Concentration and ohmic losses in free-breathing PEMFC

Non-isothermal and three-dimensional simulations were carried out to study concentration and ohmic losses in free-breathing PEMFC under diverse conditions. Flow fields, species transport, transport of water in polymer membrane and movement of liquid water in cathode and anode porous layers were determined. Numerical results were obtained under different hydrating conditions, cell temperatures, cathode catalyst loadings and channel lengths. Current density and polymer electrolyte water content distributions as well as average power density were used as main output variables to study effects of operative conditions on performance. Results show that slow oxygen transport to active sites constitutes the most limiting factor to consider. Dehydrating conditions slightly affect free-breathing PEMFC performance. The numerical model showed to be suitable to study diverse phenomenon involved in free-breathing PEMFC performance.     

PEMFC stack voltage singularity measurement and fault classification

The study summarized in this paper deals with non-intrusive fault diagnosis of Polymer Electrolyte Membrane Fuel Cell (PEMFC) stack. In the proposed approach, the diagnosis operation is based on the stack voltage singularity measurement and classification. To this aim, wavelet transform-based multifractal formalism, named WTMM (Wavelet Transform Modulus Maxima), and pattern recognition methods are combined to realize the identification of the PEMFC faults. The proposed method takes advantage of the non-linearities associated with discontinuities introduced in the dynamic response data resulting from various failure modes. Indeed, the singularities signature of poor operating conditions (faults) of the PEMFC is revealed through the computing of multifractal spectra. The obtained good classification rates demonstrate that the multifractal spectrum based on WTMM is effective to extract the incipient fault features during the PEMFC operation. The proposed method leads to a promising non-intrusive and low cost diagnostic tool to achieve on-line characterizations of dynamical FC behaviors.     

The dynamic multifractality in PEMFC stack voltage signal as a tool for the aging monitoring

Fuel Cell aging monitoring and diagnosis are key-issues for scientists and industrials who intend to spread this technology. In the present work, we propose an efficient method that enables the extraction of valuable information which contains indicators on the aging of a studied PEM Fuel Cell (PEMFC). In this context, we investigate the possibilities offered by the Wavelet Leaders based Multifractal Analysis (WLMA), which is a suitable method to study the clustering variability of non-stationary fluctuating signals. A continuous aging test of 124 h conducted under nominal operating conditions serves as data input for the development of our diagnosis method. Singularity spectra (SS) are calculated on the stack voltage signals at different periods of time. We observe that stack voltage over extended periods of operating time leads to different types of singularities, i.e., we find a narrow range of values of Hölder exponent h with non-zero fractal dimension D(h) according to the operating time of the FC. We conclude that this dynamic multifractality of the stack voltage can be considered as a pertinent tool for the monitoring of the FC aging state.     

Experimental investigation on the voltage uniformity for a PEMFC stack with different dynamic loading strategies

The operating life of the proton exchange membrane fuel cell stack is mainly decided by performances of its weakest single cell because of the “Buckets effect”, thus high voltage uniformity during a dynamic loading process is key to the stack durability. In this work, a 3-kW stack is examined experimentally on its voltage uniformity (voltage coefficient variation (Cv)) under conditions of loading from open-circuit state (0 A) to nominal current (165 A) and stack temperatures of 30 °C, 45 °C and 65 °C. Different dynamic loading strategies, namely constant loading rate strategy, decreasing loading rate strategy, and increasing loading rate (square/cube increasing loading rate) strategy, are examined and compared. Results display that during the loading process, (a) the voltage uniformity rises abruptly and goes down quickly when the loading current is small (e.g. from 0 A to 22 A), (b) the voltage uniformity under a small loading current is better than that under the open-circuit state, and (c) voltage uniformity decreases as the loading current increases from a small value to the nominal current. Comparisons of different current loading strategies show that as the stack temperature rises from 30 °C to 65 °C, the stack Cv value under the open-circuit state increases from 1.12 to 1.84 and decreases from 3.85 to 2.45 in the nominal current state. The maximum Cv for the decreasing loading rate strategy decreases from 16.25 to 9.49 and that of the constant loading rate strategy also decreases from 5.85 to 4.96. Cv values of the square current increasing loading rate strategy keep below 3.85 under conditions of the three stack temperatures and display a slight fluctuation during the whole current loading process, which indicates that the strategy can effectively make the stack being of an excellent voltage uniformity during the instantaneous response process.     

Numerical simulation of a mini PEMFC stack

Fuel cell modeling and simulation has aroused much attention recently because it can probe transport and reaction mechanism. In this paper, a computational fuel cell dynamics (CFCD) method was applied to simulate a proton exchange membrane fuel cell (PEMFC) stack for the first time. The air cooling mini fuel cell stack consisted of six cells, in which the active area was 8 cm² (2 cm × 4 cm). With reasonable simplification, the computational elements were effectively reduced and allowed a simulation which could be conducted on a personal computer without large-scale parallel computation. The results indicated that the temperature gradient inside the fuel cell stack was determined by the flow rate of the cooling air. If the air flow rate is too low, the stack could not be effectively cooled and the temperature will rise to a range that might cause unstable stack operation.     

Experimental investigation on statistical characteristics of cell voltage distribution for a PEMFC stack under dynamic driving cycle

The proton exchange membrane fuel cell (PEMFC) stack consists of individual cells in series. Its operating life is subjected to performance of the weakest cell because of the short-board effect, thus voltage uniformity during dynamic long-running process is significant to its durability. In this work, based on a 1044 h aging experiment on a 6.55 kW PEMFC stack under dynamic driving cycle, voltage uniformity is analyzed. In a single cycle, voltage uniformity becomes worse with the increase of loading current and there are some local maxima of voltage coefficient variation (C_v) at the moment of loading or unloading step. C_v value at higher current is greater and increases faster with cycles. At the end of experiment, C_v at 135 A is more than 6%. Besides, skewness (S_k) is used to evaluate the skew direction and degree of cell voltage data in a cycle. In most cycles, S_k values at 34.22 A are above 0 and S_k values at 59.70 A and 135 A are below 0. After the Box-Cox transformation, which is used to improve symmetry of data and reduce S_k, the cell voltage data have passed the verifications of normal fitting, probability-probability plot and quantile-quantile plot. Therefore, it is found that cell voltage data tend to obey skewed normal distribution, which is of positive significance for improving voltage uniformity and durability of PEMFC stack.     

Impact of alternating fuel feeding on a PEMFC stack durability

The integration of PEMFC for transport applications requires cost as well as system complexity reduction. A novel anode circuit architecture named “Alternating Fuel Feeding” (AFF) was developed. It combines on one hand, the benefits of the hydrogen recirculation and on the other hand, the simpleness of Dead-End Anode (DEA). A previous work demonstrated the benefits on the costs and on the anodic line weight. In the present work, investigations on stack durability, from the system scale to the cell scale, are performed during operation in two anode feeding modes: AFF and recirculation. The performances of stacks are evaluated along ageing tests, coupled with local measurements. At the end of life, postmortem analyses are performed on the aged cells. The degradation rates of stack performances are quite similar in both cases while more heterogeneous cell degradation are observed in recirculation mode along with the ageing according to a Fuel Cell Dynamic Load Cycle (FC-DLC).     

Evidence of a non-dimensional parameter controlling the flooding of PEMFC stack

Water management is a key issue to get satisfactory and stable Polymer exchange membrane fuel cell (PEMFC) performances. The work reported in the present paper focuses on the determination of the operational conditions when using PEMFC stack working with ambient air without extra humidification. The objectives are to reduce as much as possible the auxiliaries consumptions. As far as the reaction air blower is concerned, the specific goal of the present tests is to find the minimum air flow rate to feed the PEMFC stack in order to prevent flooding. Our particular interest concerns the control of a PEMFC stack to power a prototype vehicle for the Shell Eco Marathon race.     

Theoretical and experimental investigations on thermal management of a PEMFC stack

In recent years micro-cogeneration systems (μ-CHPs), based on fuel cells technology, have received increasing attention because, by providing both useful electricity and heat with high efficiency, even at partial loads, they can have a strategic role in reduction of greenhouse gas emissions. For residential applications, the proton exchange membrane fuel cell (PEMFC), is considered the most promising, since it offers many advantages such as high power density, low operating temperature, and fast start-up and shutdown.In this paper the electrical and thermal behaviors of a PEMFC stack, suitable for μ-CHP applications, have been investigated through experimental and numerical activity.The experimental activity has been carried out in a test station in which several measurement instruments and controlling devices are installed to define the behavior of a water-cooled PEMFC stack. The test station is equipped by a National Instruments Compact DAQ real-time data acquisition and control system running Labview™ software.The numerical activity has been conducted by using a model, properly developed by the authors, based on both electrochemical and thermal analysis.The experimental data have been used to validate the numerical model, which can support and address the experimental activity and can allow to forecast the behavior and the performance of the stack when it is a component in a more complex energy conversion system.     

Rapid degradation characteristics of an air-cooled PEMFC stack

Durability is one of the obstacles to the large-scale commercialization of proton exchange membrane fuel cell (PEMFC) stacks. Understanding its decay behavior is a prerequisite for improving durability. In this study, rapid degradation characteristics of an air-cooled PEMFC stack are investigated. Due to the simultaneous presence of various degradation sources, the maximum power of the PEMFC stack has been reduced by 39.6% after just 74.6 h of operations. Performance degradation characteristics are sought by analyzing the cell voltage, temperature distribution, ion chromatography, and surface morphology of the gas diffusion layer. The result shows that abnormal cell voltage and temperature distribution can reflect the problematic location. The fluoride ion emission rate is 0.111 mg/day, which proves that the membrane has been seriously degraded. Contact angle reduction and impurities attached to the surface of the gas diffusion layer lead to the water management failure. It is also found that the main factor for performance degradation could be different under different current conditions. And more information can be found under higher current conditions during monitoring the decay of PEMFCs. This study helps to deepen the understanding of performance degradation characteristics.     

Experimental study of dynamic performance of defective cell within a PEMFC stack

Defective cell in a PEMFC stack may reduce durability and reliability of the stack and even damage the stack. However, the dynamic performance of defective cell within a PEMFC stack is not clear. In this paper, the dynamic characteristics of the defective cell under different load conditions are analyzed. The results reveal that the defective cell has slower dynamic response rate than other single fuel cells, and the defective cell causes a poor voltage uniformity of the stack. The increased frequency of load change makes the voltage change rate of defective cell higher. The increased amplitude of load change has a more negative impact than the increased frequency of load change, and makes the defective cell more prone to flooding. Furthermore, impedance spectrum shows that these load conditions have greater negative effect for the defective cell than other cells. Finally, according to the experimental results and practical application, recommends related to control strategy of PEMFC stack are proposed to extend lifetime.     

Behaviour of a PEMFC supplying a low voltage static converter

This paper presents the behaviour of a proton exchange membrane fuel cell (PEMFC) connected to a static dc–dc converter. Two different models of the PEM fuel cell are obtained from static measurements and impedance spectroscopy. The paper points out the necessity to use different models according to the type of study performed on the system. The comparison of models at high semiconductors switching frequency (25 kHz) is illustrated. Various experimental results obtained on a 500 W PEMFC test bench are compared with simulation ones to illustrate the accuracy of the proposed models.     

Performance of PEMFC stack using expanded graphite bipolar plates

The bipolar plates are in weight and volume the major part of PEM fuel cell stack, and also a significant effect to the stack cost. To develop the low-cost and low-weight bipolar plate for PEM fuel cell, we have developed a kind of cheap expanded graphite plate material and a production process for fuel cell bipolar plates. The plates have a high electric conductivity and low density, and can be stamped directly forming fuel cell bipolar plates. Then, 1 and 10 kW stacks using expanded graphite bipolar plates are successfully assembled. The contact resistance of the bipolar plate is investigated and the electrochemical performances of the fuel cell stacks are tested. Good fuel cell performance is obtained and the voltage distribution among every single cell in the stacks is very uniform.     

Thermal and electrical energy management in a PEMFC stack – An analytical approach

An analytical method has been developed to differentiate the electrical and thermal resistance of the PEM fuel cell assembly in the fuel cell operating conditions. The usefulness of this method lies in the determination of the electrical resistance based on the polarization curve and the thermal resistance from the mass balance. This method also paves way for the evaluation of cogeneration from a PEMFC power plant. Based on this approach, the increase in current and resistance due to unit change in temperature at a particular current density has been evaluated. It was observed that the internal resistance of the cell is dependent on the electrode fabrication process, which also play a major role in the thermal management of the fuel cell stack.     

Thermal management issues in a PEMFC stack – A brief review of current status

Understanding the thermal effects is critical in optimizing the performance and durability of proton exchange membrane fuel cells (PEMFCs). A PEMFC produces a similar amount of waste heat to its electric power output and tolerates only a small deviation in temperature from its design point. The balance between the heat production and its removal determines the operating temperature of a PEMFC. These stringent thermal requirements present a significant heat transfer challenge. In this work, the fundamental heat transfer mechanisms at PEMFC component level (including polymer electrolyte, catalyst layers, gas diffusion media and bipolar plates) are briefly reviewed. The current status of PEMFC cooling technology is also reviewed and research needs are identified.     

Quantitative analysis on cold start process of a PEMFC stack with intake manifold

To systematically explore the low-temperature operating characteristics of polymer electrolyte membrane fuel cell (PEMFC) stack, a three-dimensional PEMFC stack model with intake manifold is developed in this study. The characteristics of different cold start modes in the stack are compared and analyzed. The distribution and transmission characteristics of water, ice, and heat in each cell of the stack are analyzed in detail. The location of water accumulation in each cell of the stack is also explored. Finally, finite difference sensitivity is calculated for the cumulated charge transfer density to quantify the effects of operating parameters on the cold start process at low temperature. And how these parameters affect the operation of the PEMFC stack at low temperature is investigated. The results show that inconsistency exists in stack operation due to the position particularity of the intermediate cell. Irreversible heat is the main heat source for the cold start of the stack, and the cathode catalyst layer is the main heat-generating component. The heat production proportion of cathode catalyst layer can reach 90%, which decreases with the increment of current density and the running time, especially for the edge cell. The initial ionomer water content is most sensitive to the cold start process of the stack, followed by the porosity of cathode catalyst layer. These parameters are sensitive to the cold start process mainly because of the change in volumetric exchange current density and oxygen concentration.