Design optimization of 3D printed flow path plates in high-performance bioethanol fuel cells
ISSN: 1355-2546
Article publication date: 14 June 2023
Issue publication date: 18 October 2023
Abstract
Purpose
Effective performance of a direct ethanol fuel cell (FC) stack depends on the satisfactory operation of its individual cells where it is always challenging to manage the temperature gradient, water flow and distribution of reactants. In that, the design of the bipolar fuel flow path plate plays a vital role in achieving the aforementioned parameters. Further, the bipolar plates contribute 80% of the weight and 30%–40% of its total cost. Aim of this study is to enhance the efficiency of fuel to energy conversion and to minimize the overall cost of production.
Design/methodology/approach
The authors have specifically designed, simulated and fabricated a standard 2.5 × 2.5 cm2 active area proton exchange membrane (PEM) FC flow path plate to study the performance by varying the flow fields in a single ladder, double ladder and interdigitated and varying channel geometries, namely, half curve, triangle and rectangle.
Findings
Using the 3D PEMFC model and visualizing the physical and electrochemical processes occurring during the operation of the FCs resulted in a better-performing flow path plate design. It is fabricated by using additive manufacturing technology. In addition, the assembly of the full cell with the designed flow path plate shows about an 11.44% reduction in total weight, which has a significant bearing on its total cost as well as specific energy density in the stack cell.
Originality/value
Simultaneous optimization of multiple flow path parameters being carried out for better performance is the hallmark of this study which resulted in enhanced energy density and reduced cost of device production.
Keywords
Acknowledgements
M/s Xenobiomic Research and Technological Development Pvt Ltd, Puducherry (India), is acknowledged for extending facilities of Additive Manufacturing Technology to fabricate flow plates. Mr Prabhu Deva M. and Mr K Vignesh for their help with 3D printer assembly and troubleshooting, Prof P. Elumalai for fruitful discussion on the fuel cell, Ms Asifa Awan and Mr Conor Twohig for valuable support with Ansys CFD simulation of PEMFC are thankfully acknowledged.
Funding information: MTS acknowledges University Grant Commission, India, for research fellowship (JRF/SRF-NFPwD-2018–20). Research work was supported by internal grant of Pondicherry University.
Declarations: Ethics approval and consent to participate: Not applicable.
Consent for publication: Authors give necessary consent for publication in the Journal.
Conflict of interest: The authors declare no competing interests.
Citation
T.S., M. and B.M., J.A. (2023), "Design optimization of 3D printed flow path plates in high-performance bioethanol fuel cells", Rapid Prototyping Journal, Vol. 29 No. 9, pp. 1829-1842. https://doi.org/10.1108/RPJ-08-2022-0263
Publisher
:Emerald Publishing Limited
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