High-temperature proton exchange membrane fuel cells (HT-PEMFCs) coupled with methanol reforming hold promise for distributed energy systems, yet channel hydrodynamics and geometry optimization remain underexplored. This study develops a 3D multiphysics model to investigate coupled behaviors in HT-PEMFCs fueled by methanol reformate. Results reveal bifurcation-induced Dean vortices have dual effects: they cause flow maldistribution (15–18% velocity deviation) and contribute 50% of inlet pressure loss, while generating a lateral pumping effect that enhances local mass transfer. A continuous parametric sweep of channel widths (0.9–1.9 mm) identifies a voltage-dependent performance crossover—narrower channels (1.3 mm) excel at high voltages by improving electronic conduction, whereas wider channels (1.5 mm) perform better at low voltages by mitigating mass transfer limitations. These findings provide quantitative design criteria for optimizing flow field geometry in HT-PEMFC stacks.
Guo et al. (Sat,) studied this question.