Optimizing proton exchange membrane electrolyzer cells: A comprehensive parametric analysis of flow, electrochemical, and geometrical factors

This study presents a comprehensive parametric study to optimise the performance of Proton Exchange Membrane Electrolyzer Cells (PEMECs). By systematically analyzing the effects of flow, electrochemical, and geometrical parameters, key factors that influence PEMEC efficiency and hydrogen production rates are identified. Utilizing single-phase numerical modeling in a three-dimensional approach with COMSOL Multiphysics, the study simulates the water electrolysis process, considering both free and porous media fluid flow along with detailed electrochemical reactions. The numerical simulation thoroughly explains the interplay between fluid mechanics and electrochemical phenomena within the PEMEC. The results show significant concordance with existing experimental data and predictions made by Eulerian two-phase modeling for the fluid flow field. Key findings include the analysis of polarization plots, the impact of operating temperature, membrane thickness, and conductivity on these plots, and species molar distribution. Additionally, a local sensitivity analysis highlights the relative importance of each parameter. Our findings provide valuable insights to enhance PEMEC design and operational strategies, particularly for applications in renewable energy storage and industrial hydrogen production. The identified optimizations, such as thinner membranes and higher conductivity materials, can contribute to higher efficiency, reduced energy consumption, and lower operational costs, making PEMEC technology more viable for large-scale deployment. By leveraging advanced numerical simulation techniques, this study offers a robust framework for optimizing PEMEC performance and supports the development of more efficient and sustainable hydrogen production technologies.