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The Impact of Flow Rate Variations on the Power Performance and Efficiency of Proton Exchange Membrane Fuel Cells: A Focus on Anode Flooding Caused by Crossover Effect and Concentration Loss

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  • Byung-Yeon Seo

    (Graduate School of Mechanical Engineering, Kongju National University, 1223-24 Cheonan-daero, Seobuk-gu, Cheonan-si 31080, Chungcheongnam-do, Republic of Korea)

  • Hyun Kyu Suh

    (Division of Mechanical and Automotive Engineering, Kongju National University, 1223-24 Cheonan-daero, Seobuk-gu, Cheonan-si 31080, Chungcheongnam-do, Republic of Korea)

Abstract

This study investigates the effects of anode and cathode inlet flow rates (ṁ) on the power performance of bipolar plates in a polymer electrolyte membrane fuel cell (PEMFC). The primary objective is to derive optimal flow rate conditions by comparatively analyzing concentration loss in the I−V curve and crossover phenomena at the anode, thereby establishing flow rates that prevent reactant depletion and water flooding. A single-cell computational model was constructed by assembling a commercial bipolar plate with a gas diffusion layer (GDL), catalyst layer (CL), and proton exchange membrane (PEM). The model simulates current density generated by electrochemical oxidation-reduction reactions. Hydrogen and oxygen were supplied at a 1:3 ratio under five proportional flow rate conditions: hydrogen ( m ˙ H 2 = 0.76–3.77 LPM) and oxygen ( m ˙ O 2 = 2.39–11.94 LPM). The Butler–Volmer equation was employed to model voltage drop due to overpotential, while numerical simulations incorporated contact resistivity, surface permeability, and porous media properties. Simulation results demonstrated a 24.40% increase in current density when raising m ˙ H 2 from 2.26 to 3.02 LPM and m ˙ O 2 from 7.17 to 9.56 LPM. Further increases to m ˙ H 2 = 3.77 LPM and m ˙ O 2 = 11.94 LPM yielded a 10.20% improvement, indicating that performance enhancements diminish beyond a critical threshold. Conversely, lower flow rates ( m ˙ H 2 = 0.76 and 1.5 LPM, m ˙ O 2 = 2.39 and 4.67 LPM) induced hydrogen-depleted regions, triggering crossover phenomena that exacerbated anode contamination and localized flooding.

Suggested Citation

  • Byung-Yeon Seo & Hyun Kyu Suh, 2025. "The Impact of Flow Rate Variations on the Power Performance and Efficiency of Proton Exchange Membrane Fuel Cells: A Focus on Anode Flooding Caused by Crossover Effect and Concentration Loss," Energies, MDPI, vol. 18(12), pages 1-27, June.
  • Handle: RePEc:gam:jeners:v:18:y:2025:i:12:p:3084-:d:1676766
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    References listed on IDEAS

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    1. Chen, Huicui & Zhang, Ruirui & Xia, Zhifeng & Weng, Qianyao & Zhang, Tong & Pei, Pucheng, 2023. "Experimental investigation on PEM fuel cell flooding mitigation under heavy loading condition," Applied Energy, Elsevier, vol. 349(C).
    2. Ijaodola, O.S. & El- Hassan, Zaki & Ogungbemi, E. & Khatib, F.N. & Wilberforce, Tabbi & Thompson, James & Olabi, A.G., 2019. "Energy efficiency improvements by investigating the water flooding management on proton exchange membrane fuel cell (PEMFC)," Energy, Elsevier, vol. 179(C), pages 246-267.
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    4. Shusheng Xiong & Zhankuan Wu & Wei Li & Daize Li & Teng Zhang & Yu Lan & Xiaoxuan Zhang & Shuyan Ye & Shuhao Peng & Zeyu Han & Jiarui Zhu & Qiujie Song & Zhixiao Jiao & Xiaofeng Wu & Heqing Huang, 2021. "Improvement of Temperature and Humidity Control of Proton Exchange Membrane Fuel Cells," Sustainability, MDPI, vol. 13(19), pages 1-14, September.
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