Numerical study on micro-reformer performance and local transport phenomena of the plate methanol steam micro-reformer

The objective of this work is to investigate the transport phenomena and performance of a plate steam methanol micro-reformer. Micro channels of various height and width ratios are numerically analyzed to understand their effects on the reactant gas transport characteristics and micro-reformer performance. In addition, influences of Reynolds number and geometric size of micro channel on methanol conversion of micro-reformer and gas transport phenomena are also explored. The predicted results demonstrated that better performance is noted for a micro channel reformer with lower aspect-ratio micro channel. This is due to the larger the chemical reaction surface area for a lower aspect-ratio channel reformer. It is also found that the methanol conversion decreases with increasing Reynolds number Re. The results also indicate that the smaller micro channel size experiences a better methanol conversion. This is due to the fact that a smaller micro channel has a much more uniform temperature distribution, which in turn, fuel utilization efficiency is improved for a smaller micro channel reformer.     

Three-dimensional analysis of a plate methanol steam micro-reformer and a methanol catalytic combustor with different flow channel designs

Three-dimensional models of a plate methanol steam micro-reformer and a methanol catalytic combustor with parallel flow fields and serpentine flow fields have been established. The effects of the flow field design and the fuel flow rate on the methanol conversion and transport phenomena in the micro-reformer were investigated. The results revealed that the methanol conversion of the micro-reformer with the serpentine flow field and the combustor with the serpentine flow field has been optimized as a result of improved thermal management in the micro-reformer with combustor. With a change in flow field design from the micro-reformer and the combustor with parallel flow fields to the micro-reformer and combustor with the serpentine flow fields a wall temperature increase from 225 °C to 237 °C was observed. The methanol conversion of the micro-reformer with the serpentine flow field and the combustor with the serpentine flow field could be improved by 23% relative to the employment of a parallel flow field. A numerical model provided an efficient way to characterize the transport phenomena within the micro-reformer and combustor; the results will benefit the future design of plate methanol steam micro-reformers with combustors.     

Numerical study of heat and mass transfer in the plate methanol steam micro-reformer channels

Effects of geometric and thermo-fluid parameters on performance and heat and mass transfer phenomena in micro-reformer channels were investigated by mathematical modeling. The geometric parameters considered were the channel length, channel height, catalyst thickness and catalyst porosity, while the thermo-fluid parameters included wall temperature, inlet fuel temperature, fuel ratio and Reynolds number. The results of the modeling suggest that the methanol conversion could be improved by 49%-points by increasing the wall temperature from 200 °C to 260 °C. The results also show that the CO concentration would be reduced from 1.72% to 0.95% with the H₂O/CH₃OH molar ratio values ranging from 1.0 to 1.6. The values of parameters that enhance the performance of micro-reformer were identified, such as longer channel length, smaller channel height, thicker catalyst layer, larger catalyst porosity, lower Reynolds number and higher wall temperature.     

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.     

蛇形流场结构质子交换膜燃料电池的性能研究

建立包括催化层、扩散层、质子膜在内的三维质子交换膜燃料电池模型,通过Fluent软件模拟4种不同结构的蛇形流场,通过对速度、膜中水含量以及功率密度等分析得出蛇形流场的最优结构,并对最优结构进行参数优化。研究表明,4种不同蛇形流场结构中,Multi-serpentine II为最优,随着温度、压强的增加,这种流场结构的燃料电池呈现出良好的性能,从而为质子交换膜燃料电池双极板的设计提供依据。     

Secondary flow on the performance of PEMFC with blocks in the serpentine flow field

A three-dimensional, two-phase, steady-state numerical model of PEMFC with serpentine flow field was set up. The rectangular or triangular blocks were arranged in the cathode channel to improve cell performance. The results showed that the arranged blocks in the channel can effectively enhance the mass transfer of the reactant, thus improve cell performance. The triangular block has better cell performance in comparison with the rectangular block. The block arranged in the rear of the turn has the best cell performance. The reason for the better cell performance of the arranged block is the combination of the under-rib flow and the secondary flow generated by the block. The secondary flow generated by the block is the main reason for the region near the block. Meanwhile, the under-rib flow is the main reason for the region far away from the block.     

A tapered serpentine flow field for the anode of micro direct methanol fuel cells

We develop a self-breathing micro direct methanol fuel cell (μDMFC) characterized by a new anode structure with tapered single serpentine flow fields to improve cell performance. Compared with the conventional single serpentine flow field, this new design enhances the methanol mass transport efficiency and the exhaust resultant (CO₂) rate due to the increasing pressure difference between adjacent flow channels. The μDMFCs with two single serpentine flow fields are fabricated using silicon-based micro-electro-mechanical systems (MEMS) technologies and are tested at room temperature. The experimental results reveal that the new tapered single serpentine flow field exhibits a significantly higher peak power density than that of the conventional flow field, demonstrating a substantial increase of 17.9% in mass transport coefficients.     

Transport mechanisms and performance simulations of a PEM fuel cell with interdigitated flow field

A proton exchange membrane (PEM) fuel cell with interdigitated flow field was studied numerically. A three-dimensional, gas–liquid two-phase flow and transport model was developed and utilized to simulate the multi-dimensional, multi-phase flow and transport phenomena in both the anode and cathode sides in the fuel cell and the cell performances with different influencing operational and geometric parameters. The simulations are presented with an emphasis on the physical insight and fundamental understanding afforded by the detailed distributions of working media velocity, oxygen concentration, water vapor concentration, liquid water concentration, water content in the PEM, net water flux per proton flux, current density and overpotential. Cell performances with different influencing factors are also discussed. A comparison of the model prediction and the experimental data shows good agreement.     

Numerical study of heat and mass transfer in a plate methanol steam micro reformer with methanol catalytic combustor

A numerical study is performed to examine the characteristics of heat and mass transfer and the performance of a plate methanol steam micro reformer with a methanol catalytic combustor. The effects of the flow configurations for co- and counter-current flows are explored in the present study. The influences of the Reynolds number (Re) and various geometric parameters on heat and mass transfer phenomena in the channels are also investigated numerically. It is expected that the Reynolds number (Re) and various geometric parameters can be improved by thermal management to enhance the chemical reaction and thus augment the micro reformer performance. Comparing the co- and counter-current flows via numerical simulation, the results show that the methanol conversion for counter-current flow could be improved by 10%. This is due to the fact that counter-current flow leads to a better thermal management, which in turn improves fuel conversion efficiency. With a higher Reynolds number on the combustor side, the wall temperature is increased and the methanol conversion can thus be enhanced. Meanwhile, a reduced Reynolds number on the micro reformer side would increase the methanol conversion. The results also reveal that appropriate geometric parameters exist for a micro reformer with a combustor to obtain better thermal management and methanol conversion.     

Numerical analysis of the influence of the channel cross-section aspect ratio on the performance of a PEM fuel cell with serpentine flow field design

This work numerically investigates the influence of the channel cross-section aspect ratio (defined as the ratio height/width) on the performance of a PEM fuel cell with serpentine flow field (SFF) design. The local current densities, velocity distributions, liquid water concentration in the membrane, hydrogen and oxygen concentrations and temperature were analyzed in the PEM fuel cell for 10 different aspect ratios, varying between 0.07 and 15, to understand the channel cross-section aspect ratio effect. The area of the channel cross section (1.06 mm²) and the total effective reactive area of the PEM fuel cell (256 mm²) were maintained constant in all cases. The obtained results show that at low operating voltages the cell performance is independent of the channel cross-section aspect ratio. At high operating voltages, where the influence of mass transporting velocity is predominant, as the channel cross-section aspect ratio increases the cell performance is improved. The models with high aspect ratio show, in general, more uniform current distributions, with the higher maximum and minimum intensity values, temperature distributions with smaller gradients and a superior contain of water in the membrane, which allows to obtain a higher performance. From these models the 10/06 and 12/05 aspect ratio present the best combination of variables, as shown by their polarization curves.     

Fractal channel design in a micro methanol steam reformer

The aim of the present article is to study the fractal channel pattern design and the gradient catalyst layer in relation to their effects on the performance of a micro methanol steam reformer. A three-dimensional simulation model is established for the purpose of predicting the effects of bio-channel design on the performance of a micro-reformer. The CO concentration in the production gases, which is necessary to avoid the poisoned catalyst layers of low temperature fuel cells, is also investigated. In addition, the distributions of velocity and gas concentrations are predicted, and the methanol conversion ratios are also evaluated. Due to further decreases of the CO in product gases, a gradient catalyst layer arrangement is proposed to delay the timing of hydrogen generation and thus avoid the presence of hydrogen in the catalyst layer too long. This catalyst arrangement can effectively decrease the possibility of a reverse water gas shift reaction to reduce CO generation. Results showed that the fractal channel design increases the conversion ratio, decrease CO as well as decrease the pressure drop in the channels. Relative to a parallel channel design, the CO and methanol conversion ratio of this fractal channel design pattern with uniform catalyst layer can be decreased and increased by 17% and 8%, respectively, based on a 0.3 cc/min flow rate, respectively. Meanwhile, the pressure drops in the parallel channel design and in the fractal channel design were found to be 254 Pa and 51 Pa, respectively. From an energy consumption point of view, a low pressure drop also implies low input pumping power. Furthermore, compared to the fractal design with a uniform catalyst layer, the gradient catalyst layer was demonstrated to effectively increase the conversion ratio by 8.5% and decrease CO by 11% when the inlet liquid flow rate was fixed at 1.0 cc/min.     

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.     

A novel design for a flow field configuration, of a direct methanol fuel cell

We proposed and tested a new and novel arrangement for a direct methanol fuel cell consisting of one inlet for a methanol solution and four outlets for oxidant gas (air), in both the anode and cathode flow fields. It utilizes different operating temperatures of 40 °C and 60 °C, and different methanol solution flow rates of 5 ml min⁻¹, 10 ml min⁻¹, and 20 ml min⁻¹. Test results indicate a significant reduction in produced CO₂ gas in the anode flow channels and product water in the cathode flow channels; consequently, cell performance can be greatly improved. Furthermore, methanol crossover can also be avoided and reduced.     

Fabrication of flexible micro-sensors and flow field of stainless steel-based micro-reformer by micro-electro-mechanical-systems process

Recent advances in micro-fuel cells have increased the demand for hydrogen. Therefore, a micro-reformer must be developed. Numerous portable electric devices are extremely small and reformers must therefore be shrunk and combined with micro-fuel cells. The mass production of micro-reformers raises various problems that are yet to be solved, such as the measurement of their internal temperature and flow rate. Such issues influence the efficiency of the micro-reformers. To our knowledge, no investigation has yet properly elucidated the internal operation of micro-reformers. Accordingly, in this work, a flexible micro-temperature sensor, a micro-heater, a micro-flow sensor and the flow field of a stainless steel-based micro-reformer were fabricated by micro-electro-mechanical-systems (MEMS) fabrication technique. The fabrication technique has the advantages of (1) small size, (2) flexible but precise measurement positions, and (3) mass production process.     

Transport phenomena within the liquid phase of a laboratory-scale circular methanol pool fire

The effects of altering the lower thermal boundary condition of a methanol pool from −5 °C to 50 °C was investigated within a 90 mm diameter and 12 mm deep quartz burner under steady state burning condition in a quiescent air environment. Both the burning rate and the flame height were observed to increase by 15% with increasing bottom temperature over this range of bottom boundary conditions. The temperature and velocity within the liquid were measured by a single thermocouple traversed through the pool and PIV, respectively, in order to better understand the transport of mass and energy in the liquid. Temperature measurements revealed a distinct two-layer vertical thermal structure with the upper layer of the pool being almost uniform and near the boiling temperature of the fuel, while the lower layer experienced an increasing temperature gradient as the bottom boundary temperature was lowered. The thickness of the thermally uniform layer increased as the bottom temperature was increased. The measured fluid velocity showed a complementary two-layer structure with the upper layer being dominated by a pair of counter-rotating vortices that kept this portion of the liquid well mixed and transferred heat from the hot pool wall to the pool center, while the flow in the lower layer was uniformly low in value and vertical. A model was presented to aid in understanding the energy transfer within the liquid phase. In the lower layer, the Peclet Number was in the order of unity and required that the energy transfer throughout the liquid phase to be modeled as a combination of conduction and convection. Using this physical model, the change in burning rate over the full 55 °C change in bottom temperature was predicted within 2%, thereby supporting the proposed mechanism for energy transfer into the pool’s depth.     

Effects of serpentine flow field with outlet channel contraction on cell performance of proton exchange membrane fuel cells

A serpentine flow field with outlet channels having modified heights or lengths was designed to improve reactant utilization and liquid water removal in proton exchange membrane (PEM) fuel cells. A three-dimensional full-cell model was developed to analyze the effects of the contraction ratios of height and length on the cell performance. Liquid water formation, that influences the transport phenomena and cell performance, was included in the model. The predictions show that the reductions of the outlet channel flow areas increase the reactant velocities in these regions, which enhance reactant transport, reactant utilization and liquid water removal; therefore, the cell performance is improved compared with the conventional serpentine flow field. The predictions also show that the cell performance is improved by increments in the length of the reduced flow area, besides greater decrements in the outlet flow area. If the power losses due to pressure drops are not considered, the cell performance with the contracted outlet channel flow areas continues to improve as the outlet flow areas are reduced and the lengths of the reduced flow areas are increased. When the pressure losses are also taken into account, the optimal performance is obtained at a height contraction ratio of 0.4 and a length contraction ratio of 0.4 in the present design.     

四流道蛇形结构质子交换膜燃料电池温度分布数值模拟

为研究温度对质子交换膜燃料电池性能的影响,运用多物理场直接耦合分析软件COMSOL Multiphysics,对不同电池温度的四流道蛇形流场质子交换膜燃料电池进行了数值模拟。模拟得到了不同电池温度下垂直膜电极平面以及电池中心处从阳极流道到膜,再到到阴极流道的温度变化情况;还得到了电池温度为353K时,电池入口处、中心处和出口处从阳极流道到阴极流道相应位置点的温差变化。对模拟结果进行分析和比较后发现:电池内部温度的升高与电池本身的原始温度存在线性变化关系;电池入口处、中心处和出口处的温度变化趋势存在差异,且电池入口处温升最大,中心处次之,出口处温升最小;随着电池温度的升高,电池因内部反应所产生的热量减少。模拟结果对质子交换膜燃料电池的性能优化有重要意义。     

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.     

Optimal design of parallel channel patterns in a micro methanol steam reformer

This study describes the performance of micro methanol steam reformers with channel widths optimized using the simplified conjugate gradient method (SCGM), which uses a minimum objective function of the H₂ mass fraction standard deviation in channels. A three-dimensional numerical model and optimal simplified conjugate gradient algorithm were built to predict and search for the effects of channel widths and flow rate on the performance of chemical reactions. Furthermore, this simulation model was compared to; and corresponded well with existing experimental data. Distributions of velocity, temperature, and gas concentrations (CH₃OH, CO, H₂, and CO₂) were predicted, and the methanol conversion ratio was also evaluated. The mole fraction of CO contained in the reformed gas, which is essential to preventing poisoning of the catalyst layers of fuel cells, is also investigated. In the optimization search process, the governing equations use the continuity, momentum, heat transfer, and species equations to evaluate the performance of the steam reformer. The results show that channel width optimization can not only increase the methanol conversion ratio and hydrogen production rate but also decrease the concentration of carbon monoxide. The velocity and mixture gas density distributions in channels are discussed and plotted at various locations for an inlet liquid flow rate of 0.3 cc min⁻¹. Full development is not obtained in the downstream channel flow, the velocity in channel is increased from 1.28 m s⁻¹ to 2.36 m s⁻¹ at location Y = 1 mm–32 mm, respectively. This can be attributed to a continuous increase in the lightweight H₂ species as a result of chemical reactions in the channels.