Dominant frequency of pressure drop signal as a novel diagnostic tool for the water removal in proton exchange membrane fuel cell flow channel

In this work, a transparent assembly was self-designed and manufactured to perform ex situ experimental study on the liquid water removal characteristics in PEM fuel cell parallel flow channels. It was found that the dominant frequency of the pressure drop across the flow channels may be utilized as an effective diagnostic tool for water removal. Peaks higher than 1 Hz in dominant frequency profile indicated water droplet removals at the outlet, whereas relatively lower peaks (between 0.3 and 0.8 Hz) corresponded to water stream removals. The pressure drop signal, although correlated with the water removal at the outlet, was readily influenced by the two phase flow transport in channel, particularly at high air flow rates. The real-time visualization images were presented to show a typical water droplet removal process. The findings suggest that dominant frequency of pressure drop signal may substitute pressure drop as a more effective and reliable diagnostic tool for water removal in PEM fuel cell flow channels.     

Diagnosis of PEM fuel cell stack dynamic behaviors

In this study, the steady-state performance and dynamic behavior of a commercial 10-cell Proton Exchange Membrane (PEM) fuel cell stack was experimentally investigated using a self-developed PEM fuel cell test stand. The start-up characteristics of the stack to different current loads and dynamic responses after current step-up to an elevated load were investigated. The stack voltage was observed to experience oscillation at air excess coefficient of 2 due to the flooding/recovery cycle of part of the cells. In order to correlate the stack voltage with the pressure drop across the cathode/anode, fast Fourier transform was performed. Dominant frequency of pressure drop signal was obtained to indicate the water behavior in cathode/anode, thereby predicting the stack voltage change. Such relationship between frequency of pressure drop and stack voltage was found and summarized. This provides an innovative approach to utilize frequency of pressure drop signal as a diagnostic tool for PEM fuel cell stack dynamic behaviors.     

A semiempirical dynamic model of reversible open circuit voltage drop in a PEM fuel cell

Fuel cell voltage modeling is important for fundamental research. The main focus of previous studies has been the working voltage segment, whereas the accuracy of the open circuit voltage (OCV), especially the dynamic OCV change process, has been ignored. A semiempirical model including the OCV and an electrochemical model has been proposed in this study to clarify the reversible voltage drop process. A mixed cathode potential drop that is assumed as corresponding to a piecewise function relationship with an active surface area is introduced in this study. Fitting results exactly coincide with the original data in 2 modes, namely a quasistatic condition in a bench test and a dynamic condition in a fuel cell city bus. In the dynamic OCV drop process, the voltage drop due to the hydrogen crossover current approximately corresponds to 0.003 V and the mixed cathode potential drop approximately corresponds to 0.02 V.     

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.     

Numerical investigation of pressure drop characteristics of gas channels and U and Z type manifolds of a PEM fuel cell stack

Fluid flow manifold plays a significant role in the performance of a fuel cell stack because it affects the pressure drop, reactants distribution uniformity and flow losses, significantly. In this study, the flow distribution and the pressure drop in the gas channels including the inlet and outlet manifolds, with U- and Z-type arrangements, of a 10-cell PEM fuel cell stack are analyzed at anode and cathode sides and the effects of inlet reactant stoichiometry and manifold hydraulic diameter on the pressure drop are investigated. Furthermore, the effect of relative humidity of oxidants on the pressure drop of cathode are investigated. The results indicate that increase of the manifold hydraulic diameter leads to decrease of the pressure drop and a more uniform flow distribution at the cathode side when air is used as oxidant while utilization of humidified oxidant results in increase of pressure drop. It is demonstrated that for the inlet stoichiometry of 2 and U type manifold arrangement when the relative humidity increases from 25% to 75%, the pressure drop increases by 60.12% and 116.14% for oxygen and air, respectively. It is concluded that there is not a significant difference in pressure drop of U- and Z-type arrangements when oxygen is used as oxidant. When air is used as oxidant, the effect of manifold type arrangement is more significant than other cases, and increase of the stoichiometry ratio from 1.25 to 2.5 leads to increase of pressure drop by 527.3%.     

Diagnostic tools in PEM fuel cell research: Part I Electrochemical techniques

To meet the power density, reliability, and cost requirements that will enable a widespread use of fuel cells, many research activities focus on an understanding of the thermodynamics as well as the fluid mechanical and electrochemical processes within a fuel cell. To date, a wide range of experimental diagnostics is imperative not only to help a fundamental understanding of fuel cell dynamics but also to provide benchmark-quality data for modeling research. This two-part paper reviews various tools for diagnosing polymer electrolyte membrane (PEM) fuel cells and stacks, and attempts to incorporate the most recent technical advances in PEM fuel cell diagnosis. In Part I, we review various electrochemical techniques and outline the principle, experimental implementation, and data processing of each technique. Capabilities and weaknesses of these techniques are also discussed. In Part II of the review we will cover physical/chemical methods.     

Two-phase transport in the cathode gas diffusion layer of PEM fuel cell with a gradient in porosity

Two-phase transport in the cathode gas diffusion layer (GDL) of a proton exchange membrane fuel cell (PEMFC) is studied with a porosity gradient in the GDL. The porosity gradient is formed by adding micro-porous layers (MPL) with different carbon loadings on the catalyst layer side and on the flow field side. The multiphase mixture model is employed and a direct numerical procedure is used to analyze the profiles of liquid water saturation and oxygen concentration across the GDL as well as the resulting activation and concentration losses. The results show that a gradient in porosity will benefit the removal rate of liquid water and also enhance the transport of oxygen through the cathode GDL. The present study provides a theoretical support for the suggestion that a GDL with porosity gradient will improve the cell performance.     

Two-phase pressure drop response during load transients in a PEMFC

Transient behavior of PEM fuel cells can be categorized into electrochemical, thermal and two-phase flows. Overshoot/undershoot behavior has been observed in electrochemical cell voltage during transients, and are attributed to the transition time required for saturation conditions to reestablish. Similar behavior has been reported in two-phase flow pressure drop overshoot/undershoot in a previous work by the authors. In this work, three different temperatures, five ramp rates and four amplitudes of load change were used to investigate the transient two-phase pressure drop behavior. The overshoot/undershoot behavior is observed predominantly at the lower temperature of 40 °C, and is found to decrease at higher cell temperatures. There is a linear increase in the overshoot/undershoot behavior with increase in amplitude of load change. The overshoot/undershoot behavior was found to be independent of the ramp rates used to change the load current. The magnitude of overshoot in pressure drop was always larger than the magnitude of undershoot. The pressure drop required a longer time to return to steady state after an undershoot compared to the time required to return from an overshoot incident.     

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.     

重力对PEM燃料电池性能的影响

水对质子交换膜(PEM)燃料电池的性能有极其重要的影响,良好的水管理是PEM燃料电池保持高性能的必要条件.通过试验,观察了在重力作用下液态水对PEM燃料电池性能及其内部传质的影响,分析了PEM燃料电池单体电极的不同摆放位置对其性能的影响.试验结果发现:在电流密度较小时,重力对PEM燃料电池性能的影响不明显,电流密度较大时,重力对PEM燃料电池性能的影响比较明显.试验结果对优化PEM燃料电池的结构和水管理有一定的参考价值.     

Water management studies in PEM fuel cells,Part II: Ex situ investigation of flow maldistribution,pressure drop and two-phase flow pattern in gas channels

Two-phase flow of water and reactant gases in the gas distribution channels of proton exchange membrane fuel cells (PEMFCs) plays a critical role in proper water management. In this work, the two-phase flow in PEMFC cathode parallel channels is studied over a wide range of superficial air velocity (air stoichiometry) and superficial water velocity in a specially designed ex situ experimental setup, which enables the measurement of instantaneous flow rates in individual gas channels and simultaneous visualization of the water flow structure. It is found that the two-phase flow at low superficial air velocities (air stoichiometry below 5) is dominated by slugs or semi-slugs, leading to severe flow maldistribution and large fluctuations in the pressure drop. Slug residence time, measured from the video observation and the instantaneous flow rate data, is found to be a new parameter to describe the slug flow. At higher air velocities, a water film is formed on the channel walls if they are hydrophilic. The pressure drop for the film flow is characterized by smaller but frequent fluctuations, which are found to result from the water buildup at the channel-exit manifold interface. As the superficial air velocity increases further, mist flow is obtained where little water buildup is observed. The water buildup in the gas channels at the two-phase flow is well described by the two-phase friction multiplier, defined as the ratio of the two-phase pressure drop to the single gas phase pressure drop. It is found that the two-phase friction multiplier increases with increasing water flow rate. A flow pattern map is developed using superficial water and air velocities with clearly defined transition regions.     

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.     

A fast two-phase non-isothermal reduced-order model for accelerating PEM fuel cell design development

A reduced-order model (ROM) is developed for proton exchange membrane fuel cells (PEMFCs) considering the non-isothermal two-phase effects, with the goal of enhancing computational efficiency and thus accelerating fuel cell design development. Using analytical order reduction and approximation methods, the fluxes and source terms in conventional 1D conservation equations are reduced to six computing nodes at the interfaces between each cell component. The errors associated with order reduction are minimized by introducing new approximation methods for the potential distribution, the transport properties, and the membrane hydration status. The trade-off between model accuracy and computational efficiency is studied by comparing the simulation results and computational times of the new model with a full 1D model. The new model is nearly two orders of magnitude faster without sacrificing too much accuracy (<4% difference) compared to the 1D model. The new model is then used to analyze the influence of the membrane electrode assembly (MEA) design on cell performance and internal state distributions, offering insights into MEA structural optimization. The model can be readily extended to account for more detailed physico-chemical processes, such as Knudsen diffusion or the influence of micro-porous layers, and it can be an effective tool for understanding and designing PEMFCs.     

A two-phase non-isothermal mixed-domain PEM fuel cell model and its application to two-dimensional simulations

In this paper, a two-phase non-isothermal PEM fuel cell model based on the previously developed mixed-domain PEM fuel cell model with a consistent treatment of water transport in MEA has been established using the traditional two-fluid method. This two-phase multi-dimensional PEM fuel cell model could fully incorporate both the anode and cathode sides, properly account for the various water phases, including water vapor, water in the membrane phase, and liquid water, and truly enable numerical investigations of water and thermal management issues with the existence of condensation/evaporation interfaces in a PEM fuel cell. This two-phase model has been applied in this paper in a two-dimensional configuration to determine the appropriate condensation and evaporation rate coefficients and conduct extensive numerical studies concerning the effects of the inlet humidity condition and temperature variation on liquid water distribution with or without a condensation/evaporation interface.     

Numerical investigation of transient responses of a PEM fuel cell using a two-phase non-isothermal mixed-domain model

In this paper, a transient two-phase non-isothermal PEM fuel cell model has been developed based on the previously established two-phase mixed-domain approach. This model is capable of solving two-phase flow and heat transfer processes simultaneously and has been applied herein for two-dimensional time-accurate simulations to fully examine the effects of liquid water transport and heat transfer phenomena on the transient responses of a PEM fuel cell undergoing a step change of cell voltage, with and without condensation/evaporation interfaces. The present numerical results show that under isothermal two-phase conditions, the presence of liquid water in the porous materials increases the current density over-shoot and under-shoot, while under the non-isothermal two-phase conditions, the heat transfer process significantly increases the transient response time. The present studies also indicate that proper consideration of the liquid droplet coverage at the GDL/GC interface results in the increased liquid saturation values inside the porous materials and consequently the drastically increased over-shoot and under-shoot of the current density. In fact, the transient characteristics of the interfacial liquid droplet coverage could exert influences on not only the magnitude but also the time of the transient response process.     

The potential of PEM fuel cell for a new drinking water source

The worldwide water scarcity, especially in the developing countries and arid regions, forces people to rely on unsafe sources of drinking water. There is a pressing need for these regions to develop decentralized, small-scale water utilities. However, more than 50% of the total operating costs associated with such small-scale, water-utility operations are the cost of providing electricity to run water pumps. We think that advances in a variety of renewable and sustainable energy technologies offer considerable promise for reducing the energy required for the production and distribution of water by small-scale water utilities. This paper provides a comprehensive review of the potential for using proton exchange membrane (PEM) fuel cells to provide an alternative supply of drinking water. This system can eliminate the excessive energy requirements that are currently associated with water production. Such alternative water production processes are designed to increase the production rate of drinking water by reducing the amount of water required to humidify the reactant gases during stable cell performance. The principal operational components of PEM fuel cells are reviewed and evaluated, including air stoichiometry, pressure, and cell temperature. Hydrogen-fed fuel cell systems provide sufficient water to meet the potable water needs of a typical household. Furthermore, it is concluded that PEM fuel cells have great promise for decentralized, small-scale, water-production applications, because they are capable of generating sufficient quantities of potable water by operating at maximum power and by increasing the number of polymer membranes.     

Analysis and control of a fuel delivery system considering a two-phase anode model of the polymer electrolyte membrane fuel cell stack

The fuel delivery system using both an ejector and a blower for a PEM fuel cell stack is introduced as a fuel efficiency configuration because of the possibility of hydrogen recirculation dependent upon load states.A high pressure difference between the cathode and anode could potentially damage the thin polymer electrolyte membrane. Therefore, the hydrogen pressure imposed to the stack should follow any change of the cathode pressure. In addition, stoichiometric ratio of the hydrogen should be maintained at a constant to prevent a fuel starvation at abrupt load changes.Furthermore, liquid water in the anode gas flow channels should be purged out in time to prevent flooding in the channels and other layers. The purging control also reduces the impurities concentration in cells to improve the cell performance.We developed a set of control oriented dynamic models that include a anode model considering the two-phase phenomenon and system components The model is used to design and optimize a state feedback controller along with an observer that controls the fuel pressure and stoichiometric ratio, whereby purging processes are also considered. Finally, included is static and dynamic analysis with respect to tracking and rejection performance of the proposed control.     

阴极流道分流进气对燃料电池性能影响的实验研究

针对高工作电流密度下,燃料电池内局部水淹导致的传质损失问题,本研究提出了一种阴极流道多进口分流进气方式。实验研究了三种典型分流口位置及分流进量对电池性能的影响。研究发现随着分流口远离阴极主进气口,电池性能呈现先上升后下降的趋势,且当分流口靠近主进气口时,增加分流量有助于电池性能提升,但分流量的增加对电池性能的提升存在一个极限值;因此,在对电池进行分流进气优化时需综合考虑分流口位置和分流量的影响。当分流口为SIP-30%且分流量为按化学当量比ξc = 0.75取值时,分流进气方式相比传统进气方式,电池的最大功率密度高出17.8%。     

Numerical study of water management in the air flow channel of a PEM fuel cell cathode

The water management in the air flow channel of a proton exchange membrane (PEM) fuel cell cathode is numerically investigated using the FLUENT software package. By enabling the volume of fraction (VOF) model, the air–water two-phase flow can be simulated under different operating conditions. The effects of channel surface hydrophilicity, channel geometry, and air inlet velocity on water behavior, water content inside the channel, and two-phase pressure drop are discussed in detail. The results of the quasi-steady-state simulations show that: (1) the hydrophilicity of reactant flow channel surface is critical for water management in order to facilitate water transport along channel surfaces or edges; (2) hydrophilic surfaces also increase pressure drop due to liquid water spreading; (3) a sharp corner channel design could benefit water management because it facilitates water accumulation and provides paths for water transport along channel surface opposite to gas diffusion layer; (4) the two-phase pressure drop inside the air flow channel increases almost linearly with increasing air inlet velocity.     

Diagnostic tools in PEM fuel cell research: Part II: Physical/chemical methods

To meet the power density, reliability and cost requirements that will enable a widespread use of fuel cells, many research activities focus on an understanding of the thermodynamics as well as the fluid mechanical and electrochemical processes within a fuel cell. To date, a wide range of experimental diagnostics is imperative not only to help a fundamental understanding of fuel cell dynamics but also to provide benchmark-quality data for modeling research. This paper reviews various tools for diagnosing polymer electrolyte membrane (PEM) fuel cells and stacks, and attempts to incorporate the most recent technical advances in PEM fuel cell diagnosis. In Part I of the review we covered electrochemical techniques. In Part II, we review various physical/chemical methods and outline the principle, experimental implementation and data processing of each technique. Capabilities and weaknesses of these techniques are also discussed.