Manifold geometry optimization and flow distribution analysis in commercial-scale proton exchange membrane fuel cell stacks

The manifold structure in high-power Proton Exchange Membrane Fuel Cell (PEMFC) stacks critically influences airflow distribution, thereby affecting stack performance, temperature uniformity, and longevity. Therefore, this paper explores how manifold geometry affects fluid distribution within the manifold of a fuel cell stack. In addition, a new step-shaped manifold structure is established to improve the manifold flow field structure and enhance the uniformity of gas flow distribution in each single cell. In our study, each cell within the stack is modeled as a porous medium. We examine how varying the height at different positions within the manifold impacts the uniformity of gas flow distribution, focusing on different length ratios and heights. Our results demonstrate that adjusting the manifold shape improves airflow uniformity, with length ratios having a more pronounced impact than height variations. Specifically, the mass flow coefficient of variation decreased by 22.62 % and 23.07 % for cases 9 and 12, respectively. Similarly, the velocity inhomogeneity coefficient in the inlet manifold decreased by 21.22 % and 21.34 % for cases 9 and 12, respectively. Additionally, pressure distribution in case 9 showed greater uniformity. Our findings indicate that a manifold shape with a length ratio of 2/3 and a height of 2.5 mm delivers optimal performance.