Experimental investigation of the effect of channel length on performance and water accumulation in a PEMFC parallel flow field

Longer channels within serpentine flow fields are highly effective at removing liquid water slugs and have little water accumulation; however, the long flow path causes a large pressure drop across the cell. This results in both a significant concentration gradient between the inlet and outlet, and high pumping losses. Parallel flow fields have a shorter flow path and smaller pressure drop between the inlet and outlet. This low pressure drop and multiple routes for reactants in parallel channels allows for significant formation of liquid water slugs and water accumulation. To investigate these differences, a polymer electrolyte membrane fuel cell parallel flow field with the ability to modify the length of the channels was designed, fabricated, and tested. Polarization curves and the performance, water accumulation, and pressure drop were measured during 15 min of 0.5 A cm⁻² steady-state operation. An analysis of variance was performed to determine if the channel length had a significant effect on performance. It was found that the longer 25 cm channels had significantly higher and more stable performance than the shorter 5 cm channels with an 18% and an 87% higher maximum power density and maximum current density, respectively. Channel lengths which result in a pressure drop, across the flow field, slightly larger than that required to expel liquid water slugs were found to have minimal water accumulation and high performance, while requiring minimal parasitic pumping power.     

Experimental investigation on scaling and stacking up of proton exchange membrane fuel cells

The performance of a proton exchange membrane fuel cell (PEMFC) with various flow channel design (serpentine and interdigitated) with different landing to channel ratios (L:C = 1:1; 2:2) for an active area of 25 cm² and 70 cm², for single cell and two cells stack is studied and compared. The effect of back pressure on the PEMFC performance is also investigated. This study establishes a strong relation between back pressure and power output from a PEMFC. It was concluded that the interdigitated flow channel gives better results than the serpentine flow channel configuration for various landing to channel ratios. It was also found that power outputs do not proportionally increase with active area of the membrane electrode assembly (MEA). Similarly, stacking up studies with single cell and two cell stack shows that the two cell stack has reduced power densities when compared to that of a single cell. The effect of cooling channels with natural and forced convection by using induced draught fan on the performance of a PEMFC stack is also studied. Fuel distribution and temperature management are found to be the significant factors which determine the performance of a PEMFC stack.     

Direct measurement of current density under land and two channels in PEM fuel cells with interdigitated flow fields

Interdigitated flow field is one of the commonly used designs in proton exchange membrane (PEM) fuel cells. The knowledge of how the current density differs under the inlet channel, the land and the outlet channel, is critical for flow field design and optimization. In this study, the current densities under the inlet channel, the land and the outlet channel in PEM fuel cell with an interdigitated flow field are separately measured using the technique of partially-catalyzed membrane electrode assemblies (MEAs). The experimental results show that the current density under the outlet channel is significantly lower than that under the inlet channel, and the current density under the land is higher than both channels at typical fuel cell operation voltages. Further experimental results show that the pattern of local current density remains the same with different cathode flow rates.     

Design strategy for a polymer electrolyte membrane fuel cell flow-field capable of switching between parallel and interdigitated configurations

Novel water management strategies are important to the development of next generation polymer electrolyte membrane fuel cell systems (PEMFCs). Parallel and interdigitated flow fields are two common types of PEMFC designs that have benefits and draw backs depending upon operating conditions. Parallel flow fields rely predominately on diffusion to deliver reactants and remove byproduct water. Interdigitated flow fields induce convective transport, known as cross flow, through the porous gas diffusion layer (GDL) and therefore are superior at water removal beneath land areas which can lead to higher cell performance. Unfortunately, forcing flow through the GDL results in higher pumping losses as the inlet pressure for interdigitated flow fields can be up to an order of magnitude greater than that for a parallel flow field. In this study a flow field capable of switching between parallel and interdigitated configurations was designed and tested. Results show, taking into account pumping losses, that using constant stoichiometry the parallel flow field results in a higher system power under low current density operation compared to the interdigitated configuration. The interdigitated flow-field configuration was observed to have lower overvoltage at elevated current densities resulting in a higher maximum power and a higher limiting current density. An optimal system power curve was produced by switching from parallel to interdigitated configuration based on which produces a higher system power at a given current density. This design method can be easily implemented with current PEMFC technology and requires minimal hardware. Some of the consequences this design has on system components are 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.     

Numerical investigation on the performance of PEMFC with rib-like flow channels

An innovative flow channel inspired by the physical structure of the human rib was developed in this paper. The performance of a proton exchange membrane fuel cell (PEMFC) with the proposed rib-like flow channels under different flow patterns and relative humidity of anode (RH_a) was investigated. Compared with the conventional interdigitated flow channel (CIFC) and cross-flow channel (CRFC), the maximum current density of the counter-flow channel (COFC) was 1.06 A/cm² at 0.4 V, with enhancements of 4.95% and 2.91%, respectively. In addition, the quantity referred to as non-uniformity N was introduced to quantify the concentration distribution of oxygen, the minimum non-uniformity N of 0.17 was obtained for CRFC, and the COFC exhibited a more uniform concentration distribution of temperature as compared with the CIFC and CRFC, indicating that the COFC would prevent the occurrence of local hot spots. The maximum net power density of COFC was 6.0% and 3.0% higher than that of the CIFC and CRFC. Finally, the maximum current density of RH_a = 30% was 1.06 A/cm², which was 3.9% and 7.1% higher than that of RH_a = 60% and RH_a = 100%. The temperature with RH_a = 100% was more uniform in comparison with RH_a = 30% and RH_a = 60%, and the mass fraction of H₂ decreased with the increase of values of RH_a. The proposed rib-like flow channel can further enrich PEMFC flow channel design and afford novel insights into the application of bionics in fuel cells.     

Investigation of bio-inspired flow channel designs for bipolar plates in proton exchange membrane fuel cells

Proton exchange membrane (PEM) fuel cell performance is directly related to the flow channel design on bipolar plates. Power gains can be found by varying the type, size, or arrangement of channels. The objective of this paper is to present two new flow channel patterns: a leaf design and a lung design. These bio-inspired designs combine the advantages of the existing serpentine and interdigitated patterns with inspiration from patterns found in nature. Both numerical simulation and experimental testing have been conducted to investigate the effects of two new flow channel patterns on fuel cell performance. From the numerical simulation, it was found that there is a lower pressure drop from the inlet to outlet in the leaf or lung design than the existing serpentine or interdigitated flow patterns. The flow diffusion to the gas diffusion layer was found be to more uniform for the new flow channel patterns. A 25 cm² fuel cell was assembled and tested for four different flow channels: leaf, lung, serpentine and interdigitated. The polarization curve has been obtained under different operating conditions. It was found that the fuel cell with either leaf or lung design performs better than the convectional flow channel design under the same operating conditions. Both the leaf and lung design show improvements over previous designs by up to 30% in peak power density.     

In-situ measurements of GDL effective permeability and under-land cross-flow in a PEM fuel cell

When reactant gases flow along a channel in serpentine flow field of a proton exchange membrane (PEM) fuel cell, there is a pressure difference between the adjacent channels and it produces an under-land cross-flow (or under-rib convection) from the higher pressure side to the lower pressure side through the gas diffusion layer (GDL). A unique experimental setup is developed for in-situ measurement of this cross-flow and the GDL effective permeability at the cathode side of a PEM fuel cell under dry and realistic humidified gas conditions. The non-Darcy effect, defined as a function of the Forchheimer number is studied and compared for both 1 mm and 2 mm land widths and both dry and humidified air conditions. Finally, a dimensional analysis is performed and the non-dimensional cross-flowrate is shown to increases linearly with the increase of the non-dimensional pressure difference.     

Mid-baffle interdigitated flow fields for proton exchange membrane fuel cells

A new design of an interdigitated flow field, called as a mid-baffle interdigitated flow field, was built and tested for its effect on the performance of proton exchange membrane (PEM) fuel cells. The results were compared to the conventional interdigitated flow field. Their performances at different oxidant gas flow rates and operating pressures were also examined and compared by using both O₂ and air as the cathode fuel reactants. The experimental results showed that when air was used as the cathode reactant, the cell with the mid-baffle interdigitated flow field outperformed the conventional one, giving a power output approximately 1.2-1.3 times higher depending on the air flow rates. The polarization curves of the mid-baffle interdigitated flow field showed larger limiting current densities at every air flow rate tested in this work. However, the performances of both flow fields were almost the same when the cathode reactant gas was O₂. The test also demonstrated that the flow field performance could be enhanced by increasing the oxidant gas flow rate and cell operating pressure.     

Comparison of PEMFC performance with parallel serpentine and parallel serpentine-baffled flow fields under various operating and geometrical conditions; a parametric study

Optimal flow channel design of a fuel cell is crucial to further improve the performance of polymer electrolyte membrane fuel cell (PEMFC). In this work, a comprehensive parametric study was conducted to analyze the performance of a PEMFC with conventional parallel serpentine flow fields (PSFF) and parallel serpentine-baffled flow fields (PSBFF). A three-dimensional two-phase computational fluid dynamics model was used to numerically simulate the fuel cell performance. The effects of operating parameters such as pressure, temperature, and stoichiometric ratio, as well as the geometric parameters of channel height to channel width ratio and rib width to channel width ratio for both flow fields on fuel cell performance were investigated. The results show that as pressure, temperature, and stoichiometric ratio increase, cell performance increases for both flow fields, with a more substantial rate of improvement for the PSBFF design. A 16.1% improvement in cell performance at an operating pressure of 1 atm, a 19.9% improvement at a cell temperature of 70 °C, and a 16.1% improvement at a stoichiometric ratio of 2 were obtained when PSBFF was used instead of PSFF. By increasing the channel height and rib width, the cell performance for PSBFF remains almost constant due to the improved forced convection of the gas mixture and the reduction in concentration loss, while the cell performance for PSFF decreases significantly. At the largest channel height to channel width ratio of 1.5 and rib width to channel width ratio of 1.315 studied in this work, an improvement in cell performance of 53.3% and 58.5%, respectively, was achieved when PSBFF was used instead of PSFF. In addition, PSBFF was more effective in removing water from the porous zones than PSFF under all conditions.     

Different flow fields,operation modes and designs for proton exchange membrane fuel cells with dead-ended anode

Water and nitrogen can accumulate in the anode channel in proton exchange membrane fuel cells (PEMFCs) with dead-ended anode (DEA) and can affect cell performance significantly. In this paper, the cell performance characteristics in DEA PEMFCs with three different anode flow fields under two operating modes are studied through measuring the cell voltages and local current densities. The effect of the anode exit reservoir is also studied for the three different anode flow fields. The experimental results show that the interdigitated flow field has the most stable cell performance under both constant pressure and pressure swing supply modes. Parallel and serpentine flow fields lead to very non-uniform local current distributions under constant pressure supply mode and experience severe fluctuations and spikes in local current densities under pressure swing supply mode. The results also show that anode pressure swing supply mode can achieve more stable cell performance than anode constant pressure supply mode for parallel and serpentine anode flow fields. The anode exit reservoir can significantly improve cell performance stability for parallel and serpentine flow fields, but has no significant effect on interdigitated flow fields. Besides, the results further show that PEMFCs with DEA can maintain very stable operation with anode serpentine flow field and an anode exit reservoir under pressure swing operation.     

Experimental investigations on liquid water removal from the gas diffusion layer by reactant flow in a PEM fuel cell

The cross flow from channel to channel through gas diffusion layer (GDL) under the land could play an important role for water removal in proton exchange membrane (PEM) fuel cells. In this study, characteristics of liquid water removal from GDL have been investigated experimentally, through measuring unsteady pressure drop in a cell which has the GDL initially wet with liquid water. The thickness of GDL is carefully controlled by inserting various thicknesses of metal shims between the plates. It has been found that severe compression of GDL could result in excessive pressure drop from channel inlet to channel outlet. Removing liquid water from GDL by cross flow is difficult for GDL with high compression levels and for low inlet air flow rates. However, effective water removal can still be achieved at high compression levels of GDL if the inlet air flow rate is high. Based on different compressed GDL thicknesses, different GDL porosities and permeabilities were calculated and their effects on the characteristics of liquid water removal from GDL were evaluated. Visualization of liquid water transport has been conducted by using transparent flow channel, and liquid water removal from GDL under the land was observed for all the tested inlet air flow rates, which confirms that cross flow is practically effective to remove the liquid water accumulated in GDL under the land area.     

Measurements of current and water distribution for a micro-PEM fuel cell with different flow fields

Time-dependent measurements for the mapping of current distribution via a segmented flow field plate approach in a micro-proton exchange membrane (PEM) fuel cell were conducted and the effects of flow field configuration were studied and discussed under fixed operating conditions. The results show that, among four flow fields studied herein, the interdigitated flow channel has the most uniform transient current distribution with a much higher water content at an early phase (say t < 0.5 h) than those of the other three channels: serpentine, mesh and parallel, indicating an adequate oxygen concentration of the airflow on the cathode. In addition, the effect of water content on current distribution was also examined and discussed. It was found that the volume of water in flow channels could reach a steady value of 45% for all four flow fields after a 3-h operation.     

Numerical simulation of two‐phase cross flow in the gas diffusion layer microstructure of proton exchange membrane fuel cells

The cross flow in the under‐land gas diffusion layer (GDL) between 2 adjacent channels plays an important role on water transport in proton exchange membrane fuel cell. A 3‐dimensional (3D) two‐phase model that is based on volume of fluid is developed to study the liquid water‐air cross flow within the GDL between 2 adjacent channels. By considering the detailed GDL microstructures, various types of air‐water cross flows are investigated by 3D numerical simulation. Liquid water at 4 locations is studied, including droplets at the GDL surface and liquid at the GDL‐catalyst layer interface. It is found that the water droplet at the higher‐pressure channel corner is easier to be removed by cross flow compared with droplets at other locations. Large pressure difference Δp facilitates the faster water removal from the higher‐pressure channel. The contact angle of the GDL fiber is the key parameter that determines the cross flow of the droplet in the higher‐pressure channel. It is observed that the droplet in the higher‐pressure channel is difficult to flow through the hydrophobic GDL. Numerical simulations are also performed to investigate the water emerging process from different pores of the GDL bottom. It is found that the amount of liquid water removed by cross flow mainly depends on the pore's location, and the water under the land is removed entirely into the lower‐pressure channel by cross flow.     

Investigation on cold start of polymer electrolyte membrane fuel cells with different cathode serpentine flow fields

The flow velocity and pressure distribution of the three cathode flow fields are simulated in this study. Larger pressure drop and more rapid flow rate reduce residual water, resulting in minimal ice formation during the cold start process. The simulation results show that the single variable cross section serpentine flow field has the largest pressure drop and the most rapid flow rate.The evolution of the temperature and the segment current density characteristics of three different cathode flow fields during cold start process is studied by printed circuit board technology. The results show that the 2 to 1 serpentine flow field has the best cold start performance and the best current density uniformity when cold start at constant voltage mode above −5 °C. However, the single variable cross section serpentine flow field has the best performance when cold start temperature is below −5 °C. Based on these results, cold start at −30 °C can be realized in 97s by using hot antifreeze liquid.     

Optimum thermal design of microchannel heat sinks by the simulated annealing method

By adopting the simulated annealing method, a three-dimensional numerical simulation is executed to minimize the thermal resistance of the microchannel heat sink corresponding to the optimum specification under the fixed flow power. The depths of the microchannel heat sink in this study are fixed at either 1 cm or 2 cm. Based on the theory of the fully developed flow, the pressure drop between the inlet and exit in each single channel can be analytically derived if the flow power and the associated specification of the microchannel heat sink are fixed in advance. Then, this pressure drop will be used as the input condition to calculate the temperature distribution of the microchannel heat sink. For the first part of the optimum analysis, the fin width, and channel width are chosen as the design variables to find their optimum sizes. As to the second part of the present analysis, three design variables including channel height, fin width and channel width are individually prescribed as a suitable range to search for their optimum geometric configuration when the other specifications of the microchannel heat sink are fixed as 24 different cases.     

Performance enhancement of direct methanol fuel cell using multi‐zone narrow flow fields

New serpentine and spiral flow field configurations were developed to enhance the performance of direct methanol fuel cells (DMFCs). The new configurations are based on two primary concepts, namely, narrowing the flow field and partitioning the total active area of the fuel cell. Three flow channel heights of 0.8, 0.4, and 0.2 mm were investigated in serpentine and spiral flow fields. The main active area is considered a single zone and is partitioned into two‐ and four‐zone designs while maintaining the total inlet mass flow rate of the reactant and oxidant. To determine the performance parameters of the newly proposed designs, a three‐dimensional single‐phase isothermal model was developed, numerically simulated, and validated through experimental measurements. The findings of the current study indicate that a serpentine flow field configuration with a channel height of 0.2 mm and two zones attains an enhancement of the net power density of 37% compared to a conventional single‐zone design with a flow channel height of 0.8 mm. Similarly, for a spiral flow field design, the maximum net power density increased by 26% using a two‐zone configuration with a channel height of 0.2 mm, in comparison to the conventional design of a single‐zone and a flow channel height of 0.8 mm. The newly developed designs utilize the lower height of the flow fields to decrease the dimensions of the fuel cell stacks and reduce the material costs required.     

Pressure drop on water accumulation distribution for a micro PEM fuel cell with different flow field plates

Time-dependent measurements of pressure drop in different flow fields on the cathode of a PEM fuel cell with different operating conditions of mass flow rates and cell temperatures on water accumulation were conducted. The results show that, among four flow fields studied herein, the interdigitated flow channel has the biggest pressure drop as well as the largest water accumulation at an early phase (?30 min) compared to those of the other three channels. In addition, the more water produced, the bigger the pressure drop that occurs. Similarly, the effects of mass flow rates at a fixed cell temperature were also examined and discussed.     

Performance tests of a double-passive μDMFC stack with parallel/dendrite flow field

We report an experimental study on the effect of different flow fields on the cell performance of a double-passive (both anode/cathode) μDMFC stack. Cell performance measurements were made and analyzed for seven different flow field combinations at the anode/cathode of a passive micro direct methanol fuel cell (μDMFC) stack. An optimum flow field combination, after taking a series of tests under different operating conditions, was obtained. The results show that the conventional parallel type flow field used at the anode with an innovative/new dendrite perforated type of 80° flow field can provide the best power density for both single cell and 8-cell stack which have a power density of 16.9 mA/cm² at 50 °C and 1 M methanol solution. Moreover, for an 8-cell stack, both the gravimetric and volumetric power densities can be up to 7.4 W/kg and 37.2 W/L, respectively.     

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.