Search Results (1,108)

To further enhance the economic performance of fuel cell vehicles (FCVs), this study develops a model-adaptive model predictive control (MPC) strategy. This strategy leverages the dynamic relationship between proton exchange membrane fuel cell (PEMFC) output characteristics and temperature to track its optimal operating temperature (OOT), addressing challenges of temperature control accuracy and high energy consumption in the PEMFC thermal management system (TMS). First, PEMFC and TMS models were developed and experimentally validated. Subsequently, the PEMFC power–temperature coupling curve was experimentally determined under multiple operating conditions to serve as the reference trajectory for TMS multi-objective optimization. For MPC controller design, the TMS model was linearized and discretized, yielding a predictive model adaptable to different load demands for stack temperature across the full operating range. A multi-constrained quadratic cost function was formulated, aiming to minimize the deviation of the PEMFC operating temperature from the OOT while accounting for TMS parasitic power consumption. Finally, simulations under Worldwide Harmonized Light Vehicles Test Cycle (WLTC) conditions evaluated the OOT tracking performance of both PID and MPC control strategies, as well as their impact on stack efficiency and TMS energy consumption at different ambient temperatures. The results indicate that, compared to PID control, MPC reduces temperature tracking error by 33%, decreases fan and pump speed fluctuations by over 24%, and lowers TMS energy consumption by 10%. These improvements enhance PEMFC operational stability and improve FCV energy efficiency. Full article

The geometric design of flow channels in bipolar plates is one of the critical features of proton exchange membrane fuel cells (PEMFCs), as it determines the power output of the fuel cell and has a significant impact on its performance and durability. The function of the bipolar plate is to guide the transfer of reactant gases to the gas diffusion layer and catalytic layer inside the PEMFC, while removing unreacted gases and gas–liquid byproducts. Therefore, the design of the bipolar plate flow channel is directly related to the water and thermal management of the PEMFC. In order to improve the comprehensive performance of PEMFCs and ensure their safe and stable operation, it is necessary to design the flow channels in bipolar plates rationally and effectively. This study addresses the limitations of existing bipolar plate flow channels by proposing a new coupling of serpentine and radial channels. The distribution of oxygen, water concentrations, and temperature inside the channel is simulated using the multi-physics simulation software COMSOL Multiphysics 6.0. The performance of this novel design is compared with conventional flow channels, with a particular focus on the pressure drop and current density to evaluate changes in the output performance of the PEMFC. The results show that the maximum current density of this novel design is increased by 67.36% and 10.43% compared to straight channel and single serpentine channels, respectively. The main contribution of this research is the innovative design of a new coupling of serpentine and radial channels in bipolar plates, which improves the overall performance of the PEMFC. This study provides theoretical support for the design of bipolar plate flow channels in PEMFCs and holds significant importance for the green development of energy. Full article

This study aims to determine the model parameters of proton exchange membrane fuel cells (PEMFC) by employing the Sea Horse Optimization (SHO) algorithm, a novel metaheuristic approach inspired by natural behaviors. Although conventional algorithms in the literature have achieved considerable success in parametric modeling accuracy, many of them suffer from inherent drawbacks, such as premature convergence and entrapment in local minima. The SHO algorithm, with its adaptive and dynamic nature, is designed to overcome these limitations. To further evaluate its performance, a detailed parametric sensitivity analysis is conducted on SHO-specific control parameters. In this work, experimental polarization data from a Ballard Mark V PEMFC is used as a reference to estimate the equivalent circuit model parameters ${ϵ}_1$, ${ϵ}_2$, ${ϵ}_3$, ${ϵ}_4$, $\beta$, $\lambda$, $R_c$. The SHO algorithm achieved a mean absolute error (MAE) of 0.001079 and a coefficient of determination (R²) of 0.999791, with a model-to-experiment fit ratio of 99.92%. Compared to similar studies reported in the literature, the results indicate that the SHO algorithm offers competitive performance. Moreover, the average convergence time is recorded as 1.74 s for 5000 iteration, highlighting the algorithm’s rapid convergence and low computational cost. Overall, the SHO algorithm is demonstrated to be an efficient, robust, and promising alternative to conventional methods for parameter identification in PEMFC modeling. Full article

In this study, the sensitivity of operating parameters such as the hydrogen and air excess coefficient, cathode inlet pressure, intake relative humidity, and coolant inlet temperature and their effects on the performance of single proton exchange membrane fuel cells (PEMFCs) are experimentally assessed. The results revealed that the fuel cell node voltage increases as the hydrogen and air excess coefficient increases, and the impact of the hydrogen and air excess coefficient on the fuel cell node voltage gradually increases as the current density increases. However, a higher hydrogen and air excess coefficient is not always better. The node voltage increases as the intake pressure increases. However, it is not that a higher intake pressure is always better, but rather that there is an optimal intake pressure value to achieve the best overall performance of the fuel cell. The node voltage increases as the coolant inlet temperature increases at most fuel cell current densities. However, the optimum fuel cell operating inlet temperature is not necessarily higher, as the coolant inlet temperature may have a strong coupling relationship with other operating conditions that will also affect the fuel cell performance. The fuel cell operating inlet temperature may have a strong coupling relationship with the intake relative humidity, and both of these parameters must be well-matched to achieve better fuel cell performance. Full article

This study systematically investigated the physicochemical properties and proton exchange membrane fuel cell (PEMFC) performance of perfluorosulfonic acid (PFSA) membranes with different thicknesses, which were prepared based on the resins produced by Dongyue (China) in comparison with commercial Nafion membranes. It was found that the water uptake of Dongyue membranes is significantly higher than that of Nafion, showing a significant upward trend with the thickness increase. The ion exchange capacity (IEC) of these membranes is ca. 1 mmol·g⁻¹. Moreover, the tensile strength of the Dongyue membrane was positively correlated with the thickness and was significantly higher than that of recast Nafion. Under 80 °C, all Dongyue membranes with various thicknesses (15~45 μm) exhibited PEMFC single-cell performance superior to that of Nafion. The maximum power density is observed with a thickness of 25 μm, reaching 851.76 mW·cm⁻², which is higher than that of Nafion (635.99 mW·cm⁻²). However, the oxidative stability of the prepared Dongyue PFSA series membranes exhibits a slight deficit compared to commercial Nafion membranes. Subsequently, the modification and optimization of preparation processes can be employed to improve the mechanical and chemical stability of Dongyue PFSA membranes. Full article

Approximately 20% of emissions from air travel are attributed to the auxiliary power units (APUs) carried in commercial aircraft. This paper proposes to reduce greenhouse gas emissions in international air transport by adopting proton-exchange membrane (PEM) fuel cells to replace APUs in commercial aircraft: we consider the design of three compressed hydrogen storage vessels made of 304 stainless steel, 6061-T6 aluminium, and Grade 5 (Ti-6Al-4V) titanium and capable of delivering 440 kW—enough for a PEM fuel cell for a Boeing 777. Complete structural analyses for pressures from 35 MPa to 70 MPa and wall thicknesses of 25, 50, 100, and 150 mm are used to determine the optimal material for aviation applications. Key factors such as deformation, safety factors, and Von Mises equivalent stress are evaluated to ensure structural integrity under a range of operating conditions. In addition, CO₂ emissions from a conventional 440 kW gas turbine APU and an equivalent PEM fuel cell are compared. This study provides insights into optimal material selection for compressed hydrogen storage vessels, emphasising safety, reliability, cost, and weight reduction. Ultimately, this research aims to facilitate the adoption of fuel cell technology in aviation, contributing to greenhouse emissions reduction and hence sustainable air transport. Full article

Proton Exchange Membrane Fuel Cells (PEMFCs) are seen as an alternative for heavy-duty transportation electrification. Powered by a green hydrogen source, they can provide high efficiency and low carbon emissions compared to traditional fuels. However, to be competitive, these systems require high reliability when operated in real-life conditions, as well as safe and efficient operating management. In order to achieve these goals, the X-in-the-loop (also called model-based design) methodology is well suited. It has been largely adopted for PEMFC system development and optimisation, as they are complex multi-component systems. In this paper, a systematic analysis of the scientific literature is conducted to review the methodology implementation for the design and improvement of the PEMFC systems. It exposes a precise definition of each development step in the methodology. The analysis shows that it can be employed in different ways, depending on the subsystems considered and the objectives sought. Finally, gaps in the literature and technical challenges for fuel cell systems that should be addressed are identified. Full article

This study focuses on addressing the issues of water flooding and mass transfer limitations in proton exchange membrane fuel cells (PEMFCs) under high current density conditions. A multi-scale gradient pore gas diffusion layer (GDL) is designed to enhance fuel cell performance. The pore structure is precisely controlled using a self-assembled mold, resulting in the fabrication of a GDL with a gradient distribution of pore diameters ranging from 80 to 170 μm. Experimental results indicate that, with the optimized gradient pore GDL, the peak power density of the fuel cell reaches 1.18 W·cm−², representing a 20% improvement compared to the traditional structure. A mechanism analysis reveals that this structure establishes a concentrated water transport pathway through channels while enabling gas diffusion and transport driven by concentration gradients, thereby achieving the collaborative optimization of gas–liquid transport. This approach offers a novel solution for managing water in PEMFCs operating under high current density conditions, and holds significant implications for advancing the commercialization of PEMFC technology. Full article

This study investigates the chemical stability and leaching behavior of two environmentally sustainable EPDM elastomers filled with circular carbon black (CCB) and recycled carbon black (RCB) when exposed to acidic, fuel cell-like environments. Accelerated aging tests were conducted in sulfuric acid solutions of varying concentrations (1 M, 0.1 M, and 0.001 M) at 90 °C for 1000 h to simulate long-term degradation in proton exchange membrane fuel cell (PEMFC) sealing applications. Complementary hot water extraction tests (HWET) were performed at 80 °C for up to 168 h to evaluate ionic leaching via conductivity measurements. HPLC-DAD analysis was used to assess organic leachates, while surface changes were examined by SEM and thermal transitions by DSC. Results revealed lower leaching and improved surface preservation in the CCB-filled EPDM, which remained below the critical 5 µS/cm ionic conductivity threshold for longer durations than its RCB counterpart. HPLC results showed filler-dependent trends in organic compound release, with CCB EPDM exhibiting higher leaching only under strong acid exposure. SEM confirmed greater surface damage and porosity in RCB EPDM. Overall, both materials demonstrated adequate chemical resistance, but the CCB formulation exhibited superior long-term stability, supporting its use in sustainable PEMFC sealing applications. Full article

This study systematically compares the environmental and economic performance of three wastewater treatment systems: constructed wetlands (CWs), microbial fuel cells (MFCs), and their integration (CW–MFC). Lab-scale units of each system were constructed using a multi-media matrix (gravel, zeolite, and granular activated carbon), composite native wetland species (Juncus effusus, Iris sp., and Typha angustifolia), carbon-based electrodes (graphite), and standard inoculum for CW and CW–MFC. The MFC system employed carbon-based electrodes and proton-exchange membrane. The experimental design included a parallel operation of all systems treating domestic wastewater under identical hydraulic and organic loading rates. Environmental impacts were quantified across construction and operational phases using life cycle assessment (LCA) with GaBi software 9.2, employing TRACI 2021 and ReCiPe 2016 methods, while techno-economic analysis (TEA) evaluated capital and operational costs. The key results indicate that CW demonstrates the lowest global warming potential (142.26 kg CO₂-eq) due to its reliance on natural biological processes. The integrated CW–MFC system achieved enhanced pollutant removal (82.8%, 87.13%, 78.13%, and 90.3% for COD, NO₃, TN, and TP) and bioenergy generation of 2.68 kWh, balancing environmental benefits with superior treatment efficiency. In contrast, the stand-alone MFC shows higher environmental burdens, primarily due to energy-intensive material requirements and fabrication processes. TEA results highlight CW as the most cost-effective solution (USD 627/m³), with CW–MFC emerging as a competitive alternative when considering environmental benefits and operational efficiencies (USD 718/m³). This study highlights the potential of hybrid systems, such as CW–MFC, to advance sustainable wastewater treatment technologies by minimizing environmental impacts and enhancing resource recovery, supporting their broader adoption in future water management strategies. Future research should focus on optimizing materials and energy use to improve scalability and feasibility. Full article

Commercial proton exchange membrane fuel cell (PEMFC)-based micro-combined heat and power (micro-CHP) systems are operated by rule-based energy management systems (EMSs). These EMSs are easy to implement but do not perform an explicit economic optimization. On the other hand, an optimal EMS can explicitly incorporate an economic optimization, but its implementation is more complex and may not be viable in practice. In a previous contribution, it was shown that current rule-based EMSs do not fully exploit the economic potential of micro-CHP systems due to their inability to adapt to changing scenarios. This study investigates the economic performance and behavior of an optimal EMS in 46 scenarios within the European framework. This EMS is designed using a model predictive control approach, and it is formulated as a mixed integer linear programming problem. The results reveal that there are only four basic optimal operating patterns, which vary depending on the scenario. This finding enables the design of an EMS that is computationally simpler than the optimal EMS but capable of emulating it and, therefore, is able to adapt effectively to changing scenarios. This new EMS would improve the cost-effectiveness of PEMFC-based micro-CHP systems, reducing their payback period and facilitating their mass market uptake. Full article

Nafion, while a benchmark proton exchange membrane (PEM) for fuel cells, suffers from significant performance degradation at elevated temperatures and low humidity due to dehydration and diminished mechanical stability. To address these limitations, this study investigated the development and characterization of Nafion nanocomposite membranes incorporating sulfonated silica layered materials (sSLMs). The inherent lamellar structure, high surface area, and abundant sulfonic acid functionalities of sSLMs were leveraged to synergistically enhance membrane properties. Our results demonstrate that sSLM incorporation significantly improved ion exchange capacity, water uptake, and dimensional stability, leading to superior water retention and self-diffusion at higher temperatures. Critically, the nanocomposite membranes exhibited remarkably enhanced proton conductivity, particularly under demanding conditions of 120 C and low relative humidity (i.e., 20% RH), where filler-free Nafion largely ceases to conduct. Single H₂/O₂ fuel cell tests confirmed these enhancements, with the optimal sSLM-Nafion nanocomposite membrane (N-sSLM₅) achieving a two-fold power density improvement over pristine Nafion at 120 C and 20% RH (340 mW cm⁻² vs. 117 mW cm⁻² for Nafion). These findings underscore the immense potential of sSLM as a functional filler for fabricating robust and high-performance PEMs, paving the way for the next generation of fuel cells capable of operating efficiently under more challenging environmental conditions. Full article

Proton exchange membranes are widely used in environmentally friendly applications such as fuel cells and electrochemical hydrogen compression. In these applications, an ideal proton exchange membrane should have both excellent proton conductivity and mechanical strength. Polymer proton exchange membranes, such as sulfonated poly(ether ether ketone) (SPEEK) membranes with high ion exchange capacity, can lead to higher proton conductivity. However, the ionic groups may reduce the interaction between polymer segments, lower the membrane’s mechanical strength, and even cause it to dissolve in water as the temperature exceeds 55 °C. The porous graphitic C₃N₄ (Pg–C₃N₄) nanosheet is an important two–dimensional polymeric carbon–based material and has a high content of –NH₂ and –NH– groups, which can interact with the sulfonic acid groups in the sulfonated SPEEK polymer, form a more continuous proton transfer channel, and inhibit the movement of the polymer segment, leading to higher proton conductivity and mechanical strength. In this study, we found that a SPEEK membrane containing 3% Pg–C₃N₄ nanosheets achieves the optimized proton conductivity of 138 mS/cm (80 °C and 100% RH) and a mechanical strength of 74.1 MPa, improving both proton conductivity and mechanical strength by over 50% compared to the SPEEK membrane. Full article

This study investigates the structure of a metal hydride (MH) cartridge as a hydrogen storage tank for small-scale fuel cells (FCs). This cartridge is designed to be stacked and used in layers, allowing flexible capacity adjustment according to demand. MH enables compact and safe hydrogen storage for small-scale fuel cell (FC) applications due to its high energy density and low-pressure operation. However, because hydrogen desorption from MH is an endothermic reaction, an external heat supply is required for stable performance. To enhance both the heat transfer efficiency and cartridge usability, we propose a heat supply method that utilizes waste heat from an air-cooled proton-exchange membrane fuel cell (PEMFC). The proposed cartridge incorporates four cylindrical MH tanks that require uniform heat transfer. Therefore, we proposed the tank arrangements within the cartridge to minimize the non-uniformity of heat transfer distribution on the surface. The flow of exhaust air from the PEMFC into the cartridge was analyzed using computational fluid dynamics (CFD) simulations. In addition, an empirical correlation for the Nusselt number was developed to estimate the heat transfer coefficient. As a result, it was concluded that the heat utilization rate of the exhaust heat flowing into the cartridge was 13.2%. Full article

Enhancing energy efficiency is essential for proton exchange membrane fuel cells (PEMFCs) operating in a dead-ended anode (DEA) mode. This study proposes the integration of a buffer tank, positioned between the mass flow meter and the fuel cell, to reduce hydrogen loss during purge events. The buffer tank stores hydrogen when the purge valve is closed and releases it when the valve opens, thereby stabilizing anode pressure, minimizing hydrogen waste, and improving overall system efficiency. The effectiveness of the buffer tank is experimentally evaluated under varying load currents, hydrogen supply pressures, purge intervals, and purge durations. The objective is to determine the optimal purge duration that maximizes energy efficiency, both with and without the buffer tank. The results show that the buffer tank consistently improves energy efficiency. Under optimal conditions (0.1 bar, 8 A, 0.1 s purge duration, and 20 s purge interval), efficiency increases by 3.3%. Under non-optimal conditions (0.1 bar, 1 A, 0.1 s purge duration, and 20 s interval), the improvement reaches 71.9%, demonstrating the buffer tank’s effectiveness in stabilizing performance across a wide range of operating conditions. Full article