A one-dimensional model of air-cooled proton exchange membrane fuel cell stack integrating fan arrangement and operational characteristics

Air-cooled proton exchange membrane fuel cell stack’s performance can be greatly affected by the arrangement and operational characteristics of the fans that generate the air flow. However, the influence mechanisms are complex and poorly understood. In this study, a one-dimensional analytical model specifically for air-cooled stacks integrating important fan features is developed to quickly (e.g. within 5 min for a 100-cell stack) and accurately predict the water and thermal states inside stacks and stack performance under various fan arrangements and operational characteristics. The model accuracy was validated against the experimental results of a 95-cell air-cooled stack, including the stack polarization curves, temperature distribution and air flow rates at different fan’s duty cycles. The model results showed that for high air flow resistance stacks, the air flow rate and maximum net power for fans arrangement in series are higher than those in parallel by about 10% and 0.5%, respectively. Moreover, integrating a single large fan can be better than two small fans as the former induces a higher air flow rate and static pressure. On the other hand, altering the air flow channel length or depth changes the air flow resistance in stacks, leading to a shift of the working point for a fixed fan at a certain duty cycle and greatly influencing stack performance. This one-dimensional air-cooled stack model can be a powerful tool to facilitate stack design and optimization.