Effect of Anode Flow Channel Design on the Carbon Dioxide Bubble Removal in Direct Methanol Fuel Cells

On the anode side of a direct methanol fuel cell, carbon dioxide bubbles are generated as a result of the methanol oxidation reaction. The accumulation of such bubbles prevents methanol from reaching the gas diffusion layer. Hence, a significant reduction in the reaction rate occurs, which limits the maximum current density of the cell. To keep carbon dioxide bubbles away from the gas diffusion layer interface, a new design of the anode flow channel besides wall surface treatment is developed. Such a design can introduce the Concus-Finn phenomena, which forces the carbon dioxide bubbles to move away from the gas diffusion layer due to capillary forces. This can be achieved by using a trapezoidal shape of the flow channel, as well as the combined effect of hydrophobic and hydrophilic surface treatments on the gas-diffusion layer and channel walls. To identify the optimal design of the anode flow channel, a three-dimensional, two-phase flow model is developed. The model is numerically simulated and results are validated with available measurements. Results indicated that treating the gas-diffusion layer with a hydrophilic layer increases the area in direct contact with liquid methanol. Besides, the hydrophobic top channel surfaces make it easier for the carbon dioxide bubbles to attach and spread out on the channel top surface. The current findings create a promising opportunity to improve the performance of direct methanol fuel cells.