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Modeling Porosity Distribution Strategies in PEM Water Electrolyzers: A Comparative Analytical and Numerical Study

Author

Listed:
  • Ali Bayat

    (School of Mechanical and Mechatronic Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia)

  • Prodip K. Das

    (School of Engineering, The University of Edinburgh, Edinburgh EH9 3FB, UK)

  • Suvash C. Saha

    (School of Mechanical and Mechatronic Engineering, University of Technology Sydney, Sydney, NSW 2007, Australia)

Abstract

Proton exchange membrane water electrolyzers (PEMWEs) are a promising technology for green hydrogen production. However, the adoption of PEMWE-based hydrogen production systems remains limited due to several challenges, including high material costs, limited performance and durability, and difficulties in scaling the technology. Computational modeling serves as a powerful tool to address these challenges by optimizing system design, improving material performance, and reducing overall costs, thereby accelerating the commercial rollout of PEMWE technology. Despite this, conventional models often oversimplify key components, such as porous transport and catalyst layers, by assuming constant porosity and neglecting the spatial heterogeneity found in real electrodes. This simplification can significantly impact the accuracy of performance predictions and the overall efficiency of electrolyzers. This study develops a mathematical framework for modeling variable porosity distributions—including constant, linearly graded, and stepwise profiles—and derives analytical expressions for permeability, effective diffusivity, and electrical conductivity. These functions are integrated into a three-dimensional multi-domain COMSOL simulation to assess their impact on electrochemical performance and transport behavior. The results reveal that although porosity variations have minimal effect on polarization at low voltages, they significantly influence internal pressure, species distribution, and gas evacuation at higher loads. A notable finding is that reversing stepwise porosity—placing high porosity near the membrane rather than the channel—can alleviate oxygen accumulation and improve current density. A multi-factor comparison highlights this reversed configuration as the most favorable among the tested strategies. The proposed modeling approach effectively connects porous media theory and system-level electrochemical analysis, offering a flexible platform for the future design of porous electrodes in PEMWE and other energy conversion systems.

Suggested Citation

  • Ali Bayat & Prodip K. Das & Suvash C. Saha, 2025. "Modeling Porosity Distribution Strategies in PEM Water Electrolyzers: A Comparative Analytical and Numerical Study," Mathematics, MDPI, vol. 13(13), pages 1-36, June.
    • Handle: RePEc:gam:jmathe:v:13:y:2025:i:13:p:2077-:d:1685750
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    References listed on IDEAS

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    1. Huang, Yu-Xian & Cheng, Chin-Hsiang & Wang, Xiao-Dong & Jang, Jiin-Yuh, 2010. "Effects of porosity gradient in gas diffusion layers on performance of proton exchange membrane fuel cells," Energy, Elsevier, vol. 35(12), pages 4786-4794.
    2. Roshandel, R. & Farhanieh, B. & Saievar-Iranizad, E., 2005. "The effects of porosity distribution variation on PEM fuel cell performance," Renewable Energy, Elsevier, vol. 30(10), pages 1557-1572.
    3. Park, Jaeman & Oh, Hwanyeong & Lee, Yoo Il & Min, Kyoungdoug & Lee, Eunsook & Jyoung, Jy-Young, 2016. "Effect of the pore size variation in the substrate of the gas diffusion layer on water management and fuel cell performance," Applied Energy, Elsevier, vol. 171(C), pages 200-212.
    4. Das, Prodip K. & Li, Xianguo & Liu, Zhong-Sheng, 2010. "Effective transport coefficients in PEM fuel cell catalyst and gas diffusion layers: Beyond Bruggeman approximation," Applied Energy, Elsevier, vol. 87(9), pages 2785-2796, September.
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