质子交换膜燃料电池高效主动喷雾增湿器的设计

doi:10.19894/j.issn.1000-0518.250215

摘要/Abstract

摘要：

质子交换膜燃料电池（PEMFC）的气体湿度对其性能和寿命有很大的影响，为了控制其气体湿度，通过结构优化：首先，设计了2代均流雾化腔：第1代实现液滴逆向分散，第2代引入三层均流板与四分流道，经计算流体动力学（CFD）优化后四分流道流量误差由4.24%降至1.16%，压降从8.7 kPa降至5 kPa；其次，引入二级换热架构，一级换热器利用出堆水温预热液滴，二级换热器通过调节入堆水温控制湿空气温度，可以避免液态水残留，二级换热器出口露点与理论值吻合，误差≤±1 ℃，覆盖燃料电池典型工况。结合二代雾化腔和二级换热架构，实测露点可达54.34 ℃、实测湿度可达63.76 RH%，可以满足电堆较高湿度的需求。这种融合逆流喷雾、均流结构与二级换热技术，能够突破传统膜管增湿器被动加湿、响应慢的局限，可以为燃料电池系统动态湿度管理提供解决方案。

关键词: 质子交换膜燃料电池, 喷雾增湿器, 雾化腔设计, 二级换热, 湿度调控

Abstract:

The gas humidity of proton exchange membrane fuel cells （PEMFC） has a significant impact on their performance and service life. To control the gas humidity， structural optimization was carried out as follows： first， two generations of uniform-flow atomization chambers were designed. The first generation achieved reverse dispersion of liquid droplets， and the second generation introduced a three-layer uniform-flow plate and four-zonechannels. After computational fluid dynamics（CFD） optimization， the flow error of the four-flow channels was reduced from 4.24% to 1.16%， and the pressure drop was reduced from 8.7 to 5 kPa. Secondly， a two-stage heat exchange architecture was introduced. The primary heat exchanger uses the outlet stack water temperature to preheat the liquid droplets， and the secondary heat exchanger controls the temperature of the humidified air by adjusting the inlet stack water temperature， which can avoid residual liquid water. The dew point at the outlet of the second-stage heat exchanger matches the theoretical value with an error ≤±1 ℃， covering typical working conditions of fuel cells. Combining the second-generation atomization chamber with the two-stage heat exchange architecture， the measured dew point can reach 54.34 ℃ and the measured humidity can reach 63.76 RH%， meeting the high humidity requirements of the stack. This integration of countercurrent spraying， uniform-flow structure， and two-stage heat exchange technology breaks through the limitations of passive humidification and slow response of traditional membrane tube humidifiers， providing a solution for dynamic humidity management in fuel cell systems.

Key words: Proton exchange membrane fuel cell, Spray humidifier, Atomization chamber design, Secondary heat exchange, Humidity regulation

中图分类号:

O646

李阳, 赵兴旺, 丁芳, 王显, 葛君杰, 方川. 质子交换膜燃料电池高效主动喷雾增湿器的设计[J]. 应用化学, 2025, 42(7): 982-992.

Yang LI, Xing-Wang ZHAO, Fang DING, Xian WANG, Jun-Jie GE, Chuan FANG. Design of the Efficient Active Spray Humidifier for Proton Exchange Membrane Fuel Cells[J]. Chinese Journal of Applied Chemistry, 2025, 42(7): 982-992.

图/表 14

图1 第1代喷雾增湿架构示意图TP1： Temperature-pressure integrated sensor after air compressor； P1： Pressure sensor after atomization chamber； T1： Temperature sensor after atomization chamber； RH： Humidity sensor before fuel cell stack inlet； T2： Temperature sensor before fuel cell stack inlet； P2： Pressure sensor before fuel cell stack inlet

Fig.1 Schematic diagram of the first-generation spray humidification architecture

图2 第2代喷雾增湿架构示意图TP1： Temperature-pressure integrated sensor after air compressor； P1： Pressure sensor after primary heat exchange； T1： Temperature sensor after primary heat exchange； RH： Humidity sensor before fuel cell stack inlet； T2： Temperature sensor before fuel cell stack inlet； P2： Pressure sensor before fuel cell stack inlet

Fig.2 Schematic diagram of the second-generation spray humidification architecture

表1 燃料电池系统空气路喷雾增湿水量核算

Table 1 Calculation of water volume for spray humidification in the air circuit of fuel cell system

j/（mA·cm^-2）	$T c e l l$ /℃	$R H c e l l$ /（RH%）	$P c e l l$ /（kPa·g）	$Q c e l l ? w a t e r$ /（g·min^-1）	$T e n v i r o n m e n t$ /℃	$R H e n v i r o n m e n t$ /（RH%）	$Q E W$ /（g·min^-1）	$Q S H$ /（g·s^-1）
300	64	33	40	206.997 1	-20	0.1	0.002 9	3.45

表1 燃料电池系统空气路喷雾增湿水量核算

Table 1 Calculation of water volume for spray humidification in the air circuit of fuel cell system

j/（mA·cm^-2）	$T c e l l$ /℃	$R H c e l l$ /（RH%）	$P c e l l$ /（kPa·g）	$Q c e l l ? w a t e r$ /（g·min^-1）	$T e n v i r o n m e n t$ /℃	$R H e n v i r o n m e n t$ /（RH%）	$Q E W$ /（g·min^-1）	$Q S H$ /（g·s^-1）
300	64	33	40	206.997 1	-20	0.1	0.002 9	3.45

表2 雾化腔仿真输入数据

Table 2 Simulation input data for atomization chamber

Air flow rate/（g·s^-1）

Air temperature

into chamber/℃

Required water

volume/（g·s^-1）

Nozzle size

Circulating water temperature/℃

图3 （A）第1代雾化腔仿真模型和（B）第1代雾化腔换热器联合仿真模型

Fig.3 （A） Simulation model of the first-generation atomization chamber and （B） combined simulation model of the first-generation atomization chamber and heat exchanger

表3 第1代雾化腔和第2代A雾化腔、B雾化腔四分区流道流量误差对比

Table 3 Flow rate error comparison of four-zone flow channels between the first-generation atomization chamber and the second-generation A atomization chamber， B atomization chamber

Flow rate error /%	1	2	3	4
1^st atomization chamber	-12.55	12.05	11.78	-11.28
2^nd atomization chamber A	3.99	-4.11	-4.12	4.24
2^nd atomization chamber B	-1.01	1.02	1.15	-1.16

图4 第1代雾化腔的（A）温度仿真图和（B）湿度仿真图

Fig.4 The first-generation atomization chamber （A） Temperature simulation diagram and （B） Humidity simulation diagram

图5 （A）第2代雾化腔A仿真模型；（B）第2代雾化腔B仿真模型；（C）第2代A雾化腔压降；（D）第2代B雾化腔压降

Fig.5 （A） Simulation model of the second-generation atomization chamber A；（B） Simulation model of the second-generation atomization chamber B；（C） Pressure drop of the second-generation atomization chamber A；（D） Pressure drop of the second-generation atomization chamber B

图6 （A）水平放置、（B）上进下出和（C）下进上出方式对露点的影响Air flow rate is 93.4 g/s， target pressure at heat exchanger outlet is 40 kPa·g， target temperature at heat exchanger outlet is 64 ℃， and target spray volume is 3.45 g/s

Fig.6 The influence of relative positions of （A） horizontal placement，（B） upward inlet and downward outlet and （C） downward inlet and upward outlet on dew point

图7 下进上出放置方式，（A）不同喷雾温度和（B）不同换热器水温对露点的影响Air flow rate is 93.4 g/s， target pressure at heat exchanger outlet is 40 kPa·g， target temperature at heat exchanger outlet is 64 ℃， and target spray volume is 3.45 g/s

Fig.7 In the downward inlet and upward outlet placement mode，（A） effects of different spray temperatures and （B） effects of different heat exchanger water temperatures on the dew point

图8 第1代雾化腔+二级换热器下进上出放置方式时，（A）电堆工况条件下露点和蒸发比的测试数据及（B）不同湿度条件下蒸发比的对比

Fig.8 Placement mode of downward inlet and upward outlet for the first-generation atomization chamber + secondary heat exchanger，（A） test data of dew point and evaporation ratio under stack operating conditions and （B） comparison of evaporation ratios under different humidity conditions

表4 电堆工况条件下喷雾增湿架构露点和温度的测试数据

Table 4 Test data of dew point and temperature for spray humidification architecture under stack operating conditions

Current density/（mA·cm^-2）	Measured dew point/℃	Theoretical dew point/℃	Measured temperature/℃	Theoretical temperature/℃
100	43.00	43.91	57.60	58
200	43.58	43.91	58.80	58
300	38.94	39.43	64.00	64
400	40.35	40.28	65.50	65
500	40.11	40.28	65.90	65
600	41.98	41.97	67.80	67
700	42.23	42.82	68.70	68
800	43.28	43.67	69.90	69
900	43.76	44.51	70.20	70

图9 第2代雾化腔+二级换热器下进上出放置方式时，（A）不同湿度条件下露点与蒸发比的变化；（B）喷雾增湿架构与电堆联调照片；（C）喷雾增湿架构与电堆联调时极化曲线对比

Fig.9 Placement mode of downward inlet and upward outlet for the second-generation atomization chamber + secondary heat exchanger. （A） Changes in dew point and evaporation ratio under different humidity conditions；（B） Photos of the joint debugging of the spray humidification architecture and the stack；（C） Comparison of polarization curves during the joint debugging of the spray humidification architecture and the stack

表5 喷雾增湿架构和膜管增湿架构时电堆性能对比

Table 5 Performance comparison of the stack with spray humidification architecture and membrane tube humidification architecture

Current density/（mA·cm^-2）	Performance （V） of single cell in the stack with spray humidification architecture	Performance （V） of a single cell in the stack with membrane tube humidification architecture
100	0.850	0.852
200	0.822	0.820
300	0.802	0.800
400	0.783	0.784
500	0.765	0.766
600	0.755	0.757
700	0.747	0.747
800	0.740	0.739
900	0.735	0.736

参考文献 26

[1]	WANG Y， RUI Z D， CHEN K， et al. Materials， technological status， and fundamentals of PEM fuel cells-a review［J］. Mater Today， 2020， 32： 178-203.
[2]	JIAO K， LI X. Water transport in polymer electrolyte membrane fuel cells［J］. Prog Energy Combust Sci， 2011， 37（3）： 221-291.
[3]	ZHANG G， KANDLIKAR S. A critical review of cooling techniques in proton exchange membrane fuel cell stacks［J］. Int J Hydrogen Energy， 2012， 37（3）： 2412-2429.
[4]	CHANG Y， QIN Y， YIN Y， et al. Humidification strategy for polymer electrolyte membrane fuel cells-a review［J］. Appl Energy， 2018， 230： 643-662.
[5]	CASALEGNO A， ANTONELLIS S， COLOMBO L， et al. Design of an innovative enthalpy wheel based humidification system for polymer electrolyte fuel cell［J］. Int J Hydrogen Energy， 2011， 36（8）： 5000-5009.
[6]	FU P， LAN Z， CHENY， et al. A review on modeling methods and key parameters control of proton exchange membrane fuel cell based on numerical comparison［J］. Energy Convers Manage， 2025， 324： 119309.
[7]	CHOWDURY M， PARK Y， PARK S， et al. Degradation mechanisms， long-term durability challenges， and mitigation methods for proton exchange membranes and membrane electrode assemblies with Pt/C electrocatalysts in low-temperature and high-temperature fuel cells： a comprehensive review［J］. J Electroanal Chem， 2024， 975： 118712.
[8]	KAMAL M， JAAFAR J， KHAN A， et al. A critical review of the advancement approach and strategy in speek-based polymer electrolyte membrane for hydrogen fuel cell application［J］. Energy Fuels， 2024， 38（14）： 12337-12386.
[9]	KISHORE S， PERUMAL S， ATCHUDAN R， et al. A critical review on artificial intelligence for fuel cell diagnosis［J］. Catal， 2022， 12（7）： 743.
[10]	ZHANG T， WANG P， CHEN H， et al. A review of automotive proton exchange membrane fuel cell degradation under start-stop operating condition［J］. Appl Energy， 2018， 223： 249-262.
[11]	AINDOW T， O'NEILL J. Use of mechanical tests to predict durability of polymer fuel cell membranes under humidity cycling［J］. J Power Sources， 2011， 196（8）： 3851-3854.
[12]	WANG L， HUSAR A， ZHOU T， et al. A parametric study of PEM fuel cell performances［J］. Int J Hydrogen Energy， 2003， 28（11）： 1263-1272.
[13]	ZHOU S， FAN L， ZHANG G， et al. A review on proton exchange membrane multi-stack fuel cell systems： architecture， performance， and power management［J］. Appl Energy， 2022， 310： 118555.
[14]	FANG M， WAN X， ZOU J. Development of a fuel cell humidification system and dynamic control of humidity‍［J］. Int J Energy Res， 2022， 46（15）： 22421-22438.
[15]	FANG M， ZOU J，YIN C， et al. Prediction and parametric analysis of bubble humidifier performance in a polymer electrolyte membrane fuel cell test system by response surface methodology‍［J］. Energy Sources Part A， 2022， 44（2）： 3497-3508.
[16]	EDER E， HILLER S， BRUEGGEMANN D， et al.Characteristics of air-liquid heat and mass transfer in a bubble column humidifier［J］. Appl Therm Eng， 2022， 209： 118240.
[17]	D'ADAMO A， MARTOCCIA L， CROCI F， et al. CFD simulation of the effect of membrane thickness and reactants flow rate on water management in PEM fuel cells［J］. Int J Heat Mass Tran， 2025， 249： 127207.
[18]	POLLAK M， TEGETHOFF W， KOEHLER J. Analysis of the effects of fiber positioning on water transfer in hollow fiber humidifiers using CFD and statistical uniformity metrics［J］. Heat Mass Transfer， 2025， 61（10）： 1.
[19]	GUO Z， CHEN H， GUO H， et al. Study on two-phase transport and performance characterization in orientational structure proton exchange membrane fuel cells at high water content［J］. Appl Energy， 2025， 392： 125970.
[20]	WOOD D， YI Y， NGUYEN T. Effect of direct liquid water injection and interdigitated flow field on the performance of proton exchange membrane fuel cells［J］. Electrochim Acta， 1998， 43（24）： 3795-3809.
[21]	NGUYEN T， WHITE R. A water and heat management model for proton-exchange-membrane fuel-cells‍［J］. J Electrochem Soc， 1993， 140（8）： 2178-2186.
[22]	JUNG S， KIM S， KIM M， et al. Experimental study of gas humidification with injectors for automotive PEM fuel cell systems［J］. J Power Sources， 2007， 170（2）： 324-333.
[23]	SUNG C， BAI C， CHEN J， et al. Controllable fuel cell humidification by ultrasonic atomization［J］. J Power Sources， 2013， 239： 151-156.
[24]	VERHAGE A， COOLEGEM J， MULDER M， et al. 30，000 h operation of a 70 kW stationary PEM fuel cell system using hydrogen from a chlorine factory［J］. Int J Hydrogen Energy， 2013， 28（11）： 4714-4724.
[25]	ZHANG H， QIAN Z， YANG D， et al. Design of an air humidifier for a 5 kW proton exchange membrane fuel cell stack operated at elevated temperatures［J］. Int J Hydrogen Energy， 2013， 38： 12353-12362.
[26]	HU H， XU J， ZHANG H， et al. CFD investigation of a fast-response humidifier for high-power PEMFC test stations［J］. Int J Hydrogen Energy， 2024， 52： 1056-1069.