| Summary: | The fractal-type flow-fields for fuel cell (FC) applications are promising, due to their ability to deliver uniformly, with a Peclet number Pe~1, the reactant gases to the catalytic layer. We review fractal designs that have been developed and studied in experimental prototypes and with CFD computations on 1D and 3D flow models for planar, circular, cylindrical and conical FCs. It is shown, that the FC efficiency could be increased by design optimization of the fractal system. The total entropy production (TEP) due to viscous flow was the objective function, and a constant total volume (TV) of the channels was used as constraint in the design optimization. Analytical solutions were used for the TEP, for rectangular channels and a simplified 1D circular tube. Case studies were done varying the equivalent hydraulic diameter (D<sub>h</sub>), cross-sectional area (D<sub>Σ</sub>) and hydraulic resistance (D<sub>Z</sub>). The analytical expressions allowed us to obtain exact solutions to the optimization problem (TEP→min, TV=const). It was shown that the optimal design corresponds to a non-uniform width and length scaling of consecutive channels that classifies the flow field as a quasi-fractal. The depths of the channels were set equal for manufacturing reasons. Recursive formulae for optimal non-uniform width scaling were obtained for 1D circular D<sub>h</sub> -, D<sub>Σ</sub> -, and D<sub>Z</sub> -based tubes (Cases 1-3). Appropriate scaling of the fractal system providing uniform entropy production along all the channels have also been computed for D<sub>h</sub> -, D<sub>Σ</sub> -, and D<sub>Z</sub> -based 1D models (Cases 4-6). As a reference case, Murray’s law was used for circular (Case 7) and rectangular (Case 8) channels. It was shown, that Dh-based models always resulted in smaller cross-sectional areas and, thus, overestimated the hydraulic resistance and TEP. The D<sub>Σ</sub> -based models gave smaller resistances compared to the original rectangular channels and, therefore, underestimated the TEP. The D<sub>Z</sub> -based models fitted best to the 3D CFD data. All optimal geometries exhibited larger TEP, but smaller TV than those from Murray’s scaling (reference Cases 7,8). Higher TV with Murray’s scaling leads to lower contact area between the flow-field plate with other FC layers and, therefore, to larger electric resistivity or ohmic losses. We conclude that the most appropriate design can be found from multi-criteria optimization, resulting in a Pareto-frontier on the dependencies of TEP vs TV computed for all studied geometries. The proposed approach helps us to determine a restricted number of geometries for more detailed 3D computations and further experimental validations on prototypes.
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