Lung-inspired, fractal flow-fields hold great potential in improving the performance of polymer electrolyte membrane fuel cells (PEMFCs) by providing uniform gas distribution across the electrodes ...and ensuring minimum entropy production in the whole system. However, the inherent susceptibility of the fractal flow-fields to flooding renders their use inadequate at high humidity conditions. In-depth understanding of water management in lung-inspired flow-fields is indispensable for the implementation of alternative outlet channel geometries or engineered water removal strategies to alleviate flooding. Here, liquid water formation and transport across the lung-inspired and serpentine flow-field based PEMFCs are evaluated using neutron radiography. The results reveal a propensity to flooding in the interdigitated outlet channels of the fractal flow-field with N = 4 generations as a result of slow gas velocity and narrow channel dimensions, which leads to significant performance deterioration. Neutron images also elucidate the importance of ensuring a well-defined internal channel structure of the fractal flow-fields to prevent backflow of liquid water via wicking and capillary pressure build-up arising from the narrow inlet gas channels and hydrophobic gas diffusion layer.
•Neutron radiographs are presented for the lung-inspired and serpentine flow-fields.•A well-defined channel structure of the fractal flow-field is indispensable.•Water removal strategies required to alleviate flooding in the fractal flow-field.
Some of the new liquid water management systems in polymer electrolyte membrane (PEM) fuel cells hold great potential in providing flood-free performance and internal humidification. However, current ...water management systems entail major setbacks, which either inhibit implementation into state-of-the-art architectures, such as stamped metal flow-fields, or restrict their application to certain channel configurations. Here, a novel water management strategy is presented that uses capillary arrays to control liquid water in PEMFCs. These capillaries are laser-drilled into the land of the flow-fields and allow direct removal (wicking) or supply of water (evaporation), depending on the local demand across the electrode. For a 6.25 cm2 active area parallel flow-field, a ∼92% improvement in maximum power density from capillary integration was demonstrated. The proposed mechanism serves as a simple and effective means of achieving robust and reliable fuel cell operation, without incurring additional parasitic losses due to the high pressure drop associated with conventional serpentine flow-fields.
•New capillary-based water management strategy is presented for PEM fuel cells.•The capillaries allow redistribution of liquid water across the electrode.•Parallel flow-field modified with capillaries outperforms serpentine flow-field.
•Layer wise PCB based fractal lung-inspired cathode flow field.•Cost effective and light weight method of fractal flow field development.•Enhanced performance over serpentine flow field at a range of ...operating conditions.•Uniform and sustained operation of fractal flow field with better water management.
Fractal cathode flow-fields, inspired by the flow mechanism of air inside lungs, can provide homogeneous, scalable and uniform distribution of reactants to polymer electrolyte fuel cell (PEFC) electrodes. However, the complex 3D flow-fields demonstrated previously face manufacturing challenges, such as requiring selective laser sintering, an additive manufacturing method that is expensive to scale up. Here, a lung-inspired cathode flow-field is introduced and fabricated using low-cost, lightweight printed circuit boards (PCB). The uniformity and alignment between individual PCB layers producing the fractal hierarchy of flow channels have been characterised using X-ray computed tomography (X-ray CT). The performance of the fractal flow-field exceeds that of conventional single-serpentine flow-fields and is particularly beneficial when operating on air with a low relative humidity. The lung-inspired design is shown to lead to a more stable operation than the single-serpentine design, as a result of uniform distribution of reactants.
•Design, development and testing of two different configurations of fractal PEMFCs.•Evaluation of the hydration state of fractal PEMFCs via acoustic emission method.•Performance diagnosis of fractal ...PEMFCs using acoustic emission analysis.•Correlation of acoustic emission analysis with conventional electrochemical studies.
Techniques for evaluating water management are critical to diagnose the performance of polymer electrolyte membrane fuel cells (PEMFCs). Acoustic emission as a function of polarisation (AEfP) has been recently introduced as a non-invasive, non-destructive method to analyse the water generation and removal inside a PEMFC during polarisation. AEfP was shown to provide unique insight into water management within a conventional PEMFC and correlating it to cell performance. Here, AEfP is used to characterise the performance of fractal PEMFCs by evaluating the hydration conditions inside them. This is achieved by probing the water dynamics inside two different fractal flow-field based PEMFCs, namely 1-way and 2-way fractal PEMFCs, and measuring the corresponding acoustic activity generated from them. AEfP is performed on the fractal PEMFCs under relatively humid (70% RH) and fully humidified (100% RH) reactant relative humidity (RH) conditions. Flooding in the 2-way fractal PEMFC, as opposed to the 1-way fractal PEMFC, is demonstrated under different operating conditions by the relatively higher acoustic activity it generates. Corroborating evidence of flooding in the 2-way fractal flow-field under different conditions is provided by its polarisation curves, impedance tests and galvanostatic (current hold) measurements.
An efficient approach to improve the catalytic activity of titanosilicates is introduced. The Doehlert matrix (DM) statistical model was utilized to probe the synthetic parameters of mesoporous ...titanosilicate microspheres (MTSM), in order to increase their catalytic activity with a minimal number of experiments. Synthesis optimization was carried out by varying two parameters simultaneously: homogenizing temperature and surfactant weight. Thirteen different MTSM samples were synthesized in two sequential ‘matrices’ according to Doehlert conditions and were used to catalyse the epoxidation of cyclohexene with
tert
-butyl hydroperoxide. The samples (and the corresponding synthesis conditions) with superior catalytic activity in terms of product yield and selectivity were identified. In addition, this approach revealed the limiting values of each synthesis parameter, beyond which the material becomes catalytically ineffective. This study demonstrates that the DM approach can be broadly used as a powerful and time-efficient tool for investigating the optimal synthesis conditions of heterogeneous catalysts.
•Simulations of a lung-inspired polymer electrolyte membrane fuel cell are presented.•The optimal number of generations corresponds to transition from flow to diffusion.•The effect of GDL thickness ...on the lung-inspired PEMFC performance is investigated.•The potential for 80% increase in PEMFC volumetric power density is demonstrated.
A finite-element model of a polymer electrolyte membrane fuel cell (PEMFC) with fractal branching, lung-inspired flow-field is presented. The effect of the number of branching generations N on the thickness of the gas diffusion layer (GDL) and fuel cell performance is determined. Introduction of a fractal flow-field to homogenize reactant concentration at the flow-field | GDL interface allows for the use of thinner GDLs. The model is coupled with an optimized cathode catalyst layer microstructure with respect to platinum utilization and power density, revealing that the 2020 DoE target of ~8 kW/gPt is met at N = 4 generations, and a platinum utilization of ~36 kW/gPt is achieved at N = 6 generations. In terms of the overall fuel cell stack architecture, our results indicate that either the platinum loading or the number of cells in the stack can be reduced by ~75%, the latter option of which, when combined with a 100 µm GDL, can lead to >80% increase in the volumetric power density of the fuel cell stack.
Micro-tomography (CT) can be successfully employed to characterize ex situ the structural changes occurring in graphite felt electrodes during vanadium redox flow battery (VRFB) operation. Coupled ...high resolution X-ray and electron microscopy in conjunction with XPS are used to elucidate the microstructural and chemical changes to the high voltage RFB carbon electrode. The results reveal the onset of corrosion of the carbon felt structure relatively early in the VRFB life-cycle, extended operation is expected to result in extensive microstructural evolution effects.
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•High resolution X-ray CT is used to characterize the microstructure of RFB felts.•3D microstructural evolution effects are presented revealing significant degradation.•Corrosion of the RFB felt structure starts relatively early in the VRFB life-cycle.•RFB felt corrosion is clarified by SEM, XPS and electrochemical characterization.
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