Smart Energy and Sustainable Environment , ISSN 2668-957X
2026, Volume 29, Issue 1
Pages 15-32

https://doi.org/10.46390/j.smensuen.29126.464

NUMERICAL ANALYSIS OF AIR FLOW IN UNIPOLAR PLATE CHANNELS FOR PEM FUEL CELLS

Abstract

The paper presents a numerical analysis of air flow through flow channels in unipolar PEM fuel cell: serpentine, parallel, pins. Simulations were performed at flow rates of 100 ml/min and 300 ml/min with an operating temperature of 80°C to evaluate the models based on flow distribution, pressure drop and velocity magnitude. The results show that serpentine provides sufficient velocity for the gas transportation and water management, but it has a issue related to pressure drop, being the highest from all three models. Parallel model minimizes the pressure drop, but it has a non-uniform flow on the parallel channels. Even though there are low velocity regions in the pin model, it is a balanced solution between flow distribution, pressure drop and velocity magnitude. Using CFD numerical modelling helps in analyzing the flow through unipolar plates before manufacturing and testing, leading to cost reduction and design optimization.

References

Alam Rimon, S. T., Shajid, S. R., Mourshed, M., & Hasan Khan Tushar, M. S. (2025). Flow field configurations in PEMFCs: Design, Modeling, and performance insights. In Energy Conversion and Management: X (Vol. 28). Elsevier Ltd. https://doi.org/10.1016/j.ecmx.2025.101263

Atkins, P., de Paula, J. (2006). Atkins Physical Chemistry (8th ed.). Oxford University Press. Available: https://nowgonggirlscollege.co.in/attendence/classnotes/files/1621583343.pdf [Accessed: Jan. 26, 2026]

Busqué, R., Bossio, M., Brigido, A., & Lara, A. (2023). Effects of Different Channel Geometries of Metallic Bipolar Plates on Proton Exchange Membrane Fuel Cell Performance. Energies, 16(23). https://doi.org/10.3390/en16237702

Li, X., & Sabir, I. (2005). Review of bipolar plates in PEM fuel cells: Flow-field designs. International Journal of Hydrogen Energy, 30(4), 359–371. https://doi.org/10.1016/j.ijhydene.2004.09.019

Moh Nurkhamal, Rizkia, V., Vina Nanda Garjati, & Radhi Maladzi. (2025). Enhancing Proton Exchange Membrane Fuel Cell (PEMFC) Performance through Optimized Design of Parallel Channel Bipolar Plates. Recent in Engineering Science and Technology, 3(01), 42-57. https://doi.org/10.59511/riestech.v3i01.94

Singh, M., Singla, M. K., Safaraliev, M., Singh, K., Odinaev, I., & Abdel Menaem, A. (2024). Advancements and challenges of fuel cell integration in electric vehicles: A comprehensive analysis. International Journal of Hydrogen Energy, 88, 1386–1397. https://doi.org/10.1016/j.ijhydene.2024.09.212

Sauermoser, M., Kizilova, N., Pollet, B. G., & Kjelstrup, S. (2020). Flow Field Patterns for Proton Exchange Membrane Fuel Cells. In Frontiers in Energy Research (Vol. 8). Frontiers Media S.A. https://doi.org/10.3389/fenrg.2020.00013

Xiong, K., Wu, W., Wang, S., & Zhang, L. (2021). Modeling, design, materials and fabrication of bipolar plates for proton exchange membrane fuel cell: A review. Applied Energy, 301. https://doi.org/10.1016/j.apenergy.2021.117443

* * * NASA, „Reynolds Number,” NASA Glenn Research Center - Beginner's Guide to Aeronautics, 2021. [Online]. Available: https://www.grc.nasa.gov/www/k-12/airplane/reynolds.html [Accessed: Jan. 26, 2026]

* * * Thermopedia, „Hydraulic Diameter,” A-Z Guide to Thermodynamics, Heat and Mass Transfer, and Fluids Engineering, 2011. [Online]. Available: https://www.thermopedia.com/content/856/. DOI: 10.1615/AtoZ.h.hydraulic_diameter [Accessed: Jan. 26, 2026]

* * * Ansys Innovation Space, „Calculating Turbulence Intensity,”Topics in Turbulence Modeling
using Ansys Fluent, 2024. [Online]. Available: https://innovationspace.ansys.com/courses/courses/topics-in-turbulence-modeling-using-ansys-fluent/lessons/calculating-turbulent-intensity/ [Accessed: Jan. 26, 2026]

* * *ANSYS Innovation Space, „Fluid Properties: Lesson 2 - What is a Fluid?,” 2020. [Online]. Available: https://innovationspace.ansys.com/courses/wp-content/uploads/2020/06/What-is-a-Fluid-Lesson2-Fluid-Properties-Handouts.pdf [Accessed: Jan. 26, 2026]

* * * Engineering ToolBox, „Air Density, Specific Weight and Thermal Expansion Coefficient,” 2003. [Online]. Available: https://www.engineeringtoolbox.com/air-density-specific-weight-d_600.html [Accessed: Jan. 26, 2026]

* * * Engineering ToolBox, „Air Dynamic and Kinematic Viscosity,” 2003. [Online]. Available:   https://www.engineeringtoolbox.com/air-absolute-kinematic-viscosity-d_601.html [Accessed: Jan. 26, 2026]