Flow Distribution in Proton Exchange Membrane Fuel Cell Stacks

Proton exchange membrane fuel cell (PEMFC) stacks comprise a series of individual cells in which hydrogen and oxygen are converted into electricity through electrochemical reactions. Uniform distribution of reactant gases across the active area of each cell is vital to ensure consistent performance, minimise localised flooding or drying of the membrane, and prolong stack lifetime. Flow distribution is governed by the geometry of flow channels etched into bipolar plates, the design of inlet and outlet manifolds, and the interplay between pressure drop, water management and thermal gradients. Optimal channel layouts balance low pressure loss with effective reactant delivery, while manifold designs must prevent mal-distribution that can cause cell starvation or overheating. Computational fluid dynamics (CFD) and advanced experimental techniques have revealed that even small deviations in channel dimensions or manifold inlet shapes can lead to significant variations in current density and accelerate degradation. Addressing flow uniformity is therefore a cornerstone of efforts to scale PEMFC stacks for heavy-duty transport and stationary power applications, where reliability, efficiency and system cost are tightly linked to the quality of gas distribution.

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Flow Distribution in Proton Exchange Membrane Fuel Cell Stacks publication trend

The graph below shows the total number of articles in flow distribution in proton exchange membrane fuel cell stacks across all publications each year (not limited to Nature Index journals).

Technical terms

Proton exchange membrane fuel cell (PEMFC) stack: A series of cells in which a polymer electrolyte membrane separates the anode and cathode, facilitating proton conduction and electrical generation.

Manifold: A network of inlet or outlet passages that distributes reactant gases uniformly to individual cells within a fuel cell stack.

Serpentine flow channel: A winding channel pattern in bipolar plates designed to enhance reactant distribution and water removal.

Computational fluid dynamics (CFD): A numerical simulation technique used to model fluid flow, pressure drops and species transport within complex geometries.

Non-uniformity factor: A quantitative measure of flow distribution variation across channels, often expressed as a percentage of deviation from the mean flow rate.

Bipolar plate: A conductive plate in a fuel cell stack that provides gas channels on its surfaces and conducts electrical current between cells.

References

1. Power Output Optimisation via Arranging Gas Flow Channels for Low-Temperature Polymer Electrolyte Membrane Fuel Cell (PEMFC) for Hydrogen-Powered Vehicles. Energies (2023).
2. Manifold Design in a PEM Fuel Cell Stack to Improve Flow Distribution Uniformity. Sustainability (2022).
3. Improvement of air distribution consistency in large-scale proton exchange membrane fuel cell stack manifold. Electrochemistry Communications (2022).