Effects of cell design improvement on an automotive PEMFC system

The need for a clean mobility launched multiple research directions in the powertrain field. While initially the battery electric vehicle (BEV) seemed the universal solution, the succession of pandemic emergencies and the resulting energetic crisis have defined a new scenario based on the multi-energy approach. One of the most promising technologies is the use of hydrogen to be used in a fuel cell to generate electricity. This type of electric vehicles guarantees a faster refueling time and a longer driving range than the battery electric vehicle, becoming an enabling solution for long-haul applications. In this study a combined 3D-CFD and 0D system analysis of an automotive Proton Exchange Membrane Fuel Cell (PEMFC) was carried out. In the first part, starting from a conventional parallel channel flow field configuration, the use of an optimization tool allowed to identify the optimal configuration in terms of width of feed channels and the thickness of Gas Diffusion Layers of both cathode and anode side to maximize the current density output. Besides, the 3D-CFD fuel cell analysis was carried out using an in-house developed model for the simulation of water phase-transition and membrane transport mechanisms. In the second part, the optimized cell geometry was compared to the conventional one at a system level, using a MATLAB/Simulink model of parallel hybrid FC/battery Balance of Plant (BoP) with the capability of investigating the degradation behaviour of the membrane. The study shows the benefits of combined 3D-0D modelling for the advancement of fuel cells development for mobile applications.