Numerical Analysis and Optimization of Secondary Flow Channels in a PEMFC Cooling Plate

Proton exchange membrane fuel cells (PEMFCs) offer a promising zero-emission power solution for maritime transportation, yet thermal management remains challenging due to localized overheating and non-uniform temperature distribution. To address the trade-off between pressure drop and thermal performance in marine PEMFC cooling plates, this study developed and systematically evaluated six flow channel configurations through CFD simulations. Parametric analysis coupled with orthogonal experimental design was employed to explore the effects of secondary flow channel number (<i>N</i>), angle (<i>α</i>), width (<i>d</i>), and spacing (<i>L</i>). The results demonstrated that Type B (parallel flow with secondary channels) reduced the pressure drop by 28.2% while achieving the highest cooling efficiency coefficient (2.66 × 10⁴) compared to conventional configuration. Range analysis further ranked parameter sensitivity and identified optimal parameter combinations for distinct optimization objectives: thermal performance (<i>N</i> = 7, <i>α</i> = 30°, <i>d</i> = 0.5 mm, and <i>L</i> = 2.5 mm), pressure drop (<i>N</i> = 8, <i>α</i> = 75°, <i>d</i> = 1.5 mm, and <i>L</i> = 2.5 mm), and cooling efficiency (<i>N</i> = 8, <i>α</i> = 90°, <i>d</i> = 1.5 mm, and <i>L</i> = 2.5 mm). These findings provide practical guidelines for designing cooling plates that address thermal-hydraulic requirements in marine PEMFC systems, advancing their viability for maritime propulsion applications.