Impact of Multiple Inlet and Outlet Structures of Bipolar Plate Channel on the Mass Transport in ALK Electrolyzers

Wanxiang Zhao, Chengjie Xu, Mingya Chen (), Shuiyong Wang, Lin Yang, Yimin Zhang, Mengqi Luo, Zishuo Li and Zhiyuan Wang ()
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Wanxiang Zhao: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Chengjie Xu: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Mingya Chen: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Shuiyong Wang: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Lin Yang: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Yimin Zhang: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Mengqi Luo: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Zishuo Li: Suzhou Nuclear Power Research Institute Co., Ltd., Suzhou 215004, China
Zhiyuan Wang: School of Energy and Power Engineering, University of Shanghai for Science and Technology, Shanghai 200093, China

Energies, 2025, vol. 18, issue 11, 1-16

Abstract: The flow channel structure in alkaline electrolyzers critically impacts electrolyte distribution uniformity, influencing stagnant zones, gas bubble accumulation, and electrode reactions. Conventional concave–convex bipolar plates cause uneven flow and reduced current density. Therefore, a scaled-down-sized multiple inlet setup coupled with the bipolar plate channel of three typical concave–convex structures was designed to improve the uniformity of electrolyte. Three-dimensional computational fluid dynamics was employed to analyze the flow characteristics in the channels. The results indicated that in the single inlet/outlet model, the velocity near the center axis along the mainstream direction was higher than at the edge of the channels, resulting in a non-uniform flow distribution. The vorticity intensity gradually decreased along the flow direction, while the multiple inlet/outlet structure strengthened the intensity. The multiple inlet model allowed for the electrolyte flow across more areas along the channel and enhanced the velocity uniformity. According to the velocity uniformity evaluation criteria, the flow uniformity index of the three-inlet square concave–convex structure was the highest, reaching 0.80 at the middle cross-section normal to the incoming flow and 0.88 parallel to the flow. This study may help provide a useful guide for the design and optimization of efficient electrolyzer in alkaline water electrolysis.

Keywords: alkaline electrolysis; concave–convex structure; velocity uniformity; vorticity (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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