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.     

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.     

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 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]     

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.     

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。     

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.     

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.     

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。     

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.     

Transient behavior of water generation in a proton exchange membrane fuel cell

The effect of water generation on the performance of proton exchange membrane fuel cell (PEMFC) was investigated by using a periodical linear sweep method. Three different kinds of I–V curves were obtained, which reflected different amount of water uptake in the fuel cell. The maximum water uptake that could avoid flooding in the fuel cell and the hysteresis of water diffusion were also discussed. Quantitative analysis of water uptake and water transport phenomena in this study were conducted both experimentally and theoretically. Results showed that the water uptake capacity for the fuel cell under no severe flooding was 27.837 mg cm⁻². The transient response of the internal resistance indicated that the high frequency resistance (HFR) lagged the current with a value of about 20 s. The effect of purging operation on the internal resistance of the fuel cell was also explored. Experimental data showed that the cell experienced a continuous 8-min purging process can maintain at a relatively steady and dry state.     

Numerical simulation and experimental validation of liquid water behaviors in a proton exchange membrane fuel cell cathode with serpentine channels

The volume-of-fluid (VOF) approach is one of the most promising methods of investigating water transport and water management in proton exchange membrane fuel cells (PEMFCs). A general PEMFC model combined with the VOF method has been developed by our group to simulate the mechanisms of fluid flows, mass and heat transport, and electrochemical reactions in a PEMFC, and it is necessary to validate the numerical model through experiments. In this paper, both the numerical model and an experimental visualization that can simulate the motion and transport behavior of liquid water in a cathode flow channel of a PEMFC are presented. Direct optical visualization is used in this work to capture the droplets’ motions with high spatial and temporal resolutions. The numerical model and experimental setup have similar geometric dimensions and operating conditions, and the results of the experiment are in good agreement with numerical simulations. Moreover, the physics of droplet and liquid water behavior based on certain material and liquid properties and the operating conditions in the fuel cell channel are also addressed. This analysis also offers some basic understanding of the mechanism of liquid droplet dynamics in numerical and experimental studies of micro-fluidics.     

Water management in alkaline anion exchange membrane fuel cell anode

Water management is an important issue for alkaline anion exchange membrane fuel cell (AAEMFC) due to its significant role in the energy conversion processes. In this study, a numerical model is developed to investigate the water transport in AAEMFC anode. The gas and liquid transport characteristics in the gas diffusion layer (GDL) and catalyst layer (CL) with different designs and under various operating conditions are discussed. The results show that the current density affects the liquid water distribution in anode most significantly, and the temperature is the second considerable factor. The stoichiometry ratio of the supplied reactant has insignificant effect on the liquid water transport in anode. The change of liquid water amount in anode with cathode relative humidity follows a similar trend with anode inlet relative humidity. Some numerical results are also explained with published experimental and modeling data with reasonable agreement.     

Constructal flow distributor as a bipolar plate for proton exchange membrane fuel cells

A plate-type constructal flow distributor is implemented as a gas distributor for a proton exchange membrane fuel cell. A 3D complete model is simulated using CFD techniques. The fuel cell model includes the gas flow channels, the gas diffusion layers and the membrane-electrode assembly (MEA). The governing equations for the mass and momentum transfer are solved including the pertinent source terms due to the electrochemical reactions in the different zones of the fuel cell. Three constructal flow configurations were studied; each pattern is a fractal expansion of the original design, therefore, the only difference between them is the number of branches in the geometry. It was found that the number of branches is the key parameter in the performance of a fuel cell when using the constructal distributors as flow channels. The performance of the fuel cell is reported in I-V curves, power curves, and overpotential curves in order to determine which irreversibility is the main cause of energy losses. In terms of flow analysis, it was found that the constructal flow distributor presents a low pressure drop for a wide range of Reynolds number conditions at the inlet, as well as an excellent uniformity of flow distribution. Regardless of the outstanding hydrodynamic performance of the constructal distributors and the large current density values obtained, the implementation of these designs as flow patterns for PEMFCs need further optimization; first, the manufacturing of the plates have to be addressed in an efficient way; and secondly, the application in stacks will require an elaborate design to accomplish this task.     

Two-phase flow pressure drop hysteresis in an operating proton exchange membrane fuel cell

Two-phase flow pressure drop hysteresis was studied in an operating PEM fuel cell. The variables studied include air stoichiometry (1.5, 2, 3, 4), temperature (50, 75, 90 °C), and the inclusion of a microporous layer. The cathode channel pressure drops can differ in PEM fuel cells when the current density is increased along a path and then decreased along the same path (pressure drop hysteresis). Generally, the descending pressure drop is greater than the ascending pressure drop at low current densities (<200 mA cm⁻²), and the effect is worse at low stoichiometries and low temperatures. The results show that the hysteresis occurs with or without the inclusion of a microporous layer. Initial results show a modified Lockhart-Martinelli approach seems to be able to predict the two-phase flow pressure drop during the ascending path. The results compare well with photographs taken from the cathode flow field channel of a visualization cell.     

Two-phase flow pressure drop hysteresis in parallel channels of a proton exchange membrane fuel cell

Two-phase flow pressure drop hysteresis was studied in a non-operational PEM fuel cell to understand the effect of stoichiometry, GDL characteristics, operating range, and initial conditions (dry vs. flooded) for flow conditions typical of an operating fuel cell. This hysteresis is noted when the air and water flow rates are increased and then decreased along the same path, exhibiting different pressure drops. When starting from dry conditions, the descending pressure drop tended to be higher than the ascending pressure drop at lower simulated current densities. The hysteresis effect was noted for stoichiometries of 1-4 and was eliminated at a stoichiometry of 5. It was found that the hysteresis was greater when water breakthrough occurred at higher simulated current densities, which is a function of GDL properties. The operating range had to reach a critical simulated current density (800 mA cm⁻² in this case) between the ascending and descending approach to create a pressure drop hysteresis zone. The descending step size does not change the size of the hysteresis effect, but a larger step size leads to lower fluctuations in the pressure drop signal. An initially flooded condition also showed hysteresis, but the ascending approach tended to have a higher pressure drop than the descending approach.     

Water transport in polymer electrolyte membrane fuel cells

Polymer electrolyte membrane fuel cell (PEMFC) has been recognized as a promising zero-emission power source for portable, mobile and stationary applications. To simultaneously ensure high membrane proton conductivity and sufficient reactant delivery to reaction sites, water management has become one of the most important issues for PEMFC commercialization, and proper water management requires good understanding of water transport in different components of PEMFC. In this paper, previous researches related to water transport in PEMFC are comprehensively reviewed. The state and transport mechanism of water in different components are elaborated in detail. Based on the literature review, it is found that experimental techniques have been developed to predict distributions of water, gas species, temperature and other parameters in PEMFC. However, difficulties still remain for simultaneous measurements of multiple parameters, and the cell and system design modifications required by measurements need to be minimized. Previous modeling work on water transport in PEMFC involves developing rule-based and first-principle-based models, and first-principle-based models involve multi-scale methods from atomistic to full cell levels. Different models have been adopted for different purposes and they all together can provide a comprehensive view of water transport in PEMFC. With the development of computational power, application of lower length scale methods to higher length scales for more accurate and comprehensive results is feasible in the future. Researches related to cold start (startup from subzero temperatures) and high temperature PEMFC (HT-PEMFC) (operating at the temperatures higher than 100 °C) are also reviewed. Ice formation that hinders reactant delivery and damages cell materials is the major issue for PEMFC cold start, and enhancing water absorption by membrane electrolyte and external heating have been identified as the most effective ways to reduce ice formation and accelerate temperature increment. HT-PEMFC that can operate without liquid water formation and membrane hydration greatly simplifies water management strategy, and promising performance of HT-PEMFC has been demonstrated.