this study, the air–water two phase flow behavior in PEM fuel cell parallel channels with porous media inserts was experimentally investigated using a self-designed and manufactured transparent assembly. The visualization images of the two phase flow in channels with porous media inserts were presented and three patterns were summarized. Compared with the traditional hollow channel design, the novel configuration featured less severe two phase flow mal-distribution and self-adjustment to water amount in channels, although a higher pressure drop was introduced due to the porous media inserts. The dominant frequency of pressure drop signal was found to be a diagnostic tool for water behavior in channels. The novel flow channel design with porous media inserts may become a solution to the water management problem in PEM fuel cells.     

Computational model of a PEM fuel cell with serpentine gas flow channels

A three-dimensional computational fluid dynamics model of a PEM fuel cell with serpentine flow field channels is presented in this paper. This comprehensive model accounts for the major transport phenomena in a PEM fuel cell: convective and diffusive heat and mass transfer, electrode kinetics, and potential fields. A unique feature of the model is the implementation of a voltage-to-current (VTC) algorithm that solves for the potential fields and allows for the computation of the local activation overpotential. The coupling of the local activation overpotential distribution and reactant concentration makes it possible to predict the local current density distribution more accurately. The simulation results reveal current distribution patterns that are significantly different from those obtained in studies assuming constant surface overpotential. Whereas the predicted distributions at high load show current density maxima under the gas channel area, low load simulations exhibit local current maxima under the collector plate land areas.     

Innovative cathode flow-field design for passive air-cooled polymer electrolyte membrane (PEM) fuel cell stacks

A novel cathode flow-field design suitable for a passive air-cooled polymer electrolyte membrane (PEM) fuel cell stack is proposed to enhance the water-retaining capability under excess dry air supply conditions. The innovative cathode flow-field is designed to supply more air to the cooling channels and further enables deceleration of the reactant air in the gas channels and acceleration of the coolant air in the cooling channels simultaneously along the air flow path. Therefore, the design facilitates the waste heat removal through the cooling channels while the water removal by the reactant air is minimized. The conceptual cathode flow-field design is validated using a three-dimensional PEM fuel cell model. The detailed simulation results clearly demonstrate that the new cathode flow-field design exhibits superior water-retaining capability compared with a conventional cathode flow-field design (parallel flow channel configuration) under typical air-cooled fuel cell operating conditions. This study provides a new strategy to design cathode flow-fields to alleviate notorious membrane dehydration and unstable performance issues in a passive air-cooled PEM fuel cell stack.     

In situ investigation of water transport in an operating PEM fuel cell using neutron radiography: Part 2 – Transient water accumulation in an interdigitated cathode flow field

An interdigitated cathode flow field has been tested in situ with neutron radiography to measure the water transport through the porous gas diffusion layer in a PEM fuel cell. Constant current density to open circuit cycles were tested and the resulting liquid water accumulation and dissipation rates with in-plane water distributions are correlated to measured pressure differential between inlet and outlet gas streams. The effect of varying the reactant gas relative humidity on liquid water accumulation is also demonstrated. These results provide evidence that the reactant gas establishes a consistent in-plane transport path through the diffusion layer, leaving stagnant regions where liquid water accumulates. A simplified permeability model is presented and used to correlate the relative permeability to varying gas diffusion layer liquid water saturation levels.