Three-dimensional numerical study on cell performance and transport phenomena of PEM fuel cells with conventional flow fields

In this paper, a three-dimensional numerical model of the proton exchange membrane fuel cells (PEMFCs) with conventional flow field designs (parallel flow field, Z-type flow field, and serpentine flow field) has been established to investigate the performance and transport phenomena in the PEMFCs. The influences of the flow field designs on the fuel utilization, the water removal, and the cell performance of the PEMFC are studied. The distributions of velocity, oxygen mass fraction, current density, liquid water, and pressure with the convention flow fields are presented. For the conventional flow fields, the cell performance can be enhanced by adding the corner number, increasing the flow channel length, and decreasing the flow channel number. The cell performance of the serpentine flow field is the best, followed by the Z-type flow field and then the parallel flow field.     

Local transport phenomena and cell performance of PEM fuel cells with various serpentine flow field designs

The flow field design in bipolar plates is very important for improving reactant utilization and liquid water removal in proton exchange membrane fuel cells (PEMFCs). A three-dimensional model was used to analyze the effect of the design parameters in the bipolar plates, including the number of flow channel bends, number of serpentine flow channels and the flow channel width ratio, on the cell performance of miniature PEMFCs with the serpentine flow field. The effect of the liquid water formation on the porosities of the porous layers was also taken into account in the model while the complex two-phase flow was neglected. The predictions show that (1) for the single serpentine flow field, the cell performance improves as the number of flow channel bends increases; (2) the single serpentine flow field has better performance than the double and triple serpentine flow fields; (3) the cell performance only improves slowly as the flow channel width increases. The effects of these design parameters on the cell performance were evaluated based on the local oxygen mass flow rates and liquid water distributions in the cells. Analysis of the pressure drops showed that for these miniature PEMFCs, the energy losses due to the pressure drops can be neglected because they are far less than the cell output power.     

Effects of operating parameters on transport phenomena and cell performance of PEM fuel cells with conventional and contracted flow field designs

A contracted parallel flow field design was developed to improve fuel cell performance compared with the conventional parallel flow field design. A three-dimensional model was used to compare the cell performance for both designs. The effects of the cathode reactant inlet velocity and cathode reactant inlet relative humidity on the cell performance for both designs were also investigated. For operating voltages greater than 0.7 V because the electrochemical reaction rates are lower with less oxygen consumption and less liquid water production, the cell performance is independent of the flow field designs and operating parameters. However, for lower operating voltages where the electrochemical reaction rates gradually increase, the oxygen transport and the liquid water removal efficiency differ for the various flow field designs and operating parameters; therefore, the cell performance is strongly dependent on both the design and operating parameters. For lower operating voltages, the cell performance for the contracted design is better than for the conventional design because the reactant flow velocities in the contracted region significantly increase, which enhances liquid water removal and reduces the oxygen transport resistance. For lower operating voltages, as the cathode reactant inlet velocity increases and the cathode reactant inlet relative humidity decreases, the cell performance for both designs improves.     

Effects of internal flow modification on the cell performance enhancement of a PEM fuel cell

This study presents a numerical investigation on the cell performance enhancement of a proton exchange membrane fuel cell (PEMFC) using the finite element method (FEM). The cell performance enhancement in this study has been accomplished by the transverse installation of a baffle plate and a rectangular block for the modification of flow pattern in the flow channel of the fuel cell. The baffle plates (various gap ratios, λ = 0.005–10) and the rectangular block (constant gap ratio, λ = 0.2) are installed along the same gas diffusion layer (GDL) in the channel at constant Reynolds number for the purpose of investigating the cell performance. The results show that the transverse installation of a baffle plate and a rectangular block in the fuel flow channel can effectively enhance the local cell performance of a PEMFC. Besides, the effect of a rectangular block on the overall cell performance is more obvious than a baffle plate.     

Numerical modeling of three-dimensional two-phase gas–liquid flow in the flow field plate of a PEM electrolysis cell

Numerical simulations were performed for three-dimensional two-phase water/oxygen flow in the flow field plate at the anode side of a PEM electrolysis cell. The mixture model was used to simulate two phases for the purpose of examining flow features in the flow field plate in order to effectively guide the design of electrolysis cells. The water flow rate was maintained as a constant of 260 mL/min, while the flow rate of oxygen generation was assumed to change from 0 to 14 mg/s. The obtained results including the velocity, pressure, and volume fraction distributions are presented and discussed. It is found that the obtained results for single-phase flow cases cannot be linearly extrapolated into the two-phase flow cases. The irregular velocity profile (locally low velocity magnitude near the exit port section) is not observed when the flow rate of oxygen generation is relatively low. As the mass flow rate of oxygen generation increases, reverse flow develops inside the flow channels.     

Influence of geometric parameters of the flow fields on the performance of a PEM fuel cell. A review

The proton Exchange membrane fuel cell (PEMFC) performance depends not only on many factors including the operation conditions, transport phenomena inside the cell and kinetics of the electrochemical reactions, but also in its physical components; membrane electrode assembling (MEA) and bipolar plates (BPs). Among the PEM stack components, bipolar plates are considered one of the crucial ones, as they provide one of the most important issues regarding the performance of a stack, the homogeneous distribution of the reactive gases all over the catalyst surface and bipolar plate areas through, the so call, flow channels; physical flow patterns or paths fabricated on the BPs surfaces to guide the gases all along the BPs for its correct distribution. The failure in flow distribution among different unit cells may severely influence the fuel cell stack performance. Thus, to overcome such possible failures, the design of more efficient flow channels has received considerable attention in the research community for the last decade.     

Investigation of water droplet kinetics and optimization of channel geometry for PEM fuel cell cathodes

The kinetics and transport mechanisms of water droplets in model flow field channels of a low temperature polymer electrolyte fuel cell were investigated. The pressure drop at different air flows was measured for different channel geometries in a graphite plate as employed for fuel cell bipolar plates. The minimum air flow required for the movement of a water droplet in the flow channel was identified. From the experimental findings, recommendations for the development of flow fields with high condensate removal capabilities combined with low pressure differences were drawn to allow for an efficient operation of PEM fuel cells.     

Optimization of PEM fuel cell flow field via local current density measurement

The serpentine flow field is the leading type of flow field used today in proton exchange membrane (PEM) fuel cells and for this reason optimization of serpentine flow field design is extremely important. In this study, a unique technique developed in house is utilized to separately measure current density under the land and channel on a variety of serpentine flow field geometries. Each flow field is tested under a wide variety of operating conditions thereby providing guidance for the optimum design geometry. Experimental results show that generally flow fields with both thinner lands and thinner channels provide better overall performance. However, the optimal flow field designs are highly dependent on fuel cell operating parameters.     

Turbulent flow in the distribution header of a PEM fuel cell stack

A numerical investigation of the flowfield in a model distribution header manifold of a polymer electrolyte membrane fuel cell stack is conducted. The computational model simulates two segments of an experimental setup of a pair of model headers which replicate the headers of a fuel cell stack. The model headers consist of an inlet and outlet sections connected with a plate containing an array of holes that replicate the unit cells. The flow structures in the outlet header are rather complex and are the result of the superposition of a series of impinging jets in a confined space in the presence of crossflow. The flow from each hole, which represents an individual cell outlet, enters the outlet header as a jet stream and is subjected to a crossflow. Large Eddy Simulations (LES) are performed for a portion of the outlet header to investigate the complex turbulent flow and related structures under different crossflow conditions, and are complemented by Particle Image Velocimetry (PIV) measurements. The LES results show that two large vortical structures are formed in the header cross-section, with a high-speed round jet from the cell outlet holes forcing a diversion of the crossflow, dividing it into two separate branches. Investigation of the flow restructuring after a blockage of one of the jets is performed. Simulation results using a slot opening for the jet show flow instabilities. The results of this study highlight the unsteady and highly turbulent nature of the flow in the header and provide a characterization of the complex three-dimensional structure of the flow. The flowfield and flow structures may impact the overall pressure drop along the header and the effective cross-sectional area for the flow leaving the header. The observations and insights obtained from the LES simulation and PIV measurements point to the need to further investigate the impact on flow sharing in a stack of the flowfield development in the outlet header.     

Numerical study of optimized three-dimension novel Key-shaped flow field design for proton exchange membrane fuel cell

Key-shaped three-dimension (3D) flow field channel is designed to improve the performance and mass transfer of proton exchange membrane fuel cell (PEMFC). This study comprehensively analyses the impacts on the performance and mass transfer of the flow channel from multiple dimensions such as the size, shape, and placement of the blocks. In comparison with the conventional straight single flow field channel, the new channel with rectangular blocks can effectively improve performance by 30%. Semi-elliptical and quarter-elliptical blocks are designed to make forced convection and increase the diffusion area of oxygen. The results indicate that the flow velocity in the Z-axis direction can be increased to 0.08–0.2 m/s due to the narrow space formed by variable cross-sections. In conclusion, the Key-shaped design has a potential to improve the performance of mass transfer in the cathode channel, providing a new strategy for the development of flow field design in PEMFC field.     

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.     

Configuration effects of air,fuel, and coolant inlets on the performance of a proton exchange membrane fuel cell for automotive applications

The configuration of fuel, air, and cooling water paths is one of the major factors that influence the performance of a proton exchange membrane fuel cell (PEMFC). In order to investigate the effects of these factors, a quasi-three-dimensional dynamic model of a PEMFC has been developed. For validation, simulation results are compared with experimental data in one-flow configuration case and show good agreement with the experimental cell performance data. Five different flow configurations are then simulated to systematically investigate the effects of fuel, air, and cooling channel configuration on the local current and species distribution. Voltage and power vs. current density for five different configurations are compared. The type 1 configuration, which has a fuel–air counter flow and an air-coolant co-flow, has the highest performance in all ranges of current density because the membrane remains the most hydrated. When the operating current density increases, the effects of temperature on membrane hydration slightly decrease. It is confirmed that fuel cell performance improves with increased humidity until flooding conditions appear. An interesting result shows that it is possible to lower the fuel cell operating temperature to improve fuel cell hydration, which in turn improves cell performance. In addition, the different flow configurations are shown to have an effect on the pressure losses and local current density, membrane hydration, and species mole fractions. These results suggest that the model can be used to optimize the flow configuration of a PEMFC.     

Performance study of solid oxide fuel cell with various flow field designs: numerical study

A comprehensive 3D mathematical model has been developed to study the performance of the planar anode-supported solid oxide fuel cell (SOFC) with different flow field designs such as helical, single-entry serpentine, traditional parallel, modified parallel design, double-entry serpentine and triple-entry serpentine. The model includes charge transport (electron and ion), conservation of mass, momentum, and energy. The developed model is numerically simulated and the predicted results are validated using the available experimental data from previous work. Results showed that single-entry cells suffer of back flow at the outlet of the cathode flow side in both helical and single-entry serpentine designs due to early full fuel consumption. To avoid back flow, increasing the number of entry ports at inlets and outlets in different designs is performed to increase the inlet mass flow rate. It is found that the triple-entry serpentine design attains good uniform distributions for both fuel and oxygen throughout the active surface area and achieves a high collected current of about 23.3 A with a percentage increase of 5.18% compared to the other designs at low voltage. Comparison with other designs indicates that the triple-entry serpentine gives better performance.     

Evaluation of flow field design effects on proton exchange membrane fuel cell performance

Fluid distribution, conduction, and heat control are important phenomenon in the fuel cell fraternity, therefore it is crucial to develop a state-of-the-art bipolar plate (BP) to attain optimum cell performance. Metal foam (MF) and fine mesh have attracted a lot of attention in mitigating some of the challenges associated with straight, and serpentine channels. In this study, MF, 3D fine mesh, fine wire mesh (FWM) flow fields are compared with triple serpentine flow field to develop an optimum design for improved PEMFC performance. Two different foam designs are studied to attenuate the existing drawback associated with MF, mainly caused by high water retention. The 3D fine mesh is leading in performance under anodic and cathodic stoichiometry of 1 and 3 respectively. On increasing the anodic and cathodic stoichiometry to 1.2 and 3.5 respectively, the FWM took the lead. This is brought by the improved water drainage under high stoichiometry. Because FWM is already in mass production, although for other purposes, it is cost competitive over the other designs. The fine mesh and the MF have the potential to break down large water droplet making them easy to drain. They also showed symmetric fluid flow, compared to the serpentine design.     

Numerical study of cell performance and local transport phenomena in PEM fuel cells with various flow channel area ratios

Three-dimensional models of proton exchange membrane fuel cells (PEMFCs) with parallel and interdigitated flow channel designs were developed including the effects of liquid water formation on the reactant gas transport. The models were used to investigate the effects of the flow channel area ratio and the cathode flow rate on the cell performance and local transport characteristics. The results reveal that at high operating voltages, the cell performance is independent of the flow channel designs and operating parameters, while at low operating voltages, both significantly affect cell performance. For the parallel flow channel design, as the flow channel area ratio increases the cell performance improves because fuel is transported into the diffusion layer and the catalyst layer mainly by diffusion. A larger flow channel area ratio increases the contact area between the fuel and the diffusion layer, which allows more fuel to directly diffuse into the porous layers to participate in the electrochemical reaction which enhances the reaction rates. For the interdigitated flow channel design, the baffle forces more fuel to enter the cell and participate in the electrochemical reaction, so the flow channel area ratio has less effect. Forced convection not only increases the fuel transport rates but also enhances the liquid water removal, thus interdigitated flow channel design has higher performance than the parallel flow channel design. The optimal performance for the interdigitated flow channel design occurs for a flow channel area ratio of 0.4. The cell performance also improves as the cathode flow rate increases. The effects of the flow channel area ratio and the cathode flow rate on cell performance are analyzed based on the local current densities, oxygen flow rates and liquid water concentrations inside the cell.     

Numerical modeling of anode-bleeding PEM fuel cells: Effects of operating conditions and flow field design

Operating the PEM fuel cell in the dead-ended anode mode reduces the overall cost and complexity of the system but causes a voltage loss and carbon corrosion in the cathode catalyst layer due to hydrogen starvation in the anode. Whereas allowing an ultra-low flowrate at the anode outlet offers a very high utilization of hydrogen and achieves a stable voltage transient. Here, a time-dependent pseudo-three-dimensional, two-phase, and non-isothermal model is developed to study the optimum bleeding rate, which maximizes the hydrogen utilization, achieves a stable cell voltage and avoids carbon corrosion, which is commonly observed when the bleed rate is set to zero, i.e. the dead-ended mode. The model is validated against the experimental data by comparing the polarization curves and cell voltage transients during the dead-ended anode operation of small experimental cells with serpentine and straight anode flow channels. Moreover, the effects of operating conditions on cell performance during the anode bleeding operation mode are investigated. Results demonstrate that the hydrogen utilization exceeds 99% in the anode-bleeding mode without hydrogen starvation, and the cell performance improves significantly for higher anode pressure, lower cell temperature, and lower relative humidity at the cathode inlet. Lastly, it is found that serpentine channels in the anode improve the uniformity of the distribution of hydrogen compared to straight and interdigitated channels in the anode-bleeding mode while the cathode flow field consists of serpentine channels.     

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.     

Droplet dynamics in a proton exchange membrane fuel cell flow field design with 3D geometry

Water management is crucial to achieve both high-performance and durability of proton exchange membrane fuel cell (PEMFC). Therefore, it is necessary to investigate the dynamic behavior of droplets in PEMFC channel for water management. In this paper, we explore the kinetics of droplets in a 3D flow field by experimental and theoretical analysis. More specifically, we examine the following four perspectives: 1) the movement and falling of droplets, and their force and deformation, 2) the superiority of 3D flow field drainage, 3) the pressure and viscous force under different scenarios including varying droplet sizes and velocities, and 4) the expression describing the shape change of droplets. The results show that the 3D flow field has a greater driving force on droplets and that their deformation affects the discharge of liquid water. Throughout the study, we provide better understanding of droplet dynamic in PEMFC gas channels. It enables to optimize the design and working conditions of these channels.