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

Three-dimensional simulation of a new cooling strategy for proton exchange membrane fuel cell stack using a non-isothermal multiphase model

In this study, a new cooling strategy for a proton exchange membrane (PEM) fuel cell stack is investigated using a three-dimensional (3D) multiphase non-isothermal model. The new cooling strategy follows that of the Honda's Clarity design and further extends to a cooling unit every five cells in stacks. The stack consists of 5 fuel cells sharing the inlet and outlet manifolds for reactant gas flows. Each cell has 7-path serpentine flow fields with a counter-flow configuration arranged for hydrogen and air streams. The coolant flow fields are set at the two sides of the stack and are simplified as the convective heat transfer thermal boundary conditions. This study also compares two thermal boundary conditions, namely limited and infinite coolant flow rates, and their impacts on the distributions of oxygen, liquid water, current density and membrane hydration. The difference of local temperature between these two cooling conditions is as much as 6.9 K in the 5-cell stack, while it is only 1.7 K in a single cell. In addition, the increased vapor concentration at high temperature (and hence water saturation pressure) dilutes the oxygen content in the air flow, reducing local oxygen concentration. The higher temperature in the stack also causes low membrane hydration, and consequently poor cell performance and non-uniform current density distribution, as disclosed by the simulation. The work indicates the new cooling strategy can be optimized by increasing the heat transfer coefficient between the stack and coolant to mitigate local overheating and cell performance reduction

Two-phase flow and oxygen transport in the perforated gas diffusion layer of proton exchange membrane fuel cell

Liquid water transport in perforated gas diffusion layers (GDLs)is numerically investigated using a three-dimensional (3D)two-phase volume of fluid (VOF)model and a stochastic reconstruction model of GDL microstructures. Different perforation depths and diameters are investigated, in comparison with the GDL without perforation. It is found that perforation can considerably reduce the liquid water level inside a GDL. The perforation diameter (D = 100 μm)and the depth (H = 100 μm)show pronounced effect. In addition, two different perforation locations, i.e. the GDL center and the liquid water break-through point, are investigated. Results show that the latter perforation location works more efficiently. Moreover, the perforation perimeter wettability is studied, and it is found that a hydrophilic region around the perforation further reduces the water saturation. Finally, the oxygen transport in the partially-saturated GDL is studied using an oxygen diffusion model. Results indicate that perforation reduces the oxygen diffusion resistance in GDLs and improves the oxygen concentration at the GDL bottom up to 101% (D = 100 μm and H = 100 μm)

Along-the-channel modeling and analysis of PEFCs at low stoichiometry: Development of a 1+2D model

Water management remains a key challenge in polymer-electrolyte fuel cells. In this work, a pseudo 3-D (1+2D) model is developed to account better for changes of water management along the channel, as well as verify the possibilities of using differential cells for data capture and translation to integral cell performance. An accurate 2-D membrane-electrode-assembly model is developed for differential cell modeling, which is combined with an along-the-channel stepping algorithm to account for down the channel changes in pressure, temperature, reactant concentration, and relative humidity. Variations in cell performance along the channel due to changes in operating conditions are characterized quantitatively and optimized, where drier feed conditions demonstratively require such an approach. Overall, the study identifies gaps between differential and integral cells including those related to flow velocity and highlights the need for better models to understand and link integral cell performance and water management

Biomimetic flow fields for proton exchange membrane fuel cells: A review of design trends

Bipolar Plate design is one of the most active research fields in Polymer Electrolyte Membrane Fuel Cells (PEMFCs) development. Bipolar Plates are key components for ensuring an appropriate water management within the cell, preventing flooding and enhancing the cell operation at high current densities. This work presents a literature review covering bipolar plate designs based on nature or biological structures such as fractals, leaves or lungs. Biological inspiration comes from the fact that fluid distribution systems found in plants and animals such as leaves, blood vessels, or lungs perform their functions (mostly the same functions that are required for bipolar plates) with a remarkable efficiency, after millions of years of natural evolution. Such biomimetic designs have been explored to date with success, but it is generally acknowledged that biomimetic designs have not yet achieved their full potential. Many biomimetic designs have been derived using computer simulation tools, in particular Computational Fluid Dynamics (CFD) so that the use of CFD is included in the review. A detailed review including performance benchmarking, time line evolution, challenges and proposals, as well as manufacturing issues is discussed.Ministerio de Ciencia, Innovación y Universidades ENE2017-91159-EXPMinisterio de Economía y Competitividad UNSE15-CE296

Modeling and simulations of deformation and transport in PEM fuel cells

Performance degradation and durability of PEM fuel cells depend strongly upon transport and deformation characteristics of their components especially the polymer membrane. Physical properties of the membrane, such as its ionic conductivity and Young’s modulus depend on its water content, which varies significantly with operating conditions and during transients. Recent studies indicate that cyclic transients may induce hygro-thermal fatigue that leads to the ultimate failure of the membrane shortening its lifetime, and thus, hindering the reliable use PEM fuel cells for automotive applications. In this work, we present two-dimensional simulations and analysis of coupled deformation and transport in PEM fuel cells. A two-dimensional cross-section of anode and cathode gas diffusion layers, and the membrane sandwiched between them is modeled using Maxwell-Stefan equations in gas diffusion layers, Biot’s poroelasticity and Darcy’s law for deformation and water transport in the membrane and Ohm’s law for ionic currents in the membrane and electric currents in the gas diffusion layers. Steady-state deformation and transport of water in the membrane, transient responses to step changes in load and relative humidity of the anode and cathode are obtained from simulation experiments, which are conducted by means of a commercial finite-element package, COMSOL Multiphysics

Model-based analysis for the thermal management of open-cathode proton exchange membrane fuel cell systems concerning efficiency and stability

In this work we present a dynamic, control-oriented, concentrated parameter model of an open-cathode proton exchange membrane fuel cell system for the study of stability and efficiency improvement with respect to thermal management. The system model consists of two dynamic states which are the fuel cell temperature and the liquid water saturation in the cathode catalyst layer. The control action of the system is the inlet air velocity of the cathode air flow manifold, set by the cooling fan, and the system output is the stack voltage. From the model we derive the equilibrium points and eigenvalues within a set of operating conditions and subsequently discuss stability and the possibility of efficiency improvement. The model confirms the existence of a temperature-dependent maximum power in the moderate temperature region. The stability analysis shows that the maximum power line decomposes the phase plane in two parts, namely stable and unstable equilibrium points. The model is capable of predicting the temperature of a stable steady-state voltage maximum and the simulation results serve for the design of optimal thermal management strategies.Postprint (author's final draft

CFD Applications in Energy Engineering Research and Simulation: An Introduction to Published Reviews

Computational Fluid Dynamics (CFD) has been firmly established as a fundamental discipline to advancing research on energy engineering. The major progresses achieved during the last two decades both on software modelling capabilities and hardware computing power have resulted in considerable and widespread CFD interest among scientist and engineers. Numerical modelling and simulation developments are increasingly contributing to the current state of the art in many energy engineering aspects, such as power generation, combustion, wind energy, concentrated solar power, hydro power, gas and steam turbines, fuel cells, and many others. This review intends to provide an overview of the CFD applications in energy and thermal engineering, as a presentation and background for the Special Issue “CFD Applications in Energy Engineering Research and Simulation” published by Processes in 2020. A brief introduction to the most significant reviews that have been published on the particular topics is provided. The objective is to provide an overview of the CFD applications in energy and thermal engineering, highlighting the review papers published on the different topics, so that readers can refer to the different review papers for a thorough revision of the state of the art and contributions into the particular field of interest

PEMFC performance improvement through oxygen starvation prevention, modeling, and diagnosis of hydrogen leakage

Catalyst degradation results in emerging pinholes in Proton Exchange Membrane Fuel Cells (PEMFCs) and subsequently hydrogen leakage. Oxygen starvation resulting from hydrogen leaks is one of the primary life-limiting factors in PEMFCs. Voltage reduces as a result of oxygen starvation, and the cell performance deteriorates. Starved PEMFCs also work as a hydrogen pump, increasing the amount of hydrogen on the cathode side, resulting in hydrogen emissions. Therefore, it is important to delay the occurrence of oxygen starvation within the Membrane Electrode Assembly (MEA) while simultaneously be able to diagnose the hydrogen crossover through the pinholes. In this work, first, we focus on catalyst configuration as a novel method to prevent oxygen starvation and catalyst degradation. It is hypothesized that the redistribution of the platinum catalyst can increase the maximum current density and prevent oxygen starvation and catalyst degradation. Therefore, a multi-objective optimization problem is defined to maximize fuel cell efficiency and to prevent oxygen starvation in the PEMFC. Results indicate that the maximum current density rises about eight percent, while the maximum PEMFC power density increases by twelve percent. In the next step, a previously developed pseudo two-dimensional model is used to simulate fuel cell behavior in the normal and the starvation mode. This model is developed further to capture the effect of the hydrogen pumping phenomenon and to measure the amount of hydrogen in the outlet of the cathode channel. The results obtained from the model are compared with the experimental data, and validation shows that the proposed model is fast and precise. Next, Machine Learning (ML) estimators are used to first detect whether there is a hydrogen crossover in the fuel cell and second to capture the amount of hydrogen cross over. K Nearest Neighbour (KNN) and Artificial Neural Network (ANN) estimators are chosen for leakage detection and classification. Eventually, a pair of ANN classifier-regressor is chosen to first isolate leaky PEMFCs and then quantify the amount of leakage. The classifier and regressor are both trained on the datasets that are generated by the pseudo two-dimensional model. Different performance indexes are evaluated to assure that the model is not underfitting/overfitting. This ML diagnosis algorithm can be employed as an onboard diagnosis system that can be used to detect and possibly prevent cell reversal failures