Progressive topology-curvature optimization of flow channel for PEMFC and performance assessment

Abstract

The curved bending regions of serpentine flow channels play a crucial role in mass transfer and the overall performance of the flow field in proton exchange membrane fuel cells (PEMFCs). This paper proposes a “2D Topology-Curvature Optimization” progressive design method to optimize the bend area structures, aiming to enhance PEMFC performance. Through numerical simulations, it compares the topology-curvature optimization model with both the algorithm-based optimization model and a validation model, and analyzes the mass transfer, heat transfer characteristics, and output performance of PEMFC under different flow fields. The results indicate that the optimized structures improve convection and diffusion within the flow field, effectively enhancing the transport and distribution of oxygen and water within the PEMFC. Performance improvements, ranked from highest to lowest, are TS-III > MD-G (Model-GA) > MD-P (Model-PSO) > TS-II > TS-I. Among the optimized models, TS-III (Topology Structure-III) exhibits the greatest increases in peak current density and peak power density, with improvement of 4.72% and 3.12%, respectively. When considering the relationship between performance improvement and pressure drop using the efficiency evaluation criterion (EEC), TS-II demonstrates the best overall performance.

Graphical abstract

Keywords

proton exchange membrane fuel cell (PEMFC) / structural topology / curvature design / progressive optimization / output performance / computational fluid dynamics (CFD)

References

[1] M G Ouyang . Prospects for the cyclical and structural trends of China’s new energy vehicles in the next ten years. Science & Technology Review, 2024, 42(12): 6–13

[2] Z Y Teng, H M Zhang, Z W Liu, et al. Development status and prospect of distributed solid oxide fuel cell Power generation system. Proceedings of the CSEE, 2023, 43(20): 7959–7973 (in Chinese)

[3] Z Teng , C Tan , P Liu . . Analysis on carbon emission reduction intensity of fuel cell vehicles from a life-cycle perspective. Frontiers in Energy, 2024, 18(1): 16–27

[4] X W Du . Thoughts on strategies and paths to achieve carbon peaking and carbon neutrality in China. Frontiers in Energy, 2023, 17(3): 324–331

[5] S Barakat , A I Osman , E Tag-Eldin . . Achieving green mobility: Multi-objective optimization for sustainable electric vehicle charging. Energy Strategy Reviews, 2024, 53: 101351

[6] C C Chan , W Han , H Tian . . Automotive revolution and carbon neutrality. Frontiers in Energy, 2023, 17(6): 693–703

[7] A M Dafalla , F Jiang . Effect of catalyst layer mesoscopic pore-morphology on cold start process of PEM fuel cells. Frontiers in Energy, 2021, 15(2): 460–472

[8] A Djouahi , B Negrou , B Rouabah . . Optimal sizing of battery and super-capacitor based on the MOPSO technique via a new FC-HEV application. Energies, 2023, 16(9): 3902

[9] G Cai , Y Liang , Z Liu . . Design and optimization of bio-inspired wave-like channel for a PEM fuel cell applying genetic algorithm. Energy, 2020, 192: 116670

[10] X Xie , B Yin , S Xu . . Effects of microstructure shape parameters on water removal in a PEMFC lotus-like flow channel. International Journal of Hydrogen Energy, 2022, 47(5): 3473–3483

[11] S Y Zhang , S Liu , H T Xu . . Performance of proton exchange membrane fuel cells with honeycomb-like flow channel design. Energy, 2022, 239: 122102

[12] J Shen , Z Tu , S H Chan . Performance enhancement in a proton exchange membrane fuel cell with a novel 3D flow field. Applied Thermal Engineering, 2020, 164: 114464

[13] J Mahmoudimehr , A Daryadel . Influences of feeding conditions and objective function on the optimal design of gas flow channel of a PEM fuel cell. International Journal of Hydrogen Energy, 2017, 42(36): 23141–23159

[14] A Mohammedi , Y Sahli , H Ben Moussa . 3D investigation of the channel cross-section configuration effect on the power delivered by PEMFCs with straight channels. Fuel, 2020, 263: 116713

[15] M Rahimi-Esbo , A A Ranjbar , A Ramiar . . Improving PEM fuel cell performance and effective water removal by using a novel gas flow field. International Journal of Hydrogen Energy, 2016, 41(4): 3023–3037

[16] T Zhang , J Li , Q Li . . Combination effects of flow field structure and assembly force on performance of high temperature proton exchange membrane fuel cells. International Journal of Energy Research, 2021, 45(5): 7903–7917

[17] A A Ebrahimzadeh , I Khazaee , A Fasihfar . Experimental and numerical investigation of obstacle effect on the performance of PEM fuel cell. International Journal of Heat and Mass Transfer, 2019, 141: 891–904

[18] M M Samy , R E Almamlook , H I Elkhouly . . Decision-making and optimal design of green energy system based on statistical methods and artificial neural network approaches. Sustainable Cities and Society, 2022, 84: 104015

[19] Güven A Fatih , Samy M Mahmoud . Performance analysis of autonomous green energy system based on multi and hybrid metaheuristic optimization approaches. Energy Conversion and Management, 2022, 269: 116058

[20] K Y Chang . The optimal design for PEMFC modeling based on Taguchi method and genetic algorithm neural networks. International Journal of Hydrogen Energy, 2011, 36(21): 13683–13694

[21] M Seyhan , Y E Akansu , M Murat . . Performance prediction of PEM fuel cell with wavy serpentine flow channel by using artificial neural network. International Journal of Hydrogen Energy, 2017, 42(40): 25619–25629

[22] M B Eteiba , S Barakat , M M Samy . . Optimization of an off-grid PV/Biomass hybrid system with different battery technologies. Sustainable Cities and Society, 2018, 40: 713–727

[23] M M Samy , S Barakat , H S Ramadan . A flower pollination optimization algorithm for an off-grid PV-fuel cell hybrid renewable system. International Journal of Hydrogen Energy, 2019, 44(4): 2141–2152

[24] M M Samy , H I Elkhouly , S Barakat . Multi-objective optimization of hybrid renewable energy system based on biomass and fuel cells. International Journal of Energy Research, 2021, 45(6): 8214–8230

[25] L Gao, LI P G, Huang P, et al. Development strategies of industrial software for digital design. Strategic Study of CAE, 2023, 25(2): 254–262 (in Chinese)

[26] W H Zhang , H Zhou , S Y Li . . A review of material-structure integration design for high performance thin-walled components in aerospace. Journal of Aeronautics, 2023, 44(09): 30–46

[27] D B Wang , S Wang , H R Zheng . . A review of methods and applications for fluid topology optimization. Journal of Zhengzhou University: Engineering Science, 2023, 44(2): 1–13

[28] J Alexandersen , C S Andreasen . A review of topology optimisation for fluid-based problems. Fluids, 2020, 5(1): 29

[29] T Borrvall , J Petersson . Topology optimization of fluids in Stokes flow. International Journal for Numerical Methods in Fluids, 2003, 41(1): 77–107

[30] L H Olesen , F Okkels , H Bruus . A high-level programming-language implementation of topology optimization applied to steady-state Navier–Stokes flow. International Journal for Numerical Methods in Engineering, 2006, 65(7): 975–1001

[31] E M Dede , Y Liu . Experimental and numerical investigation of a multi-pass branching microchannel heat sink. Applied Thermal Engineering, 2013, 55(1–2): 51–60

[32] M Yu , S Ruan , X Wang . . Topology optimization of thermal–fluid problem using the MMC-based approach. Structural and Multidisciplinary Optimization, 2019, 60(1): 151–165

[33] F Feppon , G Allaire , C Dapogny . . Topology optimization of thermal fluid-structure systems using body-fitted meshes and parallel computing. Journal of Computational Physics, 2020, 417: 109574

[34] Q Y Yao , C Y Zhao , Y Zhao . . Topology optimization for heat transfer enhancement in latent heat storage. International Journal of Thermal Sciences, 2021, 159: 106578

[35] Y Zhao, H Liu, Y You, et al. Numerical and experimental study on topology optimization of fin configuration in latent heat storage. In: ISES Solar World Conference 2019, Santiago, Chile, 2019

[36] H Wang , Z L Wang , Z G Qu . . Deep-learning accelerating topology optimization of three-dimensional coolant channels for flow and heat transfer in a proton exchange membrane fuel cell. Applied Energy, 2023, 352: 121889

[37] X Wang , Y Wu , X Wang . Hydrophobicity enhancement of gas diffusion layer induced by hydrothermal deposition process and the electrochemical performance of proton exchange membrane fuel cell. Surfaces and Interfaces, 2023, 38: 102839

[38] J Tan , Y Xing , W Fan . . Smooth orientation interpolation using parametric quintic-polynomial-based quaternion spline curve. Journal of Computational and Applied Mathematics, 2018, 329: 256–267

[39] J H K Haertel , K Engelbrecht , B S Lazarov . . Topology optimization of a pseudo 3D thermos fluid heat sink model. International Journal of Heat and Mass Transfer, 2018, 121: 1073–1088

[40] J Zhao , M Zhang , Y Zhu . . Topology optimization of planar cooling channels using a three-layer thermos fluid model in fully developed laminar flow problems. Structural and Multidisciplinary Optimization, 2021, 63(6): 2789–2809

[41] C Han , T Jiang , K Shang . . Heat and mass transfer performance of proton exchange membrane fuel cells with electrode of anisotropic thermal conductivity. International Journal of Heat and Mass Transfer, 2022, 182: 121957

[42] S Chen , S Xiang , Z Tan . . Exploration of the oxygen transport behavior in non-precious metal catalyst-based cathode catalyst layer for proton exchange membrane fuel cells. Frontiers in Energy, 2023, 17(1): 123–133

[43] W L Zhuge , Y J Zhang , X S Lao . . Numerical simulation of three-dimensional gas/liquid two-phase flow in a proton exchange membrane fuel cell. Frontiers in Energy, 2007, 1(3): 305–310

[44] X L Wang , Z G Qu , G F Ren . Collective enhancement in hydrophobicity and electrical conductivity of gas diffusion layer and the electrochemical performance of PEMFCs. Journal of Power Sources, 2023, 575: 233077

[45] J Shen , Z Tu , S H Chan . Enhancement of mass transfer in a proton exchange membrane fuel cell with blockage in the flow channel. Applied Thermal Engineering, 2019, 149: 1408–1418

[46] J Shen , Z Tu , S H Chan . Evaluation criterion of different flow field patterns in a proton exchange membrane fuel cell. Energy Conversion and Management, 2020, 213: 112841

Acknowledgements

This work was supported by the National Natural Science Foundation of China (Grant No. 52266018); the Doctoral Initiation Project of Xinjiang Institute of Engineering, China (No. 2023XGYBQJ01); the Xinjiang Tianshan Talent - Youth Science and Technology Top Talents Project, China (No. 2022TSYCCX0051).

Competing Interests

The authors declare that they have no competing interests.

RIGHTS & PERMISSIONS

2025 Higher Education Press