Performance prediction of plate-fin radiator for low temperature preheating system of proton exchange membrane fuel cells using CFD simulation

The objective of this paper is to analyze the heat transfer characteristics of plate-fin radiator for the cold air heating system of a PEMFC engine and to find the optimal parameter combination in order to reduce the power consumption. The effect of the coolant mass flow and temperature on the heat exchange performance of the radiator was investigated based on 3D porous medium model. The results, including the amount of heat transferred and temperature change and heat exchanger effectivity with the increasing of the air flow rate at different coolant flow rate were obtained using CFD method. Good agreement is found by comparing the simulation values with the test data and the deviation is less than 7% which indicate simulation model validation and research method feasibility used in this study. The simulation results indicate that bigger coolant flow rate and temperature result in higher outlet air temperature and the amount of heat transferred. The variation of the heat exchanger effectivity is predicted for different working conditions. Based on the Taguchi method, the influence of structural parameters of the corrugated fins on the heat transfer and pressure drop of the radiator is analyzed qualitatively. It is shown that fin length has the greatest impact on the comprehensive heat transfer performance of the radiator. This research provides a guide for optimizing the air preheating system and improving the amount of heat transferred.     

Performance improvement of air-breathing proton exchange membrane fuel cell stacks by thermal management

Air-breathing is known as a way to reduce the weight, volume, and the cost of PEMFCs. In this study, the thermal management of the high-powered air-breathing PEMFC stacks by applying different cathode flow channel configurations is carried out to improve the stack performance. In order to verify the thermal management results, numerical simulation is also performed. The research results show that a combination of the 50% and 58.3% opening ratios in the air-breathing stack reduces the stack temperature and enhances the temperature distribution uniformity, leading to a better and more stable stack performance. In addition, it is found that the stack performance is significantly improved under the assisted-air-breathing condition. Moreover, the simulation results and the experimental data are basically consistent. It is suggested to adopt the average temperature over the cross-sectional flow region from simulation as fitting the simulation results and the measured data.     

Improvement of thermal management of proton exchange membrane fuel cell stack used for portable devices by integrating the ultrathin vapor chamber

UVC (ultrathin vapor chamber) simultaneously has a high heat-conducting property, excellent temperature uniformity and simple structure. These advantages are very suitable for thermal management of the open-cathode PEMFC (proton exchange membrane fuel cell) stack. In this work, two-type UVCs with different appearances are integrated into a conventional PEMFC stack respectively. The effect of UVC on the output performance, thermal management and operating stability is investigated by the experiment combined with simulation. The results show that UVC can significantly increase the output voltage under high current density. In 35 A, the output voltage of the stack integrated the vertical UVC increases by 20.25% relative to the conventional stack. Thermal management is also improved by UVC. The highest temperature inside the stack decrease by 9 °C in 35 A, and the membrane temperature is decreased obviously. But it still exceeds the optimal operating temperature of open-cathode PEMFC stack due to the poor cooling type in the condensation side of UVC. UVC improves the operation stability of the stack and slows the deteriorative speed of output performance. This work hopes to attract more attention to the application of UVC on the thermal management of portable power sources used open-cathode PEMFC stack.     

Measurements of serpentine channel flow characteristics for a proton exchange membrane fuel cell

Flow characteristics at Re = 660–3000 in a serpentine channel are measured. A scale-up model whose channel hydraulic diameter is 50 times as large as that for a proton exchange membrane fuel cell (PEMFC) is used for the measurements. The flow conditions correspond to operating conditions for PEMFCs of 25–40 cm² at current density of 1–3 A/cm² when the fuel utilisation ratio is 0.75 and air is used for the O₂ supply. Two different porous media are used to simulate the gas diffusion layer (GDL). The results suggest that although the leakage flow rate is rather insensitive to the total flow rate, it increases significantly depending on the increase of the GDL permeability. Increasing the flow rate or the permeability enhances the sectional secondary flows and is expected to enhance mass transfer on the GDL. It is confirmed that the flow becomes turbulent around the bend even at Re = 660.     

Numerical simulation of two-phase flow in a multi-gas channel of a proton exchange membrane fuel cell

Understanding the two-phase distribution characteristics within the multi-gas channel of a fuel cell is important for improving fuel cell performance. In the paper, the volume of fluid model is used to predict the dynamic behaviour of water in the multi-gas channel, analyze the pressure drop, velocity distribution, and flow resistance coefficient between different channels, and investigate the influence of operating conditions, surface wettability and channel structure on the two-phase distribution characteristics in the channel. The results show that water undergoes the processes of growth, separation, single droplet transport, wall impact, droplet collision, liquid film formation, and liquid film transport in the multi-gas channel. Inlet velocity and surface wettability significantly affect the pressure drop, water saturation, and surface water coverage. As the inlet velocity and gas diffusion layer surface wettability increase, the flow resistance coefficient and unevenness of the distribution decrease, indicating that the in-channel flow distribution homogeneity is enhanced. The rectangular channel has better water removal and flow distribution uniformity than the tapered channel, and the unevenness of distribution decreases significantly with decreasing rectangular width, from 0.15715 to 0.00315. The research work is a guide to understanding water transport in multi-gas channels, accelerating water removal, and improving inter-channel flow distribution uniformity.     

Dynamic modeling and adaptive control of voltage in proton exchange membrane fuel cell using water management

Maintaining a constant voltage in polymer electrolyte membrane fuel cells (PEMFCs) has always attracted the attention of many researchers, and many articles have been published on this issue. Furthermore, water management in PEMFC has become an important challenge because it can improve cell efficiency and lifetime. This paper will develop a one‐dimensional dynamic model for a single PEMFC, which correlates changes in the cell voltage to changes in the cell current density and humidification rate. Subsequently, a recurrent neural network controller based on the approximation of nonlinear autoregressive moving average model is proposed. The controller manipulates the anode and the cathode water mole fractions in order to fix cell voltage and preserve cell water content within a satisfactory interval regardless of the varying cell current. The model and the controller are simulated in matlab /Simulink (Mathworks Inc., Natick, MA) software, and the results are compared with a PID controller from different viewpoints such as current disturbance and plant parameter variation. Copyright © 2011 John Wiley & Sons, Ltd.     

Improvement of proton exchange membrane fuel cell overall efficiency by integrating heat-to-electricity conversion

Proton exchange membrane fuel cells (PEMFCs) have shown to be well suited for distributed power generation due to their excellent performance. However, a PEMFC produces a considerable amount of heat in the process of electrochemical reaction. It is desirable to use thermal energy for electricity generation in addition to heating applications. Based on the operating characteristics of a PEMFC, an advanced thermal energy conversion system using “ocean thermal energy conversion” (OTEC) technology is applied to exploit the thermal energy of the PEMFC for electricity generation. Through this combination of technology, this unique PEMFC power plant not only achieves the combined heat and power efficiency, but also adequately utilizes heat to generate more valuable electricity. Exergy analysis illustrates the improvement of overall efficiency and energy flow distribution in the power plant. Analytical results show that the overall efficiency of the PEMFC is increased by 0.4-2.3% due to the thermal energy conversion (TEC) system. It is also evident that the PEMFC should operate within the optimal load range by balancing the design parameters of the PEMFC and of the TEC system.     

Experimental investigation of the thermal response of open-cathode proton exchange membrane fuel cell stack

The aim of this study is to investigate the thermal response characteristics of the proton exchange membrane fuel cell stack. In order to find out the regularities of temperature variation under rapidly increasing load change, a home-made 500 W open-cathode stack embedded with 30 thermocouples was made and tested. The result shows that the local temperature dominates the thermal response at the initial stage while the membrane hydration is the crucial impact factor at low power stage. Further, the anode flooding strongly affects the stability of the output performance and the change of temperature at the overloaded stage. The maximum temperature difference within one cell can reach a steady state faster than that of the temperature. At normal operation, there is little difference between the defined surfaces. The exergy analysis shows that the reaction air will have higher exergy if the temperature variation is more smooth. This experimental study contributes to the optimization of the cooling strategy and thermal management of the open-cathode stack in application.     

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]     

Characteristic simulation and numerical investigation of membrane electrode assembly in proton exchange membrane fuel cell

This study analyzes the characteristic numerical analysis of membrane electrode assembly in Proton Exchange Membrane Fuel Cell (PEMFC) with bipolar plate, flow channel, gas diffusion electrode, and proton exchange membrane. The numerical solution focuses on discussing the effects of different parameters, including permeability, porosity, and operation voltage, on various mass fractions, current-voltage curve, and power-voltage curve.The results show that as the porous medium with high gas permeability is an important factor that affects the mass fraction of hydrogen. Regarding the analyses of various porosities, the fuel cell performance can be effectively promoted with larger ratio of porosity and permeability. However, increasing the porosity will affect the electrical conductivity and increase the flooding of water, which will block the flow channel and reduce efficiency.     

Model-based decoupling control for the thermal management system of proton exchange membrane fuel cells

As one of the most promising sustainable energy technologies available today, proton exchange membrane fuel cell (PEMFC) engines are becoming more and more popular in various applications, especially in transportation vehicles. However, the complexity and the severity of the vehicle operating conditions present challenges to control the temperature distribution in single cells and stack, which is an important factor influencing the performance and durability of PEMFC engines. It has been found that regulating the input and output coolant water temperature can improve the temperature distribution. Therefore, the control objective in this paper is regulating the input and output temperature of coolant water at the same time. Firstly, a coupled model of the thermal management system is established based on the physical structure of PEMFC engines. Then, in order to realize the simultaneous control of the inlet and outlet cooling water temperature of the PEMFC stack, a decoupling controller is proposed and its closed-loop stability is proved. Finally, based on the actual PEMFC engine platform, the effectiveness, accuracy and reliability of the proposed decoupling controller are tested. The experimental results show that with the proposed decoupling controller, the inlet and outlet temperatures of the PEMFC stack cooling water can be accurately controlled on-line. The temperature error range is less than 0.2 °C even under the dynamic current load conditions.     

Sliding-mode-based temperature regulation of a proton exchange membrane fuel cell test bench

The temperature regulation of a cooling system of a PEMFC (Proton Exchange Membrane Fuel Cell) test bench is studied in this paper. Because of the unique configuration which is dedicated for cold start experiments, the operation at nominal temperature is unstable with a simple PI controller. A sliding-based control strategy is applied to suppress the temperature fluctuation. Firstly the structure of the cooling system is demonstrated and the cause of temperature fluctuation is analyzed. Then, a physics-based model of the cooling system is proposed on the Matlab/Simulink platform and validated with experimental data. Based on the model, a Sliding-mode controller with Extended Kalman Filter (EKF) is designed to regulate the temperature. The simulation results showed that the controlled system performed satisfactorily. Furthermore, when applied to the real system, the controller's real-time performance fulfills the test bench criterion. Experimental data show that the coolant temperature at the outlet of the fuel cell stack is kept in a range within ±1 °C, disregarding the heat generated at various working condition.     

Performance of a proton exchange membrane fuel cell stack with thermally conductive pyrolytic graphite sheets for thermal management

This work experimentally investigates the effects of the pyrolytic graphite sheets (PGS) on the performance and thermal management of a proton exchange membrane fuel cell (PEMFC) stack. These PGS with the features of light weight and high thermal conductivity serve as heat spreaders in the fuel cell stack for the first time to reduce the volume and weight of cooling systems, and homogenizes the temperature in the reaction areas. A PEMFC stack with an active area of 100 cm² and 10 cells in series is constructed and used in this research. Five PGS of thickness 0.1 mm are cut into the shape of flow channels and bound to the central five cathode gas channel plates. Four thermocouples are embedded on the cathode gas channel plates to estimate the temperature variation in the stack. It is shown that the maximum power of the stack increase more than 15% with PGS attached. PGS improve the stack performance and alleviate the flooding problem at low cathode flow rates significantly. Results of this study demonstrate the feasibility of application of PGS to the thermal management of a small-to-medium-sized fuel cell stack.     

PEMFC系统引射器设计及仿真研究

针对燃料电池汽车的运行特点,对氢气循环引射器进行了结构设计,利用Fluent软件对所设计的引射器进行了全工况模拟,确定了对引射器效率影响较大的变量。通过改变工作流体流量,并经过多次模拟后发现,为了使氢气引射器在怠速工况下不失效,引射器前端工作流体压力p_p要≥1.05 MPa。分析了工作流体质量流量G_p、喷嘴喉部直径d_(p*)和工作流体压力p_p对引射性能的影响,发现G_p对引射器的引射性能影响最大,并给出了G_p的取值范围。研究建议引射器设计时G_p在0.21~0.23 g·s~(-1)范围内最佳。     

Parallel serpentine-baffle flow field design for water management in a proton exchange membrane fuel cell

In a proton exchange membrane fuel cell (PEMFC) water management is one of the critical issues to be addressed. Although the membrane requires humidification for high proton conductivity, water in excess decreases the cell performance by flooding. In this paper an improved strategy for water management in a fuel cell operating with low water content is proposed using a parallel serpentine-baffle flow field plate (PSBFFP) design compared to the parallel serpentine flow field plate (PSFFP). The water management in a fuel cell is closely connected to the temperature control in the fuel cell and gases humidifier. The PSBFFP and the PSFFP were evaluated comparatively under three different humidity conditions and their influence on the PEMFC prototype performance was monitored by determining the current density–voltage and current density–power curves. Under low humidification conditions the PEMFC prototype presented better performance when fitted with the PSBFFP since it retains water in the flow field channels.     

Design of an integrated power system using a proton exchange membrane fuel cell

Integrated power systems could be a solution to provide energy to remote communities based on the use of renewable energies (such as wind or sun). This work proposed the design of one of those systems including alkaline water electrolysers, storage tanks and a proton exchange membrane fuel cell for generating of 53 kW (working at 60% of its maximum power). Electrode sizes and the quantity of unit cells proposed in this work were the same as those suggested in the research work by Yang et al., where a phosphoric acid fuel cell was built and studied. The results obtained in that research allowed comparing energy efficiency by scaling a laboratory prototype. The dimensions of the alkaline water electrolysers are the result of satisfying the necessity of fuel and oxidant. The energy consumption results from extrapolating laboratory devices. The integrated power system has a storage tank capacity of 16 h.     

Convergence criteria establishment for 3D simulation of proton exchange membrane fuel cell

A validated 3 dimensional (3D) computational fluid dynamics model of a single cell proton exchange membrane fuel cell (PEMFC) was used for investigating convergence criteria. The simulation study was carried out using the commercial PEMFC simulation module built in to ANSYS FLUENT 12.1 software package and compared with published experimental data. Convergence data up to 19,000 iterations were collected in order to establish expectations for convergence errors and differences in convergence rates for different boundary conditions. Species mass fluxes and current density were used to perform a dual verification of experimentally verifiable simulation predictions. The results of the simulation showed that convergence trends were consistent for different boundary conditions and that the solution trends asymptotically to a final value with species mass flux errors approaching to constant values. The data were used to establish convergence criteria for future 3D PEMFC simulations where residual monitoring alone is insufficient to ensure convergence.     

Flow sharing and turbulence phenomena in proton exchange membrane fuel cell stack headers

The distribution of the gas flow in a PEMFC stack is of paramount importance to the stack's performance and lifetime. Uneven flow distribution influences the flow rate through each cell, which in turn causes uneven distribution of the current flow of the entire cell stack and ultimately reduces the performance of the fuel cell stack. In this work, different simulation methods are compared, and large eddy simulations are selected to investigate the flow characteristics in a model stack and study the effects of operating conditions on flow sharing. The simulation results indicate different flow patterns in the inlet header and outlet header; the former features a turbulent entrance region that progressively transits to a laminar region, whereas the latter exhibits a complex flow with jets mixing downstream. Moreover, the flow patterns and distributions for different inlet/outlet configurations, i.e., U-type and Z-type, are investigated. The distribution of the flow through the unit cells for both configurations is different. The Z-type arrangement offers a more uniform flow distribution and has a smaller number of fluctuations than the U-type. The effects of different inlet flow velocity and jet inflow pattern are also studied. The findings from this work can provide guidelines to improve header design.     

Computationally efficient multi-phase models for a proton exchange membrane fuel cell: Asymptotic reduction and thermal decoupling

Generally, multi-phase models for the proton exchange membrane fuel cell (PEMFC) that seek to capture the local transport phenomena are inherently non-linear with high computational overhead. We address the latter with a reduced multi-phase, multicomponent, and non-isothermal model that is inexpensive to compute without sacrificing geometrical resolution and the salient features of the PEMFC - this is accomplished by considering a PEMFC equipped with porous-type flow fields coupled with scaling arguments and leading-order asymptotics. The reduced model is verified with the calibrated and validated full model for three different experimental fuel cells: good agreement is found. Overall, memory requirements and computational time are reduced by around 2-3 orders of magnitude. In addition, thermal decoupling is explored in an attempt to further reduce computational cost. Finally, we discuss how other types of flow fields and transient conditions can be incorporated into the mathematical and numerical framework presented here.     

Performance prediction of a proton exchange membrane fuel cell using the ANFIS model

In this study, the performance (current–voltage curve) prediction of a Proton Exchange Membrane Fuel Cell (PEMFC) is performed for different operational conditions using an Adaptive Neuro-Fuzzy Inference System (ANFIS). First, ANFIS is trained with a set of input and output data. The trained model is then tested with an independent set of experimental data. The trained and tested model is then used to predict the performance curve of the PEMFC under various operational conditions. The model shows very good agreement with the experimental data and this indicates that ANFIS is capable of predicting fuel cell performance (in terms of cell voltage) with a high accuracy in an easy, rapid and cost effective way for the case presented. Finally, the capabilities and the limitations of the model for the application in fuel cells have been discussed.