Ejectors are ideal hydrogen recirculation devices for PEMFC systems but typically exhibit poor recirculation performance at low loads. For purpose of extending ejector's operating range in vehicular applications, the entraining performance across multiple loads should be focused. In this study, A 40 kW ejector was designed with a 1D theory and optimized using a 2D CFD model. Simulations were conducted to study the influence of various diameter and axial dimensions on the ejector's performance and flow characteristics. The results reveal that as the load increases from 20% to 100%, the suboptimal diffuser exit diameter decreases from 2.5 to 1.5 times the mixing chamber diameter, the optimal nozzle exit position increases from 0.59 to 0.63 times, and the optimal mixing chamber length increases from 2.2 to 4.3 times. A convergent nozzle with a short throat significantly improves low-load entraining performance and achieves the highest performance growth in the variable-nozzle design. Additionally, an optimization method for axial dimensions based on the proposed parameter flow uniformity was established, allowing for precise determination of the optimal dimensions through a few simulations.
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