Study of flow channel geometry using current distribution measurement in a high temperature polymer electrolyte membrane fuel cell

To improve fuel cell design and performance, research studies supported by a wide variety of physical and electrochemical methods have to be carried out. Among the different techniques, current distribution measurement owns the desired feature that can be performed during operation, revealing information about internal phenomena when the fuel cell is working. Moreover, short durability is one of the main problems that is hindering fuel cell wide implementation and it is known to be related to current density heterogeneities over the electrode surface. A good flow channel geometry design can favor a uniform current density profile, hence hypothetically extending fuel cell life. With this, it was thought that a study on the influence of flow channel geometry on the performance of a high temperature polymer electrolyte membrane (PEM) fuel cell using current distribution measurement should be a very solid work to optimize flow field design. Results demonstrate that the 4 step serpentine and pin-type geometries distribute the reactants more effectively, obtaining a relatively flat current density map at higher current densities than parallel or interdigitated ones and yielding maximum powers up to 25% higher when using oxygen as comburent. If air is the oxidant chosen, interdigitated flow channels perform almost as well as serpentine or pin-type due to that the flow conditions are very important for this geometry.     

Determination of the optimal active area for proton exchange membrane fuel cells with parallel,interdigitated or serpentine designs

Effects of active area size on steady-state characteristics of a working PEM fuel cell, including local current densities, local oxygen transport rates, and liquid water transport were studied by applying a three-dimensional, two-phase PEM fuel cell model. The PEM fuel cells were with parallel, interdigitated, and serpentine flow channel design. At high operating voltages, the size effects on cell performance are not noticeable owing to the occurrence of oxygen supply limit. The electrochemical reaction rates are high at low operating voltages, producing large quantity of water, whose removal capability is significantly affected by flow channel design. The cells with long parallel flow field experience easy water accumulation, thereby presenting low oxygen transport rate and low current density. The cells with interdigitated and serpentine flow fields generate forced convection stream to improve reactant transport and liquid water removal, thereby leading to enhanced cell performance and different size effect from the parallel flow cells. Increase in active area significantly improves performance for serpentine cells, but only has limited effect on that of interdigitated cells. Size effects of pressure drop over the PEM cells were also discussed.     

Study of novel flow channels influence on the performance of direct methanol fuel cell

The existing flow channels like parallel and gird channels have been modified for better fuel distribution in order to boost the performance of direct methanol fuel cell. The main objective of the work is to achieve minimized pressure drop in the flow channel, uniform distribution of methanol, reduced water accumulation, and better oxygen supply. A 3D mathematical model with serpentine channel is simulated for the cell temperature of 80 °C, 0.5 M methanol concentration. The study resulted in 40 mW/cm² of power density and 190 mA/cm² of current density at the operating voltage of 0.25 V. Further, the numerical study is carried out for modified flow channels to discuss their merits and demerits on anode and cathode side. The anode serpentine channel is unmatched by the modified zigzag and pin channels by ensuring the better methanol distribution under the ribs and increased the fuel consumption. But the cathode serpentine channel is lacking in water management. The modified channels at anode offered reduced pressure drop, still uniform reactant distribution is found impossible. The modified channels at cathode outperform the serpentine channel by reducing the effect of water accumulation, and uniform oxygen supply. So the serpentine channel is retained for methanol supply, and modified channel is chosen for cathode reactant supply. In comparison to cell with only serpentine channel, the serpentine anode channel combined with cathode zigzag and pin channel enhanced power density by 17.8% and 10.2% respectively. The results revealed that the zigzag and pin channel are very effective in mitigating water accumulation and ensuring better oxygen supply at the cathode.     

Effect of flow field design on performances of high temperature PEM fuel cells: Experimental analysis

Among all types of fuel cells, attention is being drawn lately on high temperature Polybenzimidazole (PBI) PEM because their operative temperature range (120-180 °C) increases the tolerance to carbon monoxide. This feature allows working with low quality hydrogen produced by hydrocarbon reformation. Most of the literature on PBI PEM deals with membrane and MEA related issues, however, cell efficiency and specially, commercial feasibility are conditioned by other fuel cell components as bipolar plates. In the present study the focus is on the effect of the flow field geometry of high temperature PBI PEM composite bipolar plates on the overall performance of the cell. For this purpose, three different channel geometries are studied: two serpentine flow fields and parallel channels flow field. Results show that serpentine geometry yields higher performance though it introduces higher pressure drop along the cell as well.     

Computational Fluid Dynamics Study of Serpentine Flow Field Proton Exchange Membrane Fuel Cell Performance

Abstract

Fuel cell is an electro-chemical device that directly converts the chemical energy of fuel into usable electrical form without any toxic byproducts. Flow field plates are backbone of the fuel cell. It is the essential component of fuel cell with multifunctional character. In the present work, a complete three-dimensional steady-state isothermal single phase computational fluid dynamics model is proposed for a proton exchange membrane fuel cell with serpentine flow channel to analyze the species transport phenomenon. The numerical model was developed and analyzed using ANSYS FLUENT 15.0 and simulations were carried out to get the key parameters like variation of oxygen, hydrogen, liquid water activity, and water mass fraction in the flow channels, membrane water content, and membrane protonic conductivity. The numerical results show that, when the cell is operated at higher current densities, i.e. lower cell voltage, hydrogen and oxygen consumption is more as well as water generation is also more. The effect of cell operating temperature and reactants inlet humidity on cell performance was also studied. Finally, the polarization curve obtained was compared with the experimental results and it was found that the numerical results are having good agreement with the experimental results.     

Experimental investigation of current distribution in a direct methanol fuel cell with serpentine flow-fields under various operating conditions

The influences of various operating conditions on the current distribution of a direct methanol fuel cell with flow-fields of serpentine channels are investigated by means of a current-mapping method. The current densities generally deviate more from an even distribution when the cell temperature or flow rate of the cathode reactant is lower, or when the current loaded on the cell or the methanol concentration is higher. In addition, uneven current distributions decrease the cell performance. Relevant mass-transfer phenomena such as water flooding and methanol crossover are discussed. The characteristics of the channel configuration also affect the current density profiles. With a five-line serpentine channel, the current densities are lowered periodically where the flow direction is inverted due to the corner flow effect and the subsequent water accumulation. With a single serpentine channel, on the other hand, the current densities peak periodically where the flow direction is inverted due to enhanced air convection through the gas-diffusion layer.     

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.     

质子交换膜燃料电池双极板的设计与模拟分析

质子交换膜燃料电池是直接将化学能转换为电能的装置,双极板上的流道结构对燃料电池的工作性能具有较大的影响。根据应用要求设计了具有平行流道、蛇形流道及希尔伯特分形流道的双极板结构,模拟计算了氢气在不同类型的流道和气体扩散层中的分布状态,分析了燃料电池的输出电流密度和功率密度随电极间电压的变化特点,比较了不同的流道结构对燃料电池输出电流密度的影响,以及不同的工作温度及气体压强的情况下,燃料电池输出电流密度随温度及压强的变化规律。     

Numerical investigation of transport phenomena in high temperature proton exchange membrane fuel cells with different flow field designs

In this work, a three-dimensional, non-isothermal, steady-state model for high temperature proton exchange membrane fuel cells with phosphoric acid polybenzimidazole membrane has been developed using computational fluid dynamics. The importance of the gas flow field design on the transport characteristics and cell performance is revealed by solving the mass, momentum, species, energy, and charge conservation equations. The numerical results show that the best cell performance is provided by the fuel cell with serpentine flow channel flow field. However, the pressure drop is also very high due to the large length of the serpentine channel. In addition, the velocity, oxygen mass fraction, and temperature distributions are unevenly distributed over the entire active area of the fuel cell having straight channels with small manifolds, especially at low cell voltages when a large amount of oxygen is required. The cell performance and durability can be significantly affected by the uniformity of the reactants within the fuel cell. It is suggested that the flow field configurations must be optimized to obtain uniform distributions of the reactants, maximize the cell performance, and minimize the pressure drop penalty. The present results provide detailed information about transport characteristics within fuel cells and give guidelines for design and manufacturing of current collectors.     

Experimental investigations of the anode flow field of a micro direct methanol fuel cell

The effect of the anode flow field design on the performance of an in-house fabricated micro direct methanol fuel cell (μDMFC) with an active area 1.0 cm × 1.0 cm was investigated experimentally. Single serpentine and parallel flow fields consisting of micro channels were tested. The experimental results indicated that the serpentine flow field exhibited significantly higher cell voltages than did the parallel flow field, particularly at high current densities. The study of the effect of channel depth of the serpentine flow field suggested that there exists an optimal channel depth for the same channel width and the same open ratio when the same methanol flow rate is supplied; either shallower or deeper channels will lead to a reduction in the cell performance. Finally, it was demonstrated that performance of the μDMFC with the reactants fed by an active means was insensitive to the cell orientations, which is different from conventional DMFCs with larger flow channels reported in the literature.     

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.     

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.     

Performance analysis of a proton exchange membrane fuel cell using tree-shaped designs for flow distribution

The performance of a proton exchange membrane (PEM) fuel cell is directly associated to the flow channels design embedded in the bipolar plates. The flow field within a fuel cell must provide efficient mass transport with a reduced pressure drop through the flow channels in order to obtain a uniform current distribution and a high power density. In this investigation, three-dimensional fuel cell models are analyzed using computational fluid dynamics (CFD). The proposed flow fields are radially designed tree-shaped geometries that connect the center flow inlet to the perimeter of the fuel cell plate. Three flow geometries having different levels of bifurcation were investigated as flow channels for PEM fuel cells. The performance of the fuel cells is reported in polarization and power curves, and compared with that of fuel cells using conventional flow patterns such as serpentine and parallel channels. Results from the flow analysis indicate that tree-shaped flow patterns can provide a relatively low pressure drop as well as a uniform flow distribution. It was found that as the number of bifurcation levels increases, a larger active area can be utilized in order to generate higher power and current densities from the fuel cell with a negligible increase in pumping power.     

Numerical evaluation of a PEM fuel cell with conventional flow fields adapted to tubular plates

In this research a 3D numerical study on a PEM fuel cell model with tubular plates is presented. The study is focused on the performance evaluation of three flow fields with cylindrical geometry (serpentine, interdigitated and straight channels) in a fuel cell. These designs are proposed not only with the aim to reduce the pressure losses that conventional designs exhibit with rectangular flow fields but also to improve the mass transport processes that take place in the fuel cell cathode. A commercial computational fluid dynamics (CFD) code was used to solve the numerical model. From the numerical solution of the fluid mechanics equations and the electrochemical model of Butler-Volmer different analysis of pressure losses, species concentration, current density, temperature and ionic conductivity were carried out. The results were obtained at the flow channels and the catalyst layers as well as in the gas diffusion layers and the membrane interfaces. Numerical results showed that cylindrical channel configurations reduced the pressure losses in the cell due to the gradual reduction of the angle at the flow path and the twist of the channel, thus facilitating the expulsion of liquid water from the gas diffusion layers and in turn promoting a high oxygen concentration at the triple phase boundary of the catalyst layers. Moreover, numerical results were compared to polarization curves and the literature data reported for similar designs. These results demonstrated that conventional flow field designs applied to conventional tubular plates have some advantages over the rectangular designs, such as uniform pressure and current density distributions among others, therefore they could be considered for fuel cell designs in portable applications.     

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.     

Cross-leakage flow between adjacent flow channels in PEM fuel cells

In polymer electrolyte membrane (PEM) fuel cells, serpentine flow channels are used conventionally for effective water removal. The reactant flows along the flow channel with pressure decrease due to the frictional and minor losses as well as the reactant depletion because of electrochemical reactions in the cells. Because of the short distance between the adjacent flow channels, often in the order of 1 mm or smaller, the pressure gradient between the adjacent flow channels is very large, driving part of reactant to flow through the porous electrode backing layer (or the so-called gas diffusion layer)—this cross-leakage flow between adjacent flow channels in PEM fuel cells has been largely ignored in previous studies. In this study, the effect of cross-flow in an electrode backing layer has been investigated numerically by considering bipolar plates with single-channel serpentine flow field for both the anode and cathode side. It is found that a significant amount of reactant gas flows through the porous electrode structure, due to the pressure difference, and enters the next flow channel, in addition to a portion entering the catalyst layer for reaction. Therefore, mixing occurs between the relatively high concentration reactant stream following the flow channel and the relatively low reactant concentration stream going through the electrode. It is observed that the cross-leakage flow influences the reactant concentration at the interface between the electrode and the catalyst layer, hence the distribution of reaction rate or current density generated. In practice, this cross-leakage flow in the cathode helps drive the liquid water out of the electrode structure for effective water management, partially responsible for the good PEM fuel cell performance using the serpentine flow channels.     

The effect of anode bed geometry on the hydraulic behaviour of PEM fuel cells

The influence of the anode bed geometry on the hydraulic behaviour of PEM fuel cells is assessed. Three basic geometrical patterns are studied, namely the interdigitated, the parallel and the serpentine ones, in their original, as well as in modified forms of them, in which their angles have been smoothed. Issues concerning the anode flow field of a fuel cell, the influence of the Reynolds number on pressure drop, the mass flowrate distribution along the anode bed channels and the residence time of the fluid inside the fuel cell are investigated. All different geometries are studied by means of 3D numerical flow simulations. The results indicate that the pressure drop, flowrate nonuniformity in bed channels and residence time increase as the flow Reynolds number increases. The effect of geometry smoothing on the results is also assessed.     

Numerical investigation of the impact of two-phase flow maldistribution on PEM fuel cell performance

Flow maldistribution usually happens in PEM fuel cells when using common inlet and exit headers to supply reactant gases to multiple channels. As a result, some channels are flooded with more water and have less air flow while other channels are filled with less water but have excessive air flow. To investigate the impact of two-phase flow maldistribution on PEM fuel cell performance, a Volume of Fluid (VOF) model coupled with a 1D MEA model was employed to simulate two parallel channels. The slug flow pattern is mainly observed in the flow channels under different flow maldistribution conditions, and it significantly increases the gas diffusion layer (GDL) surface water coverage over the whole range of simulated current densities, which directly leads to poor fuel cell performance. Therefore, it is recommended that liquid and gas flow maldistribution in parallel channels should be avoided if possible over the whole range of operation. Increasing the gas stoichiometric flow ratio is not an effective method to mitigate the gas flow maldistribution, but adding a gas inlet resistance to the flow channel is effective in mitigating maldistribution. With a carefully selected value of the flow resistance coefficient, both the fuel cell performance and the gas flow distribution can be significantly improved without causing too much extra pressure drop.     

A two-phase flow and transport model for PEM fuel cells

A two-phase flow and multi-component mathematical model with a complete set of governing equations valid in different components of a PEM fuel cell is developed. The model couples the flows, species, electrical potential, and current density distributions in the cathode and anode fluid channels, gas diffusers, catalyst layers and membrane, respectively. The modeling results of typical concentration distributions are presented. The coupling of oxygen concentration, current density, overpotential and potential are shown in the membrane electrode assembly (MEA). The model predicted fuel cell polarization curves for different cathode pressures compared well with our experimental data.     

A three-dimensional full-cell CFD model used to investigate the effects of different flow channel designs on PEMFC performance

A three-dimensional “full-cell” computational fluid dynamics (CFD) model is proposed in this paper to investigate the effects of different flow channel designs on the performance of proton exchange membrane fuel cells (PEMFC). The flow channel designs selected in this work include the parallel and serpentine flow channels, single-path and multi-path flow channels, and uniform depth and step-wise depth flow channels. This model is validated by the experiments conducted in the fuel cell center of Yuan Ze University, showing that the present model can investigate the characteristics of flow channel for the PEMFC and assist in the optima designs of flow channels. The effects of different flow channel designs on the PEMFC performance obtained by the model predictions agree well with those obtained by experiments. Based on the simulation results, which are also confirmed by the experimental data, the parallel flow channel with the step-wise depth design significantly promotes the PEMFC performance. However, the performance of PEMFC with the serpentine flow channel is insensitive to these different depth designs. In addition, the distribution characteristics of fuel gases and current density for the PEMFC with different flow channels can be also reasonably captured by the present model.