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.     

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 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.     

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.     

Simultaneous direct visualisation of liquid water in the cathode and anode serpentine flow channels of proton exchange membrane (PEM) fuel cells

Water flooding is detrimental to the performance of the proton exchange membrane fuel cell (PEMFC) and therefore it has to be addressed. To better understand how liquid water affects the fuel cell performance, direct visualisation of liquid water in the flow channels of a transparent PEMFC is performed under different operating conditions. Two high-resolution digital cameras were simultaneously used for recording and capturing the images at the anode and cathode flow channels. A new parameter extracted from the captured images, namely the wetted bend ratio, has been introduced as an indicator of the amount of liquid water present at the flow channel. This parameter, along with another previously used parameter (wetted area ratio), has been used to explain the variation in the fuel cell performance as the operating conditions of flow rates, operating pressure and relative humidity change. The results have shown that, except for hydrogen flow rate, the wetted bend ratio strongly linked to the operating condition of the fuel cell; namely: the wetted bend ratio was found to increase with decreasing air flow rate, increasing operating pressure and increasing relative humidity. Also, the status of liquid water at the anode was found to be similar to that at the cathode for most of the cases and therefore the water dynamics at the anode side can also be used to explain the relationships between the fuel cell performance and the investigated operating conditions.     

Water management in a novel proton exchange membrane fuel cell stack with moisture coil cooling

Water flooding causes severe degradation of the performance and lifetime of proton exchange membrane fuel cell (PEMFC). In this study, a novel PEMFC stack with in-built moisture coil cooling was designed and the effects of moisture coil cooling on water management in the new PEMFC stack under various operating conditions were investigated. The result showed that the performance of the PEMFC stack was significantly improved due to the moisture condensation under high current density, high operating temperature, high relative humidity and high operating pressure. The output power was increases by 21.62% (525.71 W) at 1600·mA cm⁻² while the increased parasitic power was no more than 35W. Moreover, degradation of the cathode catalyst layer after 100 h operation was also reduced by using moisture coil cooling. Compared with the situation without moisture condensation, the maximum decay rate of the cathode catalyst layer thickness after 100 h operation was reduced by 13.01%. Accordingly, the novel design is valuable and can be widely used in the future design of PEMFC.     

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.     

Numerical investigation into transient response of proton exchange membrane fuel cell with serpentine flow field

The transient response of a proton exchange membrane fuel cell (PEMFC) with a serpentine flow field design is investigated using a three‐dimensional numerical model. The simulations consider three different flow field designs with 7, 11, and 15 bends, respectively. For the flow field design with 11 bends, three different channel width ratios are considered, namely 25%, 50%, and 75%. The channel width ratio is defined as the ratio of the channel width to the total channel/rib width. The simulation results show that for all of the flow field designs, an overshoot in the local current density occurs when the voltage is reduced instantaneously from 0.7 to 0.5 V because of the high and uniform oxygen mass fraction. Conversely, a significant undershoot occurs when the voltage is increased instantaneously from 0.5 to 0.7 V because of the low and nonuniform oxygen mass fraction. The overshoot and undershoot phenomena are particularly evident in the PEMFC with a 15‐bend flow field. For the flow field design with 11 bends, the channel width ratio has little effect on the current density at an operating voltage of 0.7 V. However, at an operating voltage of 0.5 V, the oxygen concentration into the catalyst and diffusion layers increases with the increasing channel width ratio, which leads to higher current density. As a result, a more significant overshoot phenomenon is observed in the flow field with a width ratio of 75%. Copyright © 2012 John Wiley & Sons, Ltd.     

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]     

质子交换膜燃料电池的水热管理

质子交换膜燃料电池电化学反应生成电能、热能和水。质子交换膜燃料电池中水管理与热管理是紧密关联互相耦合的,有效的水热管理对于提高电池的性能和寿命起着关键作用。本文对膜中水的迁移机理及影响水平衡的主要因素进行了分析,对目前较为有效的水管理方法进行了综述。另外,分析了在微重力条件下燃料电池水管理问题的重要性。燃料电池中约有40%~50%的能量耗散为热能,必须采取有效的散热方式及时排除这些热量。本文对质子交换膜燃料电池的温度分布、局部换热系数及散热等燃料电池热管理相关问题进行了分析。     

Recent development in design a state-of-art proton exchange membrane fuel cell from stack to system: Theory,integration and prospective

As an efficient energy converter, the proton exchange membrane fuel cell (PEMFC) is developed to couple various applications, including portable applications, transportation, stationary power generation, unmanned underwater vehicles, and air independent propulsion. PEMFC is a complex system consisting of different components that can be influenced by many factors, such as material properties, geometric designs operating conditions, and control strategies. The interaction between components and subsystems could affect the performance, durability, and lifespan of PEMFC system. To design a high performance, long lifespan, high durability PEMFC, it's essential to comprehensively understand the coupling effect of different factors on the overall performance and durability of PEMFCs. This review will present existing research on basis of four aspects, involving fuel cell stack design, subsystems design and management, mass transfer enhancement, and system integration. Firstly, the multi-physics intergradation and component design of PEMFC are reviewed with the designing mechanisms and recent progress. Besides, mass transfer enhancement methods are discussed by bipolar plate design and membrane electrode assembly optimization. Then, water management, thermal management, and fuel management are summarized to provide design guidance for PEMFC. The specifications design and system management for various engineering applications are briefly presented.     

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.     

A review on water balance in the membrane electrode assembly of proton exchange membrane fuel cells

Water balance has been proven to be critical not only for the performance but also for the durability of proton exchange membrane fuel cells (PEMFCs). This paper reviews experimental investigations and modeling works on water transport and balance in different constituents of the membrane electrode assembly (MEA), which is the most important component determining the performance and durability of a PEMFC. Major water transport mechanisms in the membrane and porous layers of MEA are summarized and the strategies to balance water in these components are also discussed. However, the experimental water transport data for different components under varied operating conditions are still insufficient and the understanding of transport mechanisms is still limited. To obtain better water management in PEMFCs, the design of the key components requires refinements. For future investigations more attention should be paid to the fundamental understanding and systematic data of water transport in each component of the MEA under varied operating conditions.     

Review on water management methods for proton exchange membrane fuel cells

Control of water content of proton exchange membrane fuel cells (PEMFCs) within a reasonable rangeis a question worthy of study. This paper addresses questions of water transport, water fault, and water management methods in a PEMFC. Both an excess (overflow) or lack (dehydration) of water in a fuel cell may affect the performance and the service life. Herein, we describe in detail the effects of water content on the cathode, anode, gas diffusion layer (GDL), catalyst layer (CL) and flow channel. Monitoring the flow and accumulation of water directly in the PEMFC is the most effective approach to determine which of the two scenarios, overflow or dehydration, occurs. The water transport can be effectively investigated in a transparent fuel cell, using neutron scanning, nuclear magnetic resonance, and X-ray irradiation. Regarding the PEMFC water management, this paper reviews some current methods, such as improvement of the flow field structure, changing hydrophilic materials, and optimizing control systems.     

甲醇质子交换膜燃料电池的水和热管理

甲醇质了换燃料电是未来最有希望获得工程应用的燃料电池，文章简述了燃料电的发电原理及其分类。对多孔电极，直接甲醇质子交换膜燃料电及甲醇改质质子交换膜燃料电作了分析和讨论，指出了对质子交换膜燃料电池系统进行水管理和热管理的重要性和必要性。     

Numerical simulation for metal foam two-phase flow field of proton exchange membrane fuel cell

Metal foam (MF) flow field has been the potential reactant gas distributor to improve the water management, gas reactant transport and enhance the performance of proton exchange membrane fuel cells (PEMFCs) owing to its unique porous structure. In this study, the full morphology of MF flow field is reconstructed by geometry representation method, and a two-phase volume of fluid (VOF) model is employed to investigate the gas transport and liquid water dynamics in the MF flow field. The present model is validated with the previous experimental and theoretical studies. The single-phase and two-phase flow behaviors in MF flow field and conventional parallel channel are discussed and compared. The results show that a more uniform and convective-to-electrode gas flow can be obtained in MF flow field. Although the water hold-up phenomenon, i.e., water droplets trapped in pores, is observed and slows down the water transport in MF flow field, the porous structures with favorable connectivity and numerous gas pathways still reduce the “water flooding” in the flow field. In addition, hydrophobic walls (or ligaments) are proved necessary for the water management of a MF flow field.     

Nature inspired flow field designs for proton exchange membrane fuel cell

Nature inspired flow field designs for proton exchange membrane fuel cells (PEMFCs) are a relatively recent development in the technology evolution. These novel designs have the potential to show dramatic performance improvements by effective distribution of reactant gases without water flooding. Optimization of a flow field requires balancing gas distribution, water management, electron transport, pressure drop and manufacturing simplicity. Computational fluid dynamics (CFD) simulation studies are a useful tool for evaluating nature inspired flow field designs; however, the predictions should be used with caution until validated by an experimental study. Nature inspired flow field designs can be generated using formal mathematical algorithms or by making heuristic modifications to existing natural structures. This paper reviews the current state of nature inspired PEMFC flow field designs and discusses the challenges in evaluating these designs.     

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.     

Effects of anode and cathode perforated flow field plates on proton exchange membrane fuel cell performance

The effects of both anode and cathode perforated flow field configurations on proton exchange membrane fuel cell performance are studied herein through electrochemical polarization techniques, electrochemical impedance spectroscopy, and cyclic voltammetry. The results demonstrate that serpentine flow field configuration in both anodes and cathodes is the best arrangement for cell performance (serpentine/serpentine, perforated/perforated, and serpentine/perforated). An electrochemical impedance spectroscopy examination shows that the serpentine/serpentine flow plate configuration results in a significant reduction in charge transfer resistance in a high current density (low voltage) regime. It further indicates that in a serpentine/serpentine flow pattern, a maximum electrochemical area is obtained with a higher Pt utilization of about 70% and is secured with full hydration at a cell temperature of 80°C. Finally, energy and exergy efficiencies analyses were also made. Data have been extracted and presented. Copyright © 2013 John Wiley & Sons, Ltd.     

A novel densely connected neural network for proton exchange membrane fuel cell fault diagnosis

It is of great significance to perform proton exchange membrane fuel cell (PEMFC) fault diagnosis and take action timely to mitigate or even eliminate the faults, which can strengthen PEMFC reliability and durability. In previous studies, cell voltage is extensively used for PEMFC fault diagnosis. However, there exists similar cell voltage drop phenomenon as different PEMFC faults occur, especially for faults like flooding and air starvation having extremely similar voltage dynamic variation, which makes it difficult to capture the features sensitive to faults. Moreover, cell voltages collected from different MEAs follow different distributions even in the same operation condition, which challenges the diagnosis consistency of fault diagnosis methods. In this paper, in order to break through the hindrances, a novel densely connected neural network codenamed Inc-DenseNet is proposed for PEMFC fault diagnosis, which integrates advantages of InceptionNet and DenseNet to extract more specific and robust features from cell voltage. In the analysis, the collected PEMFC voltage signal is transformed into 2D image data, which is then used to train the Inc-DenseNet. Results demonstrate that with the trained Inc-DenseNet, the diagnostic accuracy for four PEMFC states of health (normal, flooding, dehydration, air starvation) can reach 95.3%, especially for flooding and air starvation. In addition, by using the voltage datasets collected from two different MEAs, the generalization capacity of the Inc-DenseNet is proved. With the findings, the proposed network Inc-DenseNet can not only achieve high-precision fault diagnosis, but also has a high computing efficiency, which makes it promising in real-time PEMFC fault diagnosis in the future.