Design and Optimization of Flow Channels for a 10-Cell PEMFC Stack

MINIATURA 8

Funding Organization: National Science Centre

Project title: Design and Optimization of Flow Channels for a 10-Cell PEMFC Stack

Agreement number: DEC-2024/08/X/ST8/01755

Project implementation period: 10.12.2024 - 09.04.2026

Principal Investigator: dr Dineshkumar Ravi

Project value: 39 402,00 PLN

Funds granted for Lublin University of Technology: 39 402,00 PLN

Abstract: Globally research have been mainly focussed on utilizing hydrogen as a clean energy career for rural and urban transportation. The Proton Exchange Membrane Fuel Cell (PEMFC) offers a promising technology for clean and efficient energy conversion. PEMFC can offer high power density, zero emission, high efficiency and low operating temperatures makes it suitable for automotive applications. Development of PEMFC stack enables us to longer travel distances and reduces the dependency of charging the batteries frequently.  One of the critical components in a PEMFC stack is the design of flow channel. Flow channels ensure proper distribution of reactant gases namely hydrogen and oxygen to anodic and cathodic chamber respectively. They also aid effective removal of water, maintains low pressure drop across the channel.  In case of a 10-cell PEMFC stack each cell often fails to receive the stoichiometric ratio of fuel to the respective chambers. To address this issue, the present work aims to provide a proper flow channel design for a 10-Cell PEMFC stack which would ensure that individual cell receives adequate and balanced supply of reactant gases.
The first phase of the study involves a three-dimensional numerical investigation on the performance of a 10 cell PEMFC stack system. The numerical model of each cell consists of graphite plates, gas diffusion layer, membrane and end plates are modelled and assembled using Solid Works 20.0 modelling software. The numerical model is then discretized using both hexahedral and tetrahedral elements through finite volume approach using ANSYS ICEM CFD 23.2. The mesh model is then imported to ANSYS Fluent 23.2 to apply the required boundary conditions. The three-dimensional fluid flow variations have been simulated by solving the necessary governing equations namely, mass, momentum, and energy. The turbulence induced in the system will be captured using Shear Stress Transport (SST k-ω) mode of closure. The electrochemical reaction kinetics are represented by the Butler-Volmer equation, capturing the rates of the anodic and cathodic reactions. Additionally, the Ohm's Law is used to model the voltage losses due to internal resistance in the cell components, including the membrane, gas diffusion layers, and catalyst layers. The numerically predicted results will be validated with that of the standard available literature. Upon validation, the various flow channel designs will be tested for different operating conditions The predicted output values namely, individual cell and stack efficiency, heat transfer characteristics and pressure drop will be recorded and compared for variable operating conditions. The optimized flow channel unit will be considered for the development of experimental prototype. The second phase of the study involves the development of an experimental prototype in association with HydroGreen team (Lublin University of Technololgy (LUT), Lublin). HydroGreen team plays a pivotal role in advancing research and development in the field of hydrogen energy and fuel cell technology.  The optimized anodic and cathodic flow channel design will be fabricated using laser cutting/high precision milling. The assembly of all the components namely, graphite plates, membrane, gas diffusion electrode, end plates and catalyst will be carried out and tested at Hydrogreen lab.  The distribution of hydrogen and oxygen gases at LUT is carefully managed by Hydrogreen team, ensures highest safety standards. The team maintains H2 and O2 gases in Type-3 cylinders, which comply with stringent industry regulations. This careful handling and storage protocol is necessary for the safe and efficient operation. On the successful development of a 10-cell PEMFC stack prototype and it will be tested and operated in a four wheeled electric vehicle available at LUT. Furthermore, the results of the scientific activities will be presented at scientific conferences and published as a journal article in open-access SCI-indexed journals. All the research activities mentioned above will be conducted within the discipline of mechanical engineering.