Session: 09-10-02: Hydrogen Production, Storage, and Integrated Hydrogen Energy Systems II

Paper Number: 168478

Numerical Simulation and Cfd Analysis of Multi-Stack Proton Exchange Membrane Fuel Cells Comparative Performance Study Under Various Assembly Pressures 

Abstract:
This study provides an in-depth evaluation of the thermal and electrochemical performance of proton exchange membrane fuel cell (PEMFC) stacks under varying assembly pressure conditions, emphasizing the transition from single-cell to multi-stack configurations. While previous research has primarily focused on single-cell models, this work leverages advanced numerical simulation techniques to analyze the complex interactions present in two-stack and three-stack PEMFC systems with varying channel geometries.

Using ANSYS Fluent, a coupled finite element-computational fluid dynamics (FE-CFD) approach is employed to model the impact of clamping pressure on the gas diffusion layer (GDL), considering key factors such as deformation, porosity reduction, and channel intrusion across different stack configurations. This non-isothermal modeling framework integrates mass transport dynamics, thermal management, and electrochemical reactions, offering a holistic perspective on the operational behavior of multi-stack systems.

The study’s findings highlight significant variations in cell performance metrics, including efficiency, temperature profiles, and current density distribution, as the stack count increases from two to three. These changes are strongly influenced by the spatial distribution of assembly pressure, which directly affects the mechanical deformation of the GDL and the homogeneity of pressure within the stacks. Notably, center cells in three-stack arrangements exhibit distinct deformation and performance characteristics compared to edge cells, underscoring the critical role of stack placement and pressure uniformity in multi-stack designs.

Additionally, the research quantifies the trade-offs involved in assembly pressure optimization, revealing its dual impact on enhancing power density and ensuring long-term operational stability. Excessive pressure can lead to irreversible damage and reduced GDL porosity, while insufficient pressure compromises electrical conductivity and system performance. These findings provide actionable insights for the precise calibration of assembly pressure in multi-stack PEMFC systems.

Beyond numerical modeling, this work addresses practical challenges in PEMFC design, including the balance between mechanical robustness and electrochemical efficiency. The integration of thermal and electrochemical parameters within the simulation framework bridges the gap between theoretical models and real-world applications, enabling the development of PEMFC systems with improved performance and durability.

By presenting a comparative analysis of two-stack and three-stack configurations, this research contributes to the understanding of multi-stack PEMFC behavior under realistic operating conditions. The insights gained have significant implications for the design and optimization of high-efficiency, scalable PEMFC systems tailored for industrial, automotive, and renewable energy applications. This study serves as a valuable resource for advancing the next generation of fuel cell technologies with enhanced power density, operational stability, and system longevity.

Presenting Author: Umar Alqsair Prince Sattam bin Abdulaziz University

Presenting Author Biography: An associate professor and Chairman of Mechanical Engineering Department, College of Engineering, Prince Sattam bin Abdulaziz University

Authors:

Umar Alqsair Prince Sattam bin Abdulaziz University