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.     

Modeling two-phase flow in PEM fuel cell channels

This paper is concerned with the simultaneous flow of liquid water and gaseous reactants in mini-channels of a proton exchange membrane (PEM) fuel cell. Envisaging the mini-channels as structured and ordered porous media, we develop a continuum model of two-phase channel flow based on two-phase Darcy's law and the M² formalism, which allow estimate of the parameters key to fuel cell operation such as overall pressure drop and liquid saturation profiles along the axial flow direction. Analytical solutions of liquid water saturation and species concentrations along the channel are derived to explore the dependences of these physical variables vital to cell performance on operating parameters such as flow stoichiometric ratio and relative humility. The two-phase channel model is further implemented for three-dimensional numerical simulations of two-phase, multi-component transport in a single fuel-cell channel. Three issues critical to optimizing channel design and mitigating channel flooding in PEM fuel cells are fully discussed: liquid water buildup towards the fuel cell outlet, saturation spike in the vicinity of flow cross-sectional heterogeneity, and two-phase pressure drop. Both the two-phase model and analytical solutions presented in this paper may be applicable to more general two-phase flow phenomena through mini- and micro-channels.     

Experimental research on water management in proton exchange membrane fuel cells

A simulated cathode flow channel experiment system was set up based on the gas flow rate and water flow rate in the PEM fuel cell. With the assistance of the visualization system, high-sensitivity double parallel conductance probes flow regime inspecting technique was adopted successfully in the experiment system to inspect the flow regime of the gas–liquid two-phase flow in the PEM fuel cell. The research results show that the double parallel conductance probes inspecting system and the flow regime image system for the gas–liquid two-phase flow in the PEM fuel cell simulated channel both can judge the slug flow and annular flow in it, and the double parallel conductance probes flow regime inspecting system can divide the annular flow into three subtypes. The main probes inspecting system and the assistant image system validate reciprocally, which enhances the experimental veracity. The typical flow regimes of the PEM fuel cell simulated channel include slug flow, annular flow with big water film wave, annular flow with small water film wave and annular flow without water film wave. With the increase of the liquid superficial velocity, the frequencies of liquid slug and wave of liquid film increase. The flow regime map in the flow channel of the PEM fuel cell was developed. The flow regime of the gas–liquid two-phase flow in a PEM fuel cell in different operating conditions can be forecasted with this map. With the PEM fuel cell operating condition in this study, the flow regimes of gas–liquid two-phase flow for different cases are all annular flow with small water film wave, and the liquid film waves more with bigger current density. With the location closer to the channel outlet, the liquid film waves are more for the same current density.     

Transport mechanisms and performance simulations of a PEM fuel cell with interdigitated flow field

A proton exchange membrane (PEM) fuel cell with interdigitated flow field was studied numerically. A three-dimensional, gas–liquid two-phase flow and transport model was developed and utilized to simulate the multi-dimensional, multi-phase flow and transport phenomena in both the anode and cathode sides in the fuel cell and the cell performances with different influencing operational and geometric parameters. The simulations are presented with an emphasis on the physical insight and fundamental understanding afforded by the detailed distributions of working media velocity, oxygen concentration, water vapor concentration, liquid water concentration, water content in the PEM, net water flux per proton flux, current density and overpotential. Cell performances with different influencing factors are also discussed. A comparison of the model prediction and the experimental data shows good agreement.     

Numerical studies of liquid water behaviors in PEM fuel cell cathode considering transport across different porous layers

In this paper, a two-phase two-dimensional PEM fuel cell model, which is capable of handling liquid water transport across different porous materials, is employed for parametric studies of liquid water transport and distribution in the cathode of a PEM fuel cell. Attention is paid particularly to the coupled effects of two-phase flow and heat transfer phenomena. The effects of key operation parameters, including the outside cell boundary temperature, the cathode gas humidification condition, and the cell operation current, on the liquid water behaviors and cell performance have been examined in detail. Numerical results elucidate that increasing the fuel cell temperature would not only enhance liquid water evaporation and thus decrease the liquid saturation inside the PEM fuel cell cathode, but also change the location where liquid water is condensed or evaporated. At a cell boundary temperature of 80 °C, liquid water inside the catalyst layer and gas diffusion media under the current-collecting land would flow laterally towards the gas channel and become evaporated along an interface separating the land and channel. As the cell boundary temperature increases, the maximum current density inside the membrane would shift laterally towards the current-collecting land, a phenomenon dictated by membrane hydration. Increasing the gas humidification condition in the cathode gas channel and/or increasing the operating current of the fuel cell could offset the temperature effect on liquid water transport and distribution.     

Effects of gas diffusion layer deformation on the transport phenomena and performance of PEM fuel cells with interdigitated flow fields

In this study, a three-dimensional, non-isothermal, two-phase flow mathematical model is developed and applied to investigate the effect of the GDL deformation on transport phenomena and performance of proton exchange membrane (PEM) fuel cells with interdigitated flow fields. The thickness and porosity of the GDL is decreased after compression, and the corresponding transport parameters (permeability, mass diffusivity, thermal conductivity and electrical conductivity) are affected significantly. The alterations in geometry and transport parameters of the GDL are considered in the mathematical model. The oxygen concentration, temperature, liquid water saturation and volumetric current density distributions of PEM fuel cells without compression are investigated and then compared to the PEM fuel cells with various assembly forces. The numerical results show that the cell performance is considerably improved with increasing assembly forces. However, the pressure drops in the gas flow channels are also substantially increased. It is concluded that the assembly force should be as small as possible to decrease the parasitic losses with consideration of gas sealing concern.     

Effects of electrode wettabilities on liquid water behaviours in PEM fuel cell cathode

Liquid water transport is one of the key challenges for water management in a proton exchange membrane (PEM) fuel cell. Investigation of the air–water flow patterns inside fuel cell gas flow channels with gas diffusion layer (GDL) would provide valuable information that could be used in fuel cell design and optimization. This paper presents numerical investigations of air–water flow across an innovative GDL with catalyst layer and serpentine channel on PEM fuel cell cathode by use of a commercial Computational Fluid Dynamics (CFD) software package FLUENT. Different static contact angles (hydrophilic or hydrophobic) were applied to the electrode (GDL and catalyst layer). The results showed that different wettabilities of cathode electrode could affect liquid water flow patterns significantly, thus influencing on the performance of PEM fuel cells. The detailed flow patterns of liquid water were shown, several gas flow problems were observed, and some useful suggestions were given through investigating the flow patterns.     

Characterization of the dynamic response of proton exchange membrane fuel cells – A numerical study

The dynamic response of PEM (Proton exchange membrane) fuel cells is a complex phenomenon which is affected by numerous factors related to their designs and operating conditions. Despite that experimental data is available in the literature, a systematic numerical study to explain the dynamic behavior of PEM fuel cells is currently unavailable. In this paper, a one-dimensional, two-phase, dynamic model of PEM fuel cell is developed to achieve this principal objective. Transient profiles of cell voltage, activation and ohmic over-potentials, saturation level of liquid water, oxygen concentration, and membrane water content are predicted under various operating conditions. Under constant fuel and air flow rates, it is found that the cell voltage exhibits undershoot behavior following a step increase in current density due to the inherent time delay experienced by the redistribution of membrane water content with a response time of ∼50 s. The undershoot is followed by an overshoot in the presence of flooding with a significantly longer predicted response time of ∼150–200 s. It is found that the various operating conditions mainly affect the specific details of the undershoot and overshoot profiles without changing their general behavioral forms.     

Numerical study of a new cathode flow-field design with a sub-channel for a parallel flow-field polymer electrolyte membrane fuel cell

The cathode flow-field design of a polymer electrolyte membrane (PEM) fuel cell is crucial to its performance, because it determines the distribution of reactants and the removal of liquid water from the fuel cell. In this study, the cathode flow-field of a parallel flow-field PEM fuel cell was optimized using a sub-channel. The main-channel was fed with moist air, whereas the sub-channel was fed with dry air. The influences of the sub-channel flow rate (SFR, the amount of air from the sub-channel inlet as a percentage of the total cathode flow rate) and the inlet positions (SIP, where the sub-channel inlets were placed along the cathode channel) on fuel cell performance were numerically evaluated using a three-dimensional, two-phase fuel cell model. The results indicated that the SFR and SIP had significant impacts on the distribution of the feed air, removal of liquid water, and fuel cell performance. It was found that when the SIP was located at about 30% along the length of the channel from main-channel inlet and the SFR was about 70%, the PEM fuel cell exhibited much better performance than seen with a conventional design.     

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.     

Ex situ and modeling study of two-phase flow in a single channel of polymer electrolyte membrane fuel cells

In this study, we investigate the air-water two-phase flow in a single flow channel of polymer electrolyte membrane (PEM) fuel cells. In the ex situ study, both straight and serpentine channels with various gas diffusion layer (GDL) surfaces are studied. Focus is placed on the two-phase flow patterns, which are optically characterized using a microscope with a high-resolution camera, and the two-phase pressure amplifiers. We find that the GDL surface properties slightly affect the flow pattern and two-phase pressure amplifier in the flow field configuration. Flow pattern transition occurs at the superficial gas velocity of around 1 m s⁻¹, and the pressure amplifier can reach as high as 10. A two-fluid model is also presented together with one dimensional (1-D) analytical solution, and acceptable agreement is achieved between the model prediction and experimental data at high gas flow rates.     

Innovative gas diffusion layers and their water removal characteristics in PEM fuel cell cathode

Liquid water transport is one of the key challenges regarding the water management in a proton exchange membrane (PEM) fuel cell. Conventional gas diffusion layers (GDLs) do not allow a well-organized liquid water flow from catalyst layer to gas flow channels. In this paper, three innovative GDLs with different micro-flow channels were proposed to solve liquid water flooding problems that conventional GDLs have. This paper also presents numerical investigations of air–water flow across the proposed innovative GDLs together with a serpentine gas flow channel on PEM fuel cell cathode by use of a commercial computational fluid dynamics (CFD) software package FLUENT. The results showed that different designs of GDLs will affect the liquid water flow patterns significantly, thus influencing the performance of PEM fuel cells. The detailed flow patterns of liquid water were shown. Several gas flow problems for the proposed different kinds of innovative GDLs were observed, and some useful suggestions were given through investigating the flow patterns inside the proposed GDLs.     

A critical review of two-phase flow in gas flow channels of proton exchange membrane fuel cells

Water management in PEM fuel cells has received extensive attention due to its key role in fuel cell performance. The unavoidable water, from humidified gas streams and electrochemical reaction, leads to gas-liquid two-phase flow in the flow channels of fuel cells. The presence of two-phase flow increases the complexity in water management in PEM fuel cells, which remains a challenging hurdle in the commercialization of this technology. Unique water emergence from the gas diffusion layer, which is different from conventional gas-liquid two-phase flow where water is introduced from the inlet together with the gas, leads to different gas-liquid flow behaviors, including pressure drop, flow pattern, and liquid holdup along flow field channels. These parameters are critical in flow field design and fuel cell operation and therefore two-phase flow has received increasing attention in recent years. This review emphasizes gas-liquid two-phase flow in minichannels or microchannels related to PEM fuel cell applications. In situ and ex situ experimental setups have been utilized to visualize and quantify two-phase flow phenomena in terms of flow regime maps, flow maldistribution, and pressure drop measurements. Work should continue to make the results more relevant for operating PEM fuel cells. Numerical simulations have progressed greatly, but conditions relevant to the length scales and time scales experienced by an operating fuel cell have not been realized. Several mitigation strategies exist to deal with two-phase flow, but often at the expense of overall cell performance due to parasitic power losses. Thus, experimentation and simulation must continue to progress in order to develop a full understanding of two-phase flow phenomena so that meaningful mitigation strategies can be implemented.     

Measurement and modeling of liquid film thickness evolution in stratified two-phase microchannel flows

Polymer electrolyte membrane (PEM) fuel cells incorporating microchannels (D < 500 μm) can benefit from improved fuel delivery and convective cooling. However, this requires a better understanding of two-phase microchannel transport phenomena, particularly liquid–gas interactions and liquid clogging in cathode air-delivery channels. This paper develops optical fluorescence imaging of water films in hydrophilic channels with varying air velocity and water injection rate. Micromachined silicon test structures with optical access and distributed water injection simulate the cathode channels of a PEM fuel cell. Film thickness data vary strongly with air velocity and are consistent with stratified flow modeling. This work facilitates the study of regime transitions in two-phase microchannel flows and the effects of flow regimes on heat and mass transfer and axial pressure gradients.     

Effects of the gas diffusion-layer parameters on cell performance of PEM fuel cells

The characteristic parameters of the gas diffusion-layer (GDL) on cell performance and mass transfer of a proton exchange membrane fuel cell have been investigated numerically. A two-dimensional, isothermal and multi-phase numerical model has been established to investigate the influence of the GDL parameters on the transport phenomenon and cell performance of PEM fuel cells. The porosity and thickness of the GDL are employed in the analysis as the parameters. In addition, the effects of liquid water and the flow direction of the fuel and air on the performance are also considered in this paper. The results show that both the porosity and thickness of the GDL affect the fuel cell performance significantly, especially the water mass transfer. It is shown that the cell performance with consideration of a liquid water effect is always less than that without consideration of the liquid water effect. In addition, the cell performance with a co-flow pattern of fuel and air is better than that with a counter flow pattern.     

Liquid water visualization in PEM fuel cells: A review

Over the past few years, the importance of water management to the successful operation of polymer electrolyte membrane (PEM) fuel cells has stimulated an extensive research focus on liquid water transport and its effect on performance and durability. Empirical methods employed to investigate water transport in the fuel cell have the potential to provide useful feedback for developing empirical correlations and validating numerical models for fuel cell research and development. In this paper, a literature review is provided for the experimental techniques that have been applied to visualize liquid water in operating hydrogen PEM fuel cells and flow fields. The main hypotheses that have been proposed to describe liquid water transport in the gas diffusion layer (GDL) and current challenges will also be discussed.     

Two-phase flow and transport in the air cathode of proton exchange membrane fuel cells

Two-phase flow and transport of reactants and products in the air cathode of proton exchange membrane (PEM) fuel cells is studied analytically and numerically. Single- and two-phase regimes of water distribution and transport are classified by a threshold current density corresponding to first appearance of liquid water at the membrane/cathode interface. When the cell operates above the threshold current density, liquid water appears and a two-phase zone forms within the porous cathode. A two-phase, multicomponent mixture model in conjunction with a finite-volume-based computational fluid dynamics (CFD) technique is applied to simulate the cathode operation in this regime. The model is able to handle the situation where a single-phase region co-exists with a two-phase zone in the air cathode. For the first time, the polarization curve as well as water and oxygen concentration distributions encompassing both single- and two-phase regimes of the air cathode are presented. Capillary action is found to be the dominant mechanism for water transport inside the two-phase zone of the hydrophilic structure. The liquid water saturation within the cathode is predicted to reach 6.3% at 1.4 A cm⁻² for dry inlet air.     

The effect of operating parameters on water transport in PEM fuel cells

Water content in the membrane and the presence of liquid water in the catalyst layers (CL) and the gas diffusion layers (GDL) play a very important role in the performance of a PEM fuel cell. To study water transport in a PEM fuel cell, a two‐phase flow mathematical model is developed. This model couples the continuity equation, momentum conservative equation, species conservative equation, and water transport equation in the membrane. The modeling results of fuel cell performances agree well with measured experimental results. Then this model is used to simulate water transport and current density distribution in the cathode of a PEM fuel cell. The effects of operating pressure, cell temperature, and humidification temperatures on the net water transfer through the membrane, liquid water saturation, and current density distribution are studied. © 2006 Wiley Periodicals, Inc. Heat Trans Asian Res, 35(2): 89–100, 2006; Published online in Wiley InterScience ( www.interscience. wiley.com ). DOI 10.1002/htj.20107     

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.     

A flow channel design procedure for PEM fuel cells with effective water removal

Proper water management in polymer electrolyte membrane (PEM) fuel cells is critical to achieve the potential of PEM fuel cells. Membrane electrolyte requires full hydration in order to function as proton conductor, often achieved by fully humidifying the anode and cathode reactant gas streams. On the other hand, water is also produced in the cell due to electrochemical reaction. The combined effect is that liquid water forms in the cell structure and water flooding deteriorates the cell performance significantly. In the present study, a design procedure has been developed for flow channels on bipolar plates that can effectively remove water from the PEM fuel cells. The main design philosophy is based on the determination of an appropriate pressure drop along the flow channel so that all the liquid water in the cell is evaporated and removed from, or carried out of, the cell by the gas stream in the flow channel. At the same time, the gas stream in the flow channel is maintained fully saturated in order to prevent membrane electrolyte dehydration. Sample flow channels have been designed, manufactured and tested for five different cell sizes of 50, 100, 200, 300 and 441 cm². Similar cell performance has been measured for these five significantly different cell sizes, indicating that scaling of the PEM fuel cells is possible if liquid water flooding or membrane dehydration can be avoided during the cell operation. It is observed that no liquid water flows out of the cell at the anode and cathode channel exits for the present designed cells during the performance tests, and virtually no liquid water content in the cell structure has been measured by the neutron imaging technique. These measurements indicate that the present design procedure can provide flow channels that can effectively remove water in the PEM fuel cell structure.