CFD investigation of the effect of flow field channel design based on constriction and enlargement configurations on PEMFC performance

In this study, a three-dimensional CFD, non-isothermal model was developed to identify an optimal layout for key geometrical parameters of PEMFC flow field designs with constriction and enlargement cross-sections located at the middle of the channel. For this purpose, the effect of channel configurations with both constriction and enlargement cross-sections was explored and compared with a conventional constant channel segment, under varying hydraulic diameter and lengths. As results, the constriction configuration channel with a hydraulic diameter reduction of 50% has shown the best performance among the enlargement and straight channels for all considered lengths. The constriction configuration enhances fluid velocity, resulting in improved flow distribution and relatively increased pressure drop across the flow channels. Moreover, a better temperature distribution, higher oxygen consumption, improved membrane humidification, and water removal were observed. This leads to an increased net power output of the PEMFC. However, considering different hydraulic diameters of the constriction geometry, the best performance of the cell was achieved at a hydraulic diameter reduction of 60%, combined with a length of 4/7 of the total channel length. This optimal balance between pressure drops and reactants’ flow has enhanced the net power of the proposed geometry by 26.30 %, compared to the straight channel. The novel proposed single-channel configuration based on a simple constriction, is a low-cost design that has significantly improved cell performance compared to the straight one. Since operating conditions are crucial for cell performance, the effects of operating temperature and relative humidity were investigated, and the optimum conditions were determined.