The PEMFC technology is on the rise to be implemented as climate neutral power source in next generation aircraft. Despite the PEMFC’s high efficiency at ground level, it suffers from severe power losses when it is operated under high-altitude conditions, i.e. low ambient pressure and temperature.In this study, a fuel cell system consisting of a 120 cells PEMFC stack, an air blower, an anode recirculation pump and a cooling unit is investigated experimentally inside an altitude test chamber, where the ambient pressure and temperature can be controlled. In an extensive parameter study, the fuel cell’s cathode stoichiometry and the stack temperature are varied while the system is operated at different average cell voltage levels under high-altitude conditions. The ambient pressure is varied between 1000 and 500 hPa, the latter corresponding to an altitude of 5600 m. The air blower inflow temperature is varied between 40 and -30 °C. By means of statistical design of experiment methods an empirical model is derived from the measurements, which represents the system performance depending on the five-dimensional parameter space, i.e. cathode stoichiometry, stack temperature, average cell voltage, ambient pressure and blower inflow temperature.The model is evaluated in order to identify the optimal parameter configurations for stoichiometry and stack temperature control, yielding the maximum system net power at high-altitude operation. The results show that the negative effects in terms of power losses due to low ambient pressure prevail over low air temperature. However, the low temperature is non-negligible in terms of the air density, affecting the required blower power to maintain a certain stoichiometry and consequently also affecting the system net power. When operating at high-altitude conditions with optimized control parameters, the resulting net power output is significantly higher compared to the net power output obtained with the default control parameters suggested by the manufacturer. The main reason for this power increase can be found in the optimized membrane humidification. Under high-altitude conditions, humidification becomes more sensitive to deviations from the identified optimal control parameters. The results highlight the large optimization potential through altitude-adaptive control of fuel cell systems for aviation applications.
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