Metal foams as flow distributors in comparison with serpentine and parallel flow fields in proton exchange membrane electrolyzer cells

Numerical Investigation of the Performance of a Proton Exchange Membrane Water Electrolyzer under Various Outlet Manifold Structure Conditions

The oxygen discharge process significantly affects the electrochemical performance of a proton exchange membrane water electrolyzer (PEMWE), which requires an optimal structure of the flow field implemented in the bipolar plate (BP) component. In this study, we numerically investigated the two-phase (liquid water and oxygen) flow in the PEMWE's channel region with different outlet manifold structures utilizing the volume of fluid (VOF) model. Then, the oxygen volume fraction at the liquid/gas diffusion layer (L/GDL) surface, i.e., the interface of the channel and L/GDL, obtained by the liquid water and oxygen flow model was incorporated into a three-dimensional (3D) PEMWE model, which made it possible to predict the influence of the outlet manifold structure on the multiple transfers inside the whole electrolyzer as well as the electrochemical performance. The results indicate that the existence of oxygen in the flow field significantly decreased the electrolyzer voltage at a fixed operation current density and deteriorated the uniform distribution of the oxygen amount, current density (corresponding to the electrochemical reaction rate) and temperature in the membrane electrode assembly (MEA), indicating that the rapid oxygen removal from the flow field is preferred in the operation of the electrolyzer. Moreover, slight increases in the width of the outlet manifold were helpful in relieving the oxygen accumulation in the anode CL and, hence, improved the electrolyzer performance with more uniform distribution characteristics.

Cooling Design for PEM Fuel-Cell Stacks Employing Air and Metal Foam: Simulation and Experiment

A new study investigating the cooling efficacy of air flow inside open-cell metal foam embedded in aluminum models of fuel-cell stacks is described. A model based on a commercial stack was simulated and tested experimentally. This stack has three proton exchange membrane (PEM) fuel cells, each having an active area of 100 cm2, with a total output power of 500 W. The state-of-the-art cooling of this stack employs water in serpentine flow channels. The new design of the current investigation replaces these channels with metal foam and replaces the actual fuel cells with aluminum plates. The constant heat flux on these plates is equivalent to the maximum heat dissipation of the stack. Forced air is employed as the coolant. The aluminum foam used had an open-pore size of 0.65 mm and an after-compression porosity of 60%. Local temperatures in the stack and pumping power were calculated for various air-flow velocities in the range of 0.2–1.5 m/s by numerical simulation and were determined by experiments. This range of air speed corresponds to the Reynolds number based on the hydraulic diameter in the range of 87.6–700.4. Internal and external cells of the stack were investigated. In the simulations, and the thermal energy equations were solved invoking the local thermal non-equilibrium model—a more realistic treatment for airflow in a metal foam. Good agreement between the simulation and experiment was obtained for the local temperatures. As for the pumping power predicted by simulation and obtained experimentally, there was an average difference of about 18.3%. This difference has been attributed to the poor correlation used by the CFD package (ANSYS) for pressure drop in a metal foam. This study points to the viability of employing metal foam for cooling of fuel-cell systems.