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<p>High-power fuel cell stacks frequently encounter uneven gas flow distribution, which stems from factors like along-path resistance, local energy losses, and structural design limitations. This maldistribution further induces disparities in reaction rates, current density, and temperature fields across cells, ultimately leading to inconsistent degradation, compromised overall performance, and shortened lifespan. To tackle this critical issue, we developed a multi-scale model that couples three-dimensional computational fluid dynamics (CFD) with a one-dimensional network model, enabling systematic investigation of gas distribution patterns and mass transfer characteristics within the stack. The simulation results reveal that compared to the <i>U</i>-type manifold, the <i>Z</i>-type manifold benefiting from its symmetrical flow path and stable pressure drop reduces the flow standard deviation by approximately 65%, significantly enhancing flow uniformity. Appropriately enlarging the anode manifold’s cross-sectional area diminishes the extreme flow difference by nearly 88%, while reducing the flow channel size further optimizes inter-cell flow variation by over 80%. However, scaling up the stack from 30 to 300 plates causes the cathode flow standard deviation to triple, highlighting that stack size expansion exacerbates gas distribution unevenness. Notably, through structural optimization—specifically by tuning the flow channel to an optimal width/depth of 0.7&#xa0;mm, the maximum power density difference between cells is reduced from 16.5% to 8.8%, and the voltage coefficient of variation (Cv) drops from 6.53 to 4.14, representing a 57.7% improvement in performance uniformity. These findings provide critical insights into structural design strategies for high-power fuel cell stacks, offering an effective reference for optimizing stack performance, enhancing durability, and facilitating the scalability of high-power fuel cell systems.</p>

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Study on gas flow distribution characteristics and evolution law of high power fuel cell stack based on composite model

  • 期刊论文

  • 发表日期：

    2025年10月9日

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  • Guangwei Zhang,
  • Lijia Xiao,
  • Jianbin Su,
  • Lei Shi

摘要

High-power fuel cell stacks frequently encounter uneven gas flow distribution, which stems from factors like along-path resistance, local energy losses, and structural design limitations. This maldistribution further induces disparities in reaction rates, current density, and temperature fields across cells, ultimately leading to inconsistent degradation, compromised overall performance, and shortened lifespan. To tackle this critical issue, we developed a multi-scale model that couples three-dimensional computational fluid dynamics (CFD) with a one-dimensional network model, enabling systematic investigation of gas distribution patterns and mass transfer characteristics within the stack. The simulation results reveal that compared to the U-type manifold, the Z-type manifold benefiting from its symmetrical flow path and stable pressure drop reduces the flow standard deviation by approximately 65%, significantly enhancing flow uniformity. Appropriately enlarging the anode manifold’s cross-sectional area diminishes the extreme flow difference by nearly 88%, while reducing the flow channel size further optimizes inter-cell flow variation by over 80%. However, scaling up the stack from 30 to 300 plates causes the cathode flow standard deviation to triple, highlighting that stack size expansion exacerbates gas distribution unevenness. Notably, through structural optimization—specifically by tuning the flow channel to an optimal width/depth of 0.7 mm, the maximum power density difference between cells is reduced from 16.5% to 8.8%, and the voltage coefficient of variation (Cv) drops from 6.53 to 4.14, representing a 57.7% improvement in performance uniformity. These findings provide critical insights into structural design strategies for high-power fuel cell stacks, offering an effective reference for optimizing stack performance, enhancing durability, and facilitating the scalability of high-power fuel cell systems.