Measurement of the water transport rate in a proton exchange membrane fuel cell and the influence of the gas diffusion layer

Water management in a PEM fuel cell significantly affects the fuel cell performance and durability. The gas diffusion layer (GDL) of a PEM fuel cell plays a critical role in the water management process. In this short communication, we report a simple method to measure the water transport rate across the GDL. Water rejection rates across a GDL at different cathode air-flow rates were measured. Based on the measurement results, the fuel cell operating conditions, such as current density, temperature, air stoichiometry and relative humidity, corresponding to membrane drying and flooding conditions were identified for the particular GDL used. This method can help researchers develop GDLs for a particular fuel cell design with specific operating conditions and optimize the operation conditions for the given PEM fuel cell components.     

Analysis of transient response of a unit proton-exchange membrane fuel cell with a degraded gas diffusion layer

The transient response characteristics and durability problems of proton-exchange membrane fuel cells are important issues for the application of PEM fuel cells to automotive systems. The gas diffusion layer is the key component of the fuel cell because it directly influences the mass transport mechanism. In this study, the effects of GDL degradation on the transient response of the PEM fuel cell are systematically studied using transient response analysis under different stoichiometric ratios and humidity conditions. With GDLs aged by the accelerated stress test, the effects of hydrophobicity and structural changes due to carbon loss in the GDL on the transient response of PEM fuel cells are determined. The cell voltage is measured according to the sudden current density change. The degraded GDLs that had uneven hydrophobicity distributions cause local water flooding inside the GDL and induce lower and unstable voltage responses after load changes.     

Gas diffusion layer for proton exchange membrane fuel cells—A review

Gas diffusion layer (GDL) is one of the critical components acting both as the functional as well as the support structure for membrane-electrode assembly in the proton exchange membrane fuel cell (PEMFC). The role of the GDL is very significant in the H₂/air PEM fuel cell to make it commercially viable. A bibliometric analysis of the publications on the GDLs since 1992 shows a total of 400+ publications (>140 papers in the Journal of Power Sources alone) and reveals an exponential growth due to reasons that PEMFC promises a lot of potential as the future energy source for varied applications and hence its vital component GDL requires due innovative analysis and research. This paper is an attempt to pool together the published work on the GDLs and also to review the essential properties of the GDLs, the method of achieving each one of them, their characterization and the current status and future directions. The optimization of the functional properties of the GDLs is possible only by understanding the role of its key parameters such as structure, porosity, hydrophobicity, hydrophilicity, gas permeability, transport properties, water management and the surface morphology. This paper discusses them in detail to provide an insight into the structural parts that make the GDLs and also the processes that occur in the GDLs under service conditions and the characteristic properties. The required balance in the properties of the GDLs to facilitate the counter current flow of the gas and water is highlighted through its characteristics.     

Determination of effective water vapor diffusion coefficient in pemfc gas diffusion layers

The primary removal of product water in proton exchange membrane (PEM) fuel cells is through the cathode gas diffusion layer (GDL) which necessitates the understanding of vapor and liquid transport of water through porous media. In this investigation, the effect of microporous layer (MPL) coatings, GDL thickness, and polytetrafluorethylene (PTFE) loading on the effective water vapor diffusion coefficient is studied. MRC Grafil, SGL Sigracet, and Toray TGP-H GDL samples are tested experimentally with and without MPL coatings and varying PTFE loadings. A dynamic diffusion test cell is developed to produce a water vapor concentration gradient across the GDL and induce diffusion mass transfer. Tests are conducted at ambient temperature and flow rates of 500, 625, and 750 sccm. MPL coatings and increasing levels of PTFE content introduce significant resistance to diffusion while thickness has negligible effects.     

Anode water removal and cathode gas diffusion layer flooding in a proton exchange membrane fuel cell

Anode water removal (AWR) is studied as a diagnostic tool to assess cathode gas diffusion layer (GDL) flooding in PEM fuel cells. This method uses a dry hydrogen stream to remove product water from the cathode, showing ideal fuel cell performance in the absence of GDL mass transfer limitations related to water. When cathode GDL flooding is limiting, the cell voltage increases as the hydrogen stoichiometry is increased. Several cathode GDLs were studied to determine the effect of microporous layer (MPL) and PTFE coating. The largest voltage gains occur with the use of cathode GDLs without an MPL since these GDLs are prone to higher liquid water saturation. Multiple GDLs are studied on the cathode side to exacerbate GDL flooding conditions to further confirm the mechanism of the AWR process. Increased temperature and lower cathode RH allow for greater overall water removal so the voltage improvement occurs faster, though this leads to quicker membrane dehydration.     

Superhydrophobic PAN nanofibers for gas diffusion layers of proton exchange membrane fuel cells for cathodic water management

Proton exchange membrane (PEM) fuel cells are considered to be promising alternatives to natural resources for generating electricity and various other powers. Optimal water management in the gas diffusion layer (GDL) is critical to the high performance of fuel cells. The basic function of the GDL includes transporting the reactant gas from flow channels to the catalyst effectively, draining liquid water from the catalyst layer to the flow channels, and conducting electrons with low humidity. In this study, poly-acrylonitrile (PAN) was dissolved in a solvent and electrospun at various conditions to produce PAN nanofibers prior to their stabilization at atmospheric pressure at 280 °C for 1 h and carbonization at 850 °C for one more hour. The surface hydrophobicity of the carbonized PAN nanofibers were adjusted using superhydrophobic and hydrophilic agents. The thermal, mechanical, and electrical properties of the new GDLs showed better results than the conventional ones. Water condensation tests (superhydrophobic and hydrophilic) on the surfaces of the GDLs showed a crucial step towards improved water management in fuel cells. This study may open up new possibilities for developing high-performing GDL materials for future PEM fuel cell applications.     

Measurement of water transport rates across the gas diffusion layer in a proton exchange membrane fuel cell,and the influence of polytetrafluoroethylene content and micro-porous layer

Water management in a proton exchange membrane (PEM) fuel cell is one of the critical issues for improving fuel cell performance and durability, and water transport across the gas diffusion layer plays a key role in PEM fuel cell water management. In this work, we investigated the effects of polytetrafluoroethylene (PTFE) content and the application of a micro-porous layer (MPL) in the gas diffusion layer (GDL) on the water transport rate across the GDL. The results show that both PTFE and the MPL play a similar role of restraining water transport. The effects of different carbon loadings in the MPL on water transport were also investigated. The results demonstrate that the higher the carbon loading in the MPL, the more it reduces the water transport rate. Using the given cell hardware and components, the optimized operation conditions can be obtained based on a water balance analysis.     

Visualization of unstable water flow in a fuel cell gas diffusion layer

Modeling two-phase flow in proton exchange membrane (PEM) fuel cells is hampered by a lack of conceptual understanding of flow patterns in the gas diffusion layer (GDL). In this paper, pore-scale visualizations of water in different types of GDLs were used to improve current understanding of flow and transport phenomena in PEM fuel cells. Confocal microscopy was used to capture the real-time transport of water, and pressure micro-transducers were installed to measure water breakthrough pressures. Three types of fuel cell GDLs were examined: TO series (Toray Corp., Tokyo, Japan), SGL series (SGL Carbon Group, Wiesbaden, Germany), and MRC series (Mitsubishi Rayon Corp., Otake City, Japan). The visualizations and pressure measurements revealed that despite difference in “pore” structures in the three types of GDLs, water followed distinct flow paths spanning several pores with characteristics similar to the “column flow” phenomena observed previously in hydrophobic or coarse-grained hydrophilic soils. The results obtained from this study can aid in the construction of theories and models for optimizing water management in fuel cells.     

Recent progress of gas diffusion layer in proton exchange membrane fuel cell: Two-phase flow and material properties

Proton exchange membrane (PEM) fuel cells are a promising candidate as the next-generation power sources for portable, transportation, and stationary applications. Gas diffusion layers (GDL) coated with microporous layers (MPL) are a vital component of PEM fuel cells, providing multiple functions of mechanical support, reactant transport, liquid water removal, waste heat removal, and electron conductance. In this review, we explain several most important aspects in the research and development (R&D) of this fuel cell component, including material characterization, liquid water detection/quantitation, structure reconstruction, fundamental modeling, transport properties, and durability. Specially, the commonly used microstructure reconstruction methods for GDLs are presented and discussed. Visualization techniques for liquid water detection in the GDL and MPL microstructures are described. Major modeling approaches, such as the multiphase mixture (M²) formulation, pore networks model (PNM), lattice Boltzmann method (LBM) and volume of fluid (VOF) approach, are reviewed and explained. Important material properties and parameters that greatly influence two-phase flow and fuel cell performance, and GDL-related material degradation issues are discussed and summarized to further advance on the GDL material design and development.     

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 review of gas diffusion layer in PEM fuel cells: Materials and designs

The gas diffusion layer (GDL) plays a key role on reactant gas diffusion and water management in proton exchange membrane (PEM) fuel cells. This paper reviews recent developments of single- and dual-layer GDLs for PEM fuel cells and various materials and approaches used for development of novel GDL. A variety of carbon- and metal-based macroporous substrates are presented. Hydrophobic treatments using different fluorinated polymers are addressed. Engineering parameters which control the performance of microporous layer such as carbon treatment, wettability, thickness, and microstructure are also reviewed. In addition, future prospects for development of new GDL development are discussed.     

Effect of the anisotropic thermal conductivity of GDL on the performance of PEM fuel cells

Gas diffusion layers (GDLs) are one of the main components in proton exchange membrane (PEM) fuel cells. In this paper, the effect of anisotropic thermal conductivity of the GDL is numerically investigated under different operating temperatures. Furthermore, the sensitivity of the PEM fuel cell performance to the thermal conductivity of the GDL is investigated for both in-plane and through-plane directions and the temperature distributions between the different GDL thermal conductivities are compared. The results show that increasing the in-plane and through-plane thermal conductivity of the GDL increases the power density of PEM fuel cells significantly. Moreover, the temperature gradients show a greater sensitivity to the in-plane thermal conductivity of the GDL as opposed to the through-plane thermal conductivity.     

Review of gas diffusion layer for proton exchange membrane-based technologies with a focus on unitised regenerative fuel cells

Proton exchange membrane (PEM) based technologies (fuel cells and electrolysers) offer promising sustainable power generation and storage solutions for a diverse range of stationary and mobile applications. Unitised regenerative fuel cell (URFC) is an electrochemical cell that can operate both as a fuel cell (FC) and an electrolyser (E). However, for a widespread commercialisation, further improvements are required that address the durability, performance, and cost limitations. One of the main challenging components in developing URFCs is the gas diffusion layer (GDL) as it plays different vital roles, some of which are paradoxical in FC and E-modes. Therefore, in this paper, the published research on GDL of PEM-URFCs as well as relevant studies on PEM fuel cells and electrolysers are critically reviewed. The materials and novel methods to address the corrosion in E-mode are discussed. This is followed by presenting and discussing different properties of GDLs affecting the performance in FC and E-modes: i.e. porosity, thickness, pore size, transport properties, thermal and electrical conductivity, and the GDL compressibility. Finally, the main modifications of the GDLs, such as hydrophobisation and microporous layer application, to improve the performance of a URFC are analysed and discussed.     

Effective thermal conductivity and thermal contact resistance of gas diffusion layers in proton exchange membrane fuel cells. Part 1: Effect of compressive load

Heat transfer through the gas diffusion layer (GDL) is a key process in the design and operation of a PEM fuel cell. The analysis of this process requires determination of the effective thermal conductivity as well as the thermal contact resistance associated with the interface between the GDL and adjacent surfaces/layers.In the present study, a custom-made test bed that allows the separation of effective thermal conductivity and thermal contact resistance in GDLs under vacuum and ambient conditions is described. Measurements under varying compressive loads are performed using Toray carbon paper samples with a porosity of 78% for a range of thicknesses. The measurements are complemented by compact analytical models that achieve good agreement with experimental data. A key finding is that thermal contact resistance is the dominant component of the total thermal resistance; neglecting this phenomenon may result in significant errors in evaluating heat transfer rates and temperature distributions.     

Analytic determination of the effective thermal conductivity of PEM fuel cell gas diffusion layers

Accurate information on the temperature field and associated heat transfer rates are particularly important in devising appropriate heat and water management strategies in proton exchange membrane (PEM) fuel cells. An important parameter in fuel cell performance analysis is the effective thermal conductivity of the gas diffusion layer (GDL). Estimation of the effective thermal conductivity is complicated because of the random nature of the GDL micro structure. In the present study, a compact analytical model for evaluating the effective thermal conductivity of fibrous GDLs is developed. The model accounts for conduction in both the solid fibrous matrix and in the gas phase; the spreading resistance associated with the contact area between overlapping fibers; gas rarefaction effects in microgaps; and salient geometric and mechanical features including fiber orientation and compressive forces due to cell/stack clamping. The model predictions are in good agreement with existing experimental data over a wide range of porosities. Parametric studies are performed using the proposed model to investigate the effect of bipolar plate pressure, aspect ratio, fiber diameter, fiber angle, and operating temperature.     

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.     

Gas diffusion layer deformation and its effect on the transport characteristics and performance of proton exchange membrane fuel cell

Cell/stack assembly force can strongly affect the transport characteristics and performance of a proton exchange membrane fuel cell (PEMFC) through causing the structural deformation. In this study, a mathematical model has been developed to investigate the effect of the assembly force for different gas diffusion layers (GDL) and membranes. The results indicate that the predominant deformation of the cell structure occurs in the porous GDL due to its weak mechanical strength. Thicker GDLs result into lower water content in the GDL structure, and can sustain a larger assembly force without the risk of “electrode flooding”; while thinner GDLs have higher water content, can maintain the hydration required for the membrane, and yield a better cell performance with less sensitivity to the variations in the assembly force. Thinner membranes yield better cell performance, but the cell performance is more sensitive to the changes in the assembly force. A combination of thin GDL and membrane is beneficial for better cell performance with reasonable sensitivity to the assembly force. For thinner GDLs, an optimal assembly force exists beyond which the cell performance is reduced; and practical cell assembly force will limit the GDL thickness.     

Steady saturation distribution in hydrophobic gas-diffusion layers of polymer electrolyte membrane fuel cells: A pore-network study

A pore-network model is developed to simulate liquid water transport in a hydrophobic gas-diffusion layer (GDL) during the operation of polymer electrolyte membrane fuel cells (PEMFCs). The steady saturation distribution in GDLs is determined through a numerical procedure using a pore-network model combined with invasion-percolation path-finding and subsequent viscous two-phase flow calculation. The simulation results indicate that liquid water transport in hydrophobic GDLs is a strongly capillary-driven process that almost reaches the pure invasion-percolation limit with zero capillary number. A uniform flux condition is found to better reflect the actual phenomenon occurring at the inlet boundary for liquid water entering a GDL than a uniform pressure condition. The simulation further clarifies the effect of the invaded pore fraction at a uniform-flux inlet boundary in modifying water transport in GDLs. Finally, the effect of the GDL thickness on the steady saturation distribution is investigated.     

Gas diffusion through differently structured gas diffusion layers of PEM fuel cells

Proton exchange membrane fuel cell (PEMFC) gas diffusion layers (GDLs) play important parts in diffusing gas, discharging liquid water, and conducting electricity, etc. When liquid water is discharged through GDL to gas channel, there will be some pores of GDLs occupied by liquid water. In this study, based on a one-dimensional model, the distribution of liquid water phase saturation is analyzed for different GDL structures including GDL with uniform porosity, GDL with sudden change porosity (GDL with microporous layer (MPL)) and GDL with gradient porosity distribution. The effect on gas diffusion of the changes of porosity and liquid saturation due to water remaining in GDL pores is calculated. The conclusions are that for uniform porosity GDL, the gas diffusion increases with the increase of porosity and contact angle and increases with the decrease of the thickness of GDL; for GDL with MPL, the larger the MPL porosity and the thinner the MPL thickness are, the stronger the gas diffusion is; for gradient change porosity GDL with the same average equivalent porosity, the larger the porosity gradient is, the more easily the gas diffuses. The optimization for GDL gradient structure shows that the GDL with a linear porosity distribution of 0.4x+0.4$0.4x+0.4$ is the best of the computed cases.     

Liquid water transport mechanism in the gas diffusion layer

We developed an equivalent capillary model of a microscale fiber-fence structure to study the microscale evolution and transport of liquid in a porous media and to reveal the basic principles of water transport in gas diffusion layer (GDL). Analytical solutions using the model show that a positive hydraulic pressure is needed to drive the liquid water to penetrate through the porous GDL even consisting of the hydrophilic fibers. Several possible contributions for the water configuration, such as capillary pressure, gravity, vapor condensation, wettability and microstructures of the GDL, are discussed using the lattice Boltzmann method (LBM). It is found that the distribution manners of the fibers and the spatial mixed-wettability in the GDL also play an important role in the transport of liquid water.