Parameter Optimization for Dual-Mode Operation of Unitized Regenerative Fuel Cells via Steady-State Simulation

Yuhang Hu, Yijia Li, Yuehua Li (), Fang Yang, Bin Zhang and Dan Wang
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Yuhang Hu: School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China
Yijia Li: School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China
Yuehua Li: School of Mechanical Engineering, University of Science and Technology Beijing, Beijing 100083, China
Fang Yang: Xiangyang DAAN Automobile Test Center Corporation Limited, Xiangyang 441004, China
Bin Zhang: Xiangyang DAAN Automobile Test Center Corporation Limited, Xiangyang 441004, China
Dan Wang: Xiangyang DAAN Automobile Test Center Corporation Limited, Xiangyang 441004, China

Energies, 2025, vol. 18, issue 22, 1-18

Abstract: Mathematical modeling of unitized regenerative fuel cells (URFCs) faces significant challenges in reconciling parameter conflicts between fuel cell (FC) and electrolysis cell (EC) modes. This study establishes a COMSOL-based multi-physics framework coupling water–gas–heat–electric transport for both operational states. The critical factors associated with the model were identified through a systematic sensitivity analysis of structural and operational parameters, including temperature, exchange current density, conductivity, porosity, and flow rates. FC modes exhibited strong sensitivity to exchange current density (27.8–40.5% performance variation) and conductivity of membrane (10.1–35.6%), while temperature degraded performance (−4.2% to −4.0%). Spatial analysis revealed temperature-induced membrane dehydration and accelerated gas depletion at electrodes, thus explaining the negative correlation. EC modes were dominantly governed by temperature (8.6–9.4%), exchange current density (13.0–16.4%), and conductivity (2.5–13.3%). Channel simulations revealed that elevated temperature contributed to enhanced liquid water fluidity, while high flow rates had a relatively limited effect on mitigating species concentration gradients. Parameter optimization guided by sensitivity thresholds (e.g., porosity > 0.4 in FC GDLs, conductivity > 222 S/m in EC modes) enabled dual-mode calibration. The model achieved <4% error in polarization curve validation under experimental conditions, demonstrating robust prediction of voltage–current dynamics. This work resolves key conflicts of URFC modeling through physics-informed parameterization to provide a foundation for efficient dual-mode system design.

Keywords: unitized regenerative fuel cell (URFC); multi-physics modeling; parameter sensitivity analysis; water–thermal mass coupling; structural parameter optimization (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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