Optimization of flow channel design and configuration in polymer electrolyte membrane fuel cell

Abstract Polymer Electrolyte Membrane Fuel Cells (PEMFCs) have emerged as a promising sustainable energy technology capable of efficiently converting hydrogen and oxygen into electricity. Their adoption plays a vital role in reducing carbon emissions and dependence on fossil fuels for transportation and stationary power generation. However, maintaining an optimal balance between thermal regulation and electrical performance remains a critical engineering challenge. Excessive temperature gradients can deteriorate membrane integrity, leading to reduced durability and overall system efficiency. This study aims to determine the optimal combination of flow channel number and configuration in Polymer Electrolyte Membrane Fuel Cells (PEMFCs) to achieve balanced thermal management and electrical performance. The research addresses the gap in systematically evaluating both parameters together for practical, high-efficiency applications. Three parallel flow field designs with 8, 11, and 15 channels were modeled under co-flow, counter-flow, and cross-flow configurations. Computational Fluid Dynamics (CFD) simulations were performed using Nafion as the electrolyte membrane and carbon as the gas diffusion layer. Temperature distribution and current density were analyzed to assess thermal uniformity and electrochemical output. The 15-channel cross-flow design achieved the most uniform temperature profile, with a minimal temperature difference of 0.048 %. The 8-channel counter-flow configuration generated the highest current density of 5582.33 A/m 2 but exhibited less uniform thermal distribution. The 11-channel cross-flow configuration provided the best balance, attaining a current density of 4103.92 A/m 2 while maintaining a uniform temperature contour. The 11-channel cross-flow configuration optimizes PEMFC performance by combining effective thermal management with strong electrical output and reducing the risk of hot spots. These findings offer a scalable design strategy for enhancing PEMFC durability and efficiency in transportation and stationary power applications.