Gas Diffusion Layer Research Articles

Enhancing PEMEC Efficiency: A synergistic approach using CFD analysis and Machine learning for performance optimization

The proton exchange membrane electrolytic cell (PEMEC) is a clean, pollution-free, and promising device for producing hydrogen from water electrolysis. This paper enhances the electrochemical performance of the PEMEC by developing a comprehensive three-dimensional two-phase non-isothermal heat and mass transfer cell model. An analysis was conducted to study the influence of various operating parameters on the temperature safety and efficiency of the cell. The performance of the latter was optimized by adopting the machine learning technology, which aimed at identifying optimal conditions for improved performance. The obtained results showed that, when the inlet water flow rate and membrane thickness were increased, the average temperature of the anode catalyst layer (A-CL) was decreased by 1.4 K and 2.31 K, respectively. This allowed to improve the safety of the electrolytic cell. However, it would reduce the hydrogen and oxygen mole fraction in the electrolyzer. On the contrary, enhancing the porosity or thickness of the anode gas diffusion layer can increase the average A-CL temperature and decrease the oxygen and hydrogen mole fraction. Therefore, the backpropagation neural network and non-dominated sorting genetic algorithm were used to predict and optimize the performance of the electrolyzer, in order to maximize its temperature safety, electrochemical reaction rate, and hydrogen evolution efficiency as much as possible. The results of this study provide a theoretical foundation for the selection of suitable cell models according to different conditions in engineering applications. It also has an application value in energy saving and sustainable development.

Numerical Simulation of Effects of Catalyst Layer Parameters on Heat Transfer in Proton Exchange Membrane Fuel Cells

A non-isothermal, two-dimensional, two-phase fuel cell agglomerate model is used, and studies are done on how platinum loading and catalyst layer thickness affect heat transfer in fuel cells. Results indicate that as the cathode platinum content and catalyst layer (CL) thickness rise, the electrical property is improved. The maximum power density corresponding to the platinum loading of 0.40 mg/cm2 increases by 8.92% compared with 0.20 mg/cm2, and the maximum power density corresponding to the CL thickness of 17.5 µm increases by 4.63% compared with 10.0 µm. Temperature variation trends in CLs from entry to exit and inside the cell along the thickness direction do not change. Furthermore, with the CL thickness as well as platinum content increasing, the temperature increment inside cathode gas diffusion layer as well as CL is more obvious, and temperature distribution uniformity within the cell deteriorates. The impact of platinum loading on the temperature in the cell is more obvious than that of CL thickness. In the selection about platinum content and thickness of CL, temperature distribution uniformity and electrical property should be weighed.

Impact of Air-Cathodes on Operational Stability of Single-Chamber Microbial Fuel Cell Biosensors for Wastewater Monitoring

The increasing global water pollution leads to the need for urgent development of rapid and accurate water quality monitoring methods. Microbial fuel cells (MFCs) have emerged as real-time biosensors for biochemical oxygen demand (BOD), but they grapple with several challenges, including issues related to reproducibility, operational stability, and cost-effectiveness. These challenges are substantially shaped by the selection of an appropriate air-breathing cathode. Previous studies indicated a critical influence of the cathode on both the enduring electrochemical performance of MFCs and the taxonomic diversity at the electroactive anode. However, the effect of different gas diffusion electrodes (GDE) on 3D-printed single-chamber MFCs for BOD biosensing application and its effect on the bioelectroactive anode was not investigated before. Our study focuses on comparing GDE cathode materials to enhance MFC performance for precise and rapid BOD analysis in wastewater. We examined for over 120 days two Pt-coated air-breathing cathodes with distinct carbonaceous gas diffusion layers (GDLs) and catalyst layers (CLs): cost-effective carbon paper (CP) with hand-coated CL and more expensive woven carbon cloth (CC) with CL pre-applied by the supplier. The results show significant differences in electrochemical characteristics and anodic biofilm composition between MFCs with CP and CC GDE cathodes. CP-MFCs exhibited lower sensitivity (16.6 C L mg−1 m−2) and a narrower dynamic range (25 to 600 mg L−1), attributed to biofouling-related degradation of the GDE. In contrast, CC-MFCs demonstrated superior performance with higher sensitivity (37.6 C L mg−1 m−2) and a broader dynamic range (25 to 800 mg L−1). In conclusion, our study underscores the pivotal role of cathode selection in 3D-printed MFC biosensors, influencing anodic biofilm enrichment time and overall BOD assessment performance. We recommend the use of cost-effective CP GDL with hand-coated CL for short-term MFC biosensor applications, while advocating for CC GDL supplied with CL as the preferred choice for long-term sensing implementations with enduring reliability.

Effect of Ti3SiC2 concentration on corrosion resistance and ICR in bipolar plates composite ceramic coatings

Ti3SiC2, a MAX-phase ceramic, amalgamates metallic and ceramic traits, delivering exceptional electrical conductivity and corrosion resistance. In this research, Ti3SiC2 composite coatings were applied to 316 L stainless steel via low-power atmospheric plasma spraying (APS), aiming to bolster the electrical and corrosion resistance attributes of bipolar plates (BPPs). A power input of 15 kW notably enhanced coating density, yielding a Ti3SiC2 concentration of 19.2 wt% in the coating. Extremes in the spraying power led to either diminished deposition efficiency or a reduction of Ti3SiC2 mass fraction below 5 wt%. Tafel curves demonstrated that specimens with elevated Ti3SiC2 mass fractions exhibited robust corrosion resistance, characterized by a self-corrosion potential of −162.5 mV and a self-corrosion current density of 1.7217 × 10−6 A·cm−2. Moreover, the interfacial contact resistance (ICR) between the coating and the gas diffusion layer was remarkably low (down to 5.49 mΩ·cm−2), indicating enhanced surface electron transfer with increasing Ti3SiC2 mass fractions.

The ultra-thin flexible graphite/epoxy bipolar plates adjusted by different surface tension modifiers and application in the fuel cell stack

The graphite-resin composite bipolar plates prepared by the traditional hybrid pressing process exhibit poor conductivity, processability, and wettability due to the graphite flake layer being covered by resin, hindering the formation of a continuous conductive network, which significantly constrains their promotion and application in the field of proton exchange membrane fuel cells (PEMFC). In this paper, an ultra-thin flexible graphite/epoxy composite bipolar plates (BPs) with a thickness of only 0.775 mm is prepared followed by a process of flexible graphite preforming and impregnation curing. The hydrophilicity-modified BPs surface has a contact angle of 59.01° as well as flexural and compressive strengths of 11 MPa and 4 MPa and possesses a high in-plane conductivity of 380 S/cm and a low in-plane specific resistance of 6 mΩ cm2. The electrostack test results show that the hydrophilic runner channel is more conducive to the diffusion and spreading of H2O generated from the cathode-side reduction reaction in the flow channel, so that O2 smoothly passes through the gas diffusion layer to participate in the reduction reaction of O2, and exhibits higher electric power at high current density, while the hydrophobically modified BPs has relatively poor overall performance due to ohmic losses.

Effect of high-intensity vibration parameter on droplet transport characteristics in gas channel of proton exchange membrane fuel cell

In aerospace applications, proton exchange membrane fuel cells are subject to high-intensity vibration. Vibration has a substantial effect on water transport in fuel cells. However, there is a lack of research on the effects of multi-directional and high-intensity vibration conditions on fuel cells. In this study, the droplet transport characteristics in the gas channel under high-intensity vibration conditions are investigated for the first time. Moreover, the effects of vibration direction and vibration frequency on the droplet dynamic transport process are specifically studied. The droplet transport state, drainage performance, and pressure drop variation in the gas channel under different vibration conditions are analyzed and interpreted. The results show that low-frequency vibration in the longitudinal direction is more conducive to the droplet discharge, and the pressure drop undergoes a periodic change corresponding to the vibration frequency. Vertical vibration promotes droplet detachment from the gas diffusion layer surface, which contributes to the reduction in water coverage ratio on its surface, despite an increase in the channel pressure drop. Under the influence of horizontal vibration, droplets are more susceptible to adsorption on the channel sidewalls and turn into a liquid film, which leads to a longer discharge time and a reduction in pressure drop.

Generative Artificial Intelligence for Designing Multi-Scale Hydrogen Fuel Cell Catalyst Layer Nanostructures.

Multiscale design of catalyst layers (CLs) is important to advancing hydrogen electrochemical conversion devices toward commercialized deployment, which has nevertheless been greatly hampered by the complex interplay among multiscale CL components, high synthesis cost and vast design space. We lack rational design and optimization techniques that can accurately reflect the nanostructure-performance relationship and cost-effectively search the design space. Here, we fill this gap with a deep generative artificial intelligence (AI) framework, GLIDER, that integrates recent generative AI, data-driven surrogate techniques and collective intelligence to efficiently search the optimal CL nanostructures driven by their electrochemical performance. GLIDER achieves realistic multiscale CL digital generation by leveraging the dimensionality-reduction ability of quantized vector-variational autoencoder. The powerful generative capability of GLIDER allows the efficient search of the optimal design parameters for the Pt-carbon-ionomer nanostructures of CLs. We also demonstrate that GLIDER is transferable to other fuel cell electrode microstructure generation, e.g., fibrous gas diffusion layers and solid oxide fuel cell anode. GLIDER is of potential as a digital tool for the design and optimization of broad electrochemical energy devices.

Determination Of Two-Phase Flow Regimes Of A Condensing Water-Air Mixture In An Array Of Micro Channels

Proton exchange membrane (PEM) full cells (FCs) are a promising alternative to combustion engines for mobile applications. Their signature low operating temperature leads to the possible existence of product water in its liquid form. Liquid water formation and transport are important phenomena to understand and model in order to facilitate the development of new, more efficient PEMFCs. This contribution investigates the two-phase flow phenomena separately by introducing a gaseous air-vapor mixture into an optically accessible fuel cell flow plate with 14 parallel micro channels (confinement number Co = 7.3) and a carbon paper inlay representing the FC's gas diffusion layer and bringing it to the point of onset of condensation. Special care is taken to provide a controlled and reproducible air-vapor mixture with low pressure pulsation. One key feature of the experiment is that the flow plate used is designed to be as similar to a regular research fuel cell flow plate as possible, retaining its channel surface properties and electrical parameters. It can also be heated to a given temperature to mimic the fuel cell operating conditions. Therefore, the same plate can also be used in in-situ experiments in an operated fuel cell. An air mass flow rate of 500 - 1000 mLn / min with relative humidities of 75% - 95% at 65°C and 75°C was investigated. The emerging flow patterns were captured using a high-speed camera at 250 Hz and categorized using canonical two-phase flow regime nomenclature. It is shown that the present setup can produce the relevant two-phase flow patterns that can be found in operated fuel cells as reported by previous studies and is furthermore equipped to investigate flow states not easily reached with an operated fuel cell (e.g. flooded channels).

Comprehensive Analysis of Wettability in Waterproofed Gas Diffusion Layers for Polymer Electrolyte Fuel Cells.

In polymer electrolyte fuel cells (PEFCs), the gas diffusion layer (GDL) is crucial for managing the flooding tolerance, which is the ability to remove the water produced during power generation from the assembled cell. However, an improved understanding of the properties of GDLs is required to develop effective waterproofing strategies. This study investigated the influence of the polytetrafluoroethylene (PTFE) content on the pore diameter, porosity, wettability, water saturation, and flooding tolerance of waterproofed carbon papers as cathode GDLs in PEFCs. The addition of minimal PTFE (∼6 wt %) to carbon paper provided external waterproofing, whereas internal waterproofing was achieved at a higher PTFE content (∼13 wt %). However, excessive PTFE (∼37 wt %) led to macropore collapse within the carbon paper, reducing fuel cell performance. Although PTFE addition was expected to improve the flooding tolerance, operando synchrotron X-ray radiography revealed that the water saturation level in carbon paper increased with increasing PTFE content. These findings provide a benchmark for assessing whether GDLs meet the flooding tolerance requirements of PEFCs and may be applicable to waterproofed GDLs in electrochemical devices for water and CO2 electrolysis.

Liquid Water Visualization in the Pt‐Loading Cathode Catalyst Layers of Polymer Electrolyte Fuel Cells Using Operando Synchrotron X‐ray Radiography

Water management is important for addressing the challenges posed by next‐generation fuel cell electric vehicles. Although X‐ray imaging techniques are useful for probing the mechanism of water transport in the gas diffusion layer of polymer electrolyte fuel cells, they cannot be easily applied to the Pt‐loading catalyst layer because of its low X‐ray transmittance due to the high absorption coefficient of Pt. Herein, a method to realize the high‐resolution X‐ray imaging of a 30 μm‐thick cathode catalyst layer in polymer electrolyte fuel cells using synchrotron X‐ray radiography is proposed, thus bridging the above gap. The results of operando synchrotron X‐ray radiography measurements reveal that water accumulation in the cathode catalyst layer depends on the cell temperature, feed gas humidity, and cell voltage, while time‐slice analysis shows that the water accumulation rate in the cathode catalyst layer immediately after the power generation is faster than that in the cathode gas diffusion layer. The proposed imaging method can be used to evaluate the water storage capacity of the catalyst layer and thus deepen the understanding of flooding phenomena and cold‐start behavior at subzero temperatures.

Robust channel structures of proton exchange membrane fuel cells for uniform clamping pressure to gas diffusion layers

Robust channel structures of proton exchange membrane fuel cells for uniform clamping pressure to gas diffusion layers

Unveiling the Role of PTFE Surface Coverage on Controlling Gas Diffusion Layer Water Content.

Gas diffusion layers (GDLs) are usually coated with a hydrophobic agent to achieve a delicate balance between liquid and gas phases to maximize mass transport. Yet, most GDL numerical models to date have assumed an average contact angle for all materials, thereby eliminating the possibility of studying the role of the polytetrafluoroethylene (PTFE) content. This study introduces two mixed wettability algorithms to predict the mixed wetting behavior of GDLs composed of multiple materials. The algorithms employ contact angle and distance to solid materials to determine the critical capillary pressure for each pore voxel. The application of the algorithms to the estimation of capillary pressure vs saturation curves for two GDLs, namely, a micro-computed tomography (μ-CT) reconstructed SGL 39BA GDL and a stochastically reconstructed Toray 120C GDL, showed that, in agreement with experimental data, the addition of PTFE resulted in a decrease in saturation at a given capillary pressure. For Toray-120C, the mixed wettability model was capable of reproducing experimentally observed features in the intrusion curve at low saturation that could not be reproduced with a single wettability model, providing a clear link between PTFE coverage and intrusion at low saturation. Numerical results also predicted an increased breakthrough pressure and a decrease in saturation with increasing PTFE, in agreement with experimental observations. The decreased saturation at breakthrough improves gas transport through the layer while maintaining the layer's ability to remove water. Diffusivity simulations confirm the increase in diffusivity at breakthrough with increasing PTFE, thereby providing a rationale for the addition of PTFE, as well as for the optimal amount. This study emphasizes the importance of multimaterial wetting models and calls for more detailed investigations into PTFE and ionomer distributions in GDLs and catalyst layers, respectively.

Performance of proton exchange membrane fuel cell system by considering the effects of the gas diffusion layer thickness, catalyst layer thickness, and operating temperature of the cell

BackgroundIn this research, the effect of anode and cathode channel cross-sectional shape on the performance of PEM fuel cell was investigated and the appropriate length and dimensions of the channel were determined. Finally, for the determined geometric conditions, the cell performance at different voltages was investigated. MethodsThe purpose of this study was to investigate the structural characteristics of the fuel cell on its performance. The results show that the pressure and temperature in the catalyst layer (CL) of the cathode side are greater than the anode, and the temperature in the central regions of the catalyst layer is higher than the lateral regions. Also, the channel with a length of 100 mm is optimal in terms of producing the maximum current density and the amount of pressure drop is much lower than the channel with a length of 150 mm, which reduces the power consumption of the cell. Significant findingsIn general, a higher electric current is produced by increasing the thickness of the gas diffusion layer (GDL) and the catalyst layer. At a voltage of 0.8 V, with increasing thickness from 0.25 mm to 0.5 mm, the current density increases above 6 %. The percentage increase in current density at 60 °C–80 °C for 0.85 V and 0.75 V voltages is 42.1 % and 9.28 %, respectively.

Study of Mass Transport in the Anode of a Proton Exchange Membrane Fuel Cell with a New Hydrogen Flow‐Rate Modulation Technique

AbstractHydrogen transport in the anode of a proton‐exchange membrane fuel cell (PEMFC) has been studied with a modulation technique relating the hydrogen flow‐rate ( ) and the faradaic current ( ), called Current‐modulated Hydrogen flow‐rate Spectroscopy (CH2S). A simple analytical expression for the transfer function, H(jω)=n F / , is provided, showing a skewed semicircle in Nyquist representation (−H'' vs. H'), extending from H’=0 to H’=1, and with the maximum frequency at ωmax=2.33(DH2 /Li2), where DH2 is the effective hydrogen diffusivity and Li the thickness of the anode gas diffusion layer (GDL). The expression for CH2S is also calculated with an existing reversible chemical reaction in the GDL. Experimental results under different operation conditions show two transport processes limiting the anode reaction, one attributed to molecular diffusion through the partially saturated GDL, and the other to the microporous layer (MPL), or its interfaces with GDL or with the catalyst layer (CL). CH2S provides the hydrogen diffusivities (DH2,i) associated to each process under the different conditions. Current density decreases slightly the diffusivity of the GDL, while it becomes activated in the MPL; using two GDLs in the anode improves both GDL and MPL diffusivities; humidification decreases the diffusivity in both, GDL and MPL; finally, a superhydrophobic anodic CL prepared by electrospray improves hydrogen diffusivity in GDL and MPL.

Effects of porosity and porosity distribution in gas diffusion layer on the performances of proton exchange membrane fuel cell

The transmission capability of the gas diffusion layer directly impacts electrochemical reaction and water drainage, consequently, the comprehensive performance and lifetime of the proton exchange membrane fuel cell. The gas diffusion layer's porosity and distribution must be designed effectively as a porous component. This study focuses on experimentally validated models to investigate the effects of porosity and distribution in the gas diffusion layer using three-dimensional numerical simulation. A porosity of 0.6, with a unitary distribution, provides comprehensive improvements in power density while minimizing pressure drops. Additionally, four different distribution patterns of porosity (28 cases) are studied while maintaining an overall porosity of 0.6. The linear porosity distribution (along the flow path) with positive slopes outperforms the alternant distribution due to the cumulative effects on the micro-subsection of the gas diffusion layer. The stepped and/or the sinusoidal distribution can also improve the performances, but just when the step gradient and/or the amplitude are sufficiently small. The adverse effects on the uniformity of current density cause the sinusoidal distribution to be inferior to linear and stepped distribution patterns. The transmission of oxygen significantly affects the dynamic performances, with the distribution patterns of porosity critically influencing sensitivity.

Operando X-ray radiography of liquid water distribution in 100 mm polymer electrolyte fuel cell channels

Preventing the accumulation of water in the gas diffusion layer (GDL) proves effective in enhancing the performance of polymer electrolyte fuel cells (PEFCs). To understand the water transport phenomena in GDLs and channels of PEFCs, cell hardware for operando synchrotron X-ray radiography was developed with a 100 mm channel length, facilitating the separate quantification of liquid water in the cathode and anode GDLs. The presence of liquid water in the cathode and anode GDLs was confirmed during operation with a supply of dry gas in a counter-flow configuration. Furthermore, the amount of liquid water in the cathode and anode GDLs increased toward the cathode inlet, while the amount of water in the cathode and anode channel regions increased toward each outlet. The liquid water distribution in the GDLs along the channel direction can be attributed to water transport from cathode to anode (back-diffusion), decreasing toward the anode outlet. Therefore, conducting radiography experiments aligned parallel to the GDLs and perpendicular to the channel could provide valuable insights for a more comprehensive understanding of water transport in cells.

Similarities and Differences between Gas Diffusion Layers Used in Proton Exchange Membrane Fuel Cell and Water Electrolysis for Material and Mass Transport.

Proton-exchange membrane fuel cells (PEMFCs) and water electrolysis (PEMWE) are rapidly developing hydrogen energy conversion devices. Catalyst layers and membranes have been studied extensively and reviewed. However, few studies have compared gas diffusion layers (GDLs) in PEMWE and PEMFC. This review compares the differences and similarities between the GDLs of PEMWE and PEMFC in terms of their material and mass transport characteristics. First, the GDL materials are selected based on their working conditions. Carbon materials are prone to rapid corrosion because of the high anode potential of PEMWEs. Consequently, metal materials have emerged as the primary choice for GDLs. Second, the mutual counter-reactions of the two devices result in differences in mass transport limitations. In particular, water flooding and the effects of bubbles are major drawbacks of PEMFCs and PEMWE, respectively; well-designed structures can solve these problems. Imaging techniques and simulations can provide a better understanding of the effects of materials and structures on mass transfer. Finally, it is anticipated that this review will assist research on GDLs of PEMWE and PEMFC.

Effect of gas diffusion layer surface property on platinum nanowire array electrode performance in proton exchange membrane fuel cells

3D-ordered catalyst electrodes have been recognized as one effective strategy to reach high current density operation for proton exchange membrane fuel cell (PEMFC) applications. Gas diffusion electrodes (GDEs) with platinum nanowire arrays in-situ grown on gas diffusion layer (GDL) surface is an important contribution in this area, but the performance is highly dependent on the GDL surface properties. In this study, the GDLs available in the market are systematically investigated, with a focus on the influence of the GDL surface properties on the in-situ growth of Pt nanowire arrays to fabricate GDEs as cathodes for PEMFCs. The experimental results indicate that mesopores especially micropores play a key role. They enable a hydrophilic surface for the isopropanol pretreated GDL, facilitating the in-situ growth of Pt nanowires to form a uniform array with a large electrochemical surface area (ECSA), finally leading to a high-power density. With Freudenberg H24CX483 carbon paper GDL, the highest power density of 0.9 W cm−2 is achieved. The understanding achieved here could be further used to develop novel GDLs for fabricating the next generation of electrodes for large current density operations.

Influence of binder content on gas-water two-phase flow and displacement phase diagram in the gas diffusion layer of PEMFC: A pore network view

Understanding the gas-water flow dynamics in the gas diffusion layer (GDL) is one of the keys to improving the proton exchange membrane fuel cell's (PEMFC) overall performance and avoiding water flooding. Yet, the relationship between the two-phase flow and micro-scale GDL structures (including binder, PTFE, and fiber skeleton) is not well understood. In this study, three-dimensional GDL structures with different fractions of binder contents (φb=0%∼50%) and a fixed porosity of 75.6 % are confidently reconstructed based on high-resolution images from the confocal microscope, implying that the addition of binder will increase the number of large pores and cause a bimodal throat size distribution through morphology analysis. Thereafter, drainage simulations are performed under a wide range of capillary number (−9 < log Ca <0) and viscosity ratio (−3 < log M < 2) by the pore network model (PNM), which robustly predicts the displacement phase diagram of viscous fingering, capillary fingering, stable displacement, and transitional regime. In the viscous fingering and stable displacement regime, the nonwetting phase saturation (Snw) is nearly the same for different φb, implying the fluid invading pathway does not change much with the addition of binder. However, in the capillary fingering regime (refer to the actual operating conditions), Snw increases rapidly with φbat the breakthrough time and its transient value continues to increase until the steady state, which may be attributed to the increased fractions of pores above the capillary threshold attributed by the bimodal throat size distribution. In addition, the effective water permeability increases sharply with φb, whereas the gas permeability remains almost constant, which means such pore structure alteration by adding the binder is beneficial to water disposal in PEMFC. This research provides insights into delineating the effect of pore and throat size distribution alteration by adding binder on two-phase dynamics in GDL.

Numerical investigation of mesoscale multiphase mass transport mechanism in fibrous porous media

At present, the proton exchange membrane fuel cell (PEMFC) is one of the most promising new energy solutions. The structure and material properties of the gas diffusion layer (GDL) are important factors that restrict the efficient water management and structural stability of PEMFCs. The complex mesoscopic fibrous porous structure of the GDL results in complex multiphase flow dynamics problems that have highly nonlinear characteristics. It is difficult to describe the details of mesoscopic multiphase coupled transport dynamics and numerically solve problems in which there is a two-phase flow with a high-density ratio. To solve these problems, a mesoscopic multiphase coupled transport model based on a lattice Boltzmann method and volume-of-fluid (LBM-VOF) model is proposed. Moreover, we also discuss the mechanism of the interaction between the fibrous porous structure and internal multiphase flow. The results obtained illustrate that the proposed method can obtain dynamic details of the flow field for fibrous porous media. The surface wettability of fibres strongly influences both the distribution and stability of liquid water clusters within porous materials. Concurrently, the fibre diameter assumes a pivotal role in governing lateral water diffusion and exclusion efficiency. This work lays a foundation for efficient water and thermal management of PEMFCs.