Liquid Cooling Flow Field Design and Thermal Analysis of Proton Exchange Membrane Fuel Cells for Space Applications

Proton exchange membrane (PEM) fuel cells are a promising technology with many features, including having a high energy density, efficiency, lightness, and producing energy directly instead of storing it. PEM fuel cells are currently used in mobile vehicles, military applications, portable systems, stationary systems, and air-independent propulsion systems for sea and space. Elimination of the cooling problems associated with PEM fuel cells in space applications is of great importance to produce more efficient systems. With this motivation in mind, this study examined PEM fuel cell elements and cooling flow channel design for space applications. The effect of the designed flow channel on the PEM fuel cell temperature distribution was investigated. Five different PEM fuel cell cooling channels were designed and modeled computationally, and the most suitable cooling channel design was selected based on the thermal analysis. While modeling the PEM fuel cell, space environment operating conditions, pure reactant supply (oxygen and hydrogen), electrochemical reaction in the membrane, physical properties of liquid coolant, physical properties of fuel cell elements, and heat transfer in the fuel cell were considered. The temperature distribution obtained as a result of the thermal analysis was examined, and it was seen that the PEM fuel cell cooling channel design was successful in maintaining the operating temperature of the PEM fuel cell. According to the data obtained, the cooler inlet temperature is approximately 40°C and the cooler outlet temperature is approximately 75°C in flat serpentine design. These values were obtained as a result of the analysis made with a mixture of 50% ethylene glycol and 50% water selected as the liquid coolant. As a result, a fuel cell can be formed by producing a fit bipolar plate with the analyzed PEM fuel cell cooling flow channel design, and current density and homogeneity can be determined by applying single-cell performance tests to the fuel cell.