FINAL YEAR PROJECT 2(MPRB424)

DEVELOPMENT OF A SPREADSHEET-BASED
FUEL CELL SIMULATOR: MODELING 2D FLOW
IN A SERPENTINE CHANNEL

NAME : AINAA SYAHIRAH AHMAD ANUAR

STUDENT ID : ME096481
SUPERVISOR : DR SAIFUL HASMADY ABU HASAN
EXAMINER : PROF. DR. MD. MUJIBUR RAHMAN
DATE : 25/9/2018

1
 BACKGROUND

• Depleting
Fossil fuels • Leads to global warming

• Hydrogen (solution)
Alternative • Clean
Solution • Energy carrier

• Proton Exchange
Membrane Fuel Cell
Needs (PEMFC)
efficient • Convert chemical to
Converter for electrical energy
Hydrogen • Low temperature
operation
• High power density 2
 PROTON EXCHANGE MEMBRANE FUEL CELLS (PEMFC)[1]

Flow field plate of

serpentine channel [3]
Single layer of PEMFC [2]

SOURCE
[1] http://www.mdpi.com/1424-8220/9/11/9104/htm/
[2] https://www.robotshop.com/letsmakerobots/using-a-pem-hydrogen-fuel-cell
[3] https://www.researchgate.net/figure/Geometry-of-the-Bipolar-Plates-serpentine-flow-pattern-left-straight-channel_fig1_257939859
3
Thus, simulation is needed to understand the
fundamental phenomena :-

We need to find other

Commercial Alternative
software

• Needs • Cheaper
training • Reliable
• Expensive • Accessible
by everyone

4
 PROBLEM STATEMENTS

• Temperature and water management are problems exist in the fuel cell.

HIGH TEMPERATURE LOW TEMPERATURE

Dry membrane causes proton • Flooding of Gas Diffusion
not conducting Layer (GDL)
• Gas flow blocked

• Therefore, theoretical-based study is needed to understand the

fundamental of these problems.
• Complex computational study and numerical analysis are usually
performed using expensive commercial softwares.

5
 OBJECTIVES

• To develop a spreadsheet-based Excel simulator to

solve for 2D velocity profile in a serpentine channel.

• To validate simulator accuracy by comparison with

commercial software.

6
 METHODOLOGY
Literature Review

FYP1
Identifying calculation schematic,
governing equation and boundary
conditions

Perform numerical analysis in

Excel

Validate with Commercial CFD

FYP2
Parametric Analysis

Thesis writing
7
 LITERATURE REVIEW
No Year Title Journal Comment
1 2010 Design and Application of a Spreadsheet-based ISIJ International, Vol. 50 application of a 1-
Model of the Blast Furnace Factory dimensional static blast
furnace model,
“Masmod” using
Microsoft Excel

2 2010 Spreadsheet-based modeling of liner wear impact Minerals Engineering GMT software (Grinding
on charge motion in tumbling mills Media Trajectory)

3 2011 Solving Groundwater Flow Inverse Problem Using Hydrologic Engineering Applied numerical
Spreadsheet Solver solution for a ground
water inverse problem by
using Excel.

4 2015 Microsoft EXCEL 2010 offers an improved random Clinica Chimica Acta Microsoft excel offers a
number generator allowing efficient simulation in simulation distribution in
chemical laboratory studies. “Data Analysis Add- In”
such as Gaussian
distribution

5 2016 Streamline performance of Excel in stepwise Computer Applications in Visual Basic Application
implementation of numerical solutions. Engineering Education (VBA) as optimal
programming language in
Microsoft excel simulation

8
CALCULATION DOMAIN SCHEMATIC

5mm

0.5mm 1mm

9
 GOVERNING EQUATIONS

MOMENTUM EQUATION IN 2D (Navier Stokes Equation):-

x-momentum equation
𝜕 𝜕 𝜕 𝜕𝑢 𝜕 𝜕𝑢 𝜕𝑝
(𝜌𝑢𝑢) + (𝜌𝑣𝑢) = 𝜇 + 𝜇 −
𝜕𝑥 𝜕𝑦 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥
y-momentum equation
𝜕 𝜕 𝜕 𝜕𝑣 𝜕 𝜕𝑣 𝜕𝑝
(𝜌𝑢𝑣) + (𝜌𝑣𝑣) = 𝜇 + 𝜇 −
𝜕𝑥 𝜕𝑦 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑦
Continuity equation
𝜕𝑢 𝜕𝑣
(𝜌𝑢) + (𝜌𝑣) = 0
𝜕𝑥 𝜕𝑦
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DISCRETIZED EQUATIONS

DISCRETIZED MOMENTUM
EQUATIONS

PRESSURE CORRECTION EQUATION

STAGGERED GRID
ARRANGEMENT
11
SEMI-IMPLICIT METHOD FOR PRESSURE- LINKED EQUATIONS
(SIMPLE) ALGORITHM

Worksheet Ustar

Worksheet Vstar

Worksheet Pprime

Worksheet Pstar

FLOWCHART OF
SIMPLE ALGORITHM
12
IMPLEMENTATION IN MICROSOFT EXCEL

Vin = 1m/s

Pout= 0 Pa (gage)

Test Case 25x13

• Δ x = 1m
• Δ y = 1m
• 𝜌 air = 1.225 kg/m3
• 𝜇 = 1.73 x 10-5 Pa-s
• Convergence criteria = 13
 WORKSHEET, PSTAR
s

INPUT
PARAMATER

VELOCITY
MAGNITUDE

14
s WORKSHEET, USTAR

15
 WORKSHEET, VSTAR
s

16
 WORKSHEET, PPRIME
s

17
SIMULATION VIDEO

fn + F9 18
 RESULT
P distribution

u-velocity
profile

v-velocity
profile

Velocity
magnitude
profile

19
 DISCUSSION
error analysis using different number of height (mm)

Percentage Error (%) against Height(mm)

6

5
5.118
Percentage Error (%)

4 4.42
3.78
3

1
1.34
1
0
0.5 1 1.5 2 2.5
Height (mm)

20
 DISCUSSION
Using different type of fluid, Hydrogen

Outlet velocity (m/s) against number of nodes

1.2

1
Outlet velocity (m/s)

0.8

0.6

0.4

0.2

0
12 13 14 15 16 17 18 19 20 21 22 23 24 25
Hydrogen 0.208 0.295 0.324 0.397 0.466 0.504 0.52 0.522 0.517 0.511 0.507 0.499 0.468 0.328
Air 0.165 0.261 0.336 0.418 0.484 0.523 0.541 0.544 0.538 0.526 0.506 0.468 0.395 0.235
Number of nodes

21
 VALIDATION WITH FLUENT ANSYS
Comparison Microsoft Excel with Fluent ANSYS for Velocity (m/s) against position (mm)
1.6
1.4
1.2
velocity (m/s)

1
0.8
0.6
Microsoft Excel
0.4
0.2 Fluent ANSYS
0

Position (mm)

22
 CONCLUSION

• A spreadsheet-based simulator has been developed to solve

two-dimensional momentum transport inside a serpentine flow
channel.

• Microsoft Excel is found to have capability to perform complex

numerical simulation but very exhaustive and requires more
effort compared to commercial software.

• However, it is found that the data stored in the spreadsheet is

more organized which allows easier detection of errors.
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 DISCUSSION

• Solve more complex channel while varying the density value instead
of making assumption and increase the number of nodes for better
and precise result.

• Evaluate different number of area to compare different field flow in

different area.

24
THANK YOU
Q&A

25
 SERPENTINE FLOW CHANNEL

An overview of serpentine flow channel [4]

26
SOURCE
[4]Munson, Bruce Roy, T. H. Okiishi, Wade W. Huebsch, and Alric P. Rothmayer. Fundamentals of Fluid Mechanics. Hoboken, NJ: John Wiley & Sons, 2013..
Simulation CONT

27
Serpentine flow channel CONT

• By using the channel dimension, the flow can be

calculated to determine either the the flow is
developing or fully developed.

• The shape of the velocity profile in the channel is

depends on Reynolds number to determine type of
flow either laminar (Re<2100) or turbulent
(Re>4000).
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i

P = Position of the node in current iteration

j

W = West
E = East
N = North
S = South
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Governing equations
Navier stokes equation
cont

Term Convection Diffusion Source

𝜕 𝜕 𝜕 𝜕𝑢 𝜕 𝜕𝑢 𝜕𝑝 𝑆𝑀𝑥 = 0
(𝜌𝑢𝑢) + (𝜌𝑣𝑢) 𝜇 + 𝜇 −
𝜕𝑥 𝜕𝑦 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥
x-momentum
𝜕 𝜕 𝜕 𝜕𝑣 𝜕 𝜕𝑣 𝜕𝑝 𝑆𝑀𝑦 = 0
(𝜌𝑢𝑣) + 𝜕𝑦(𝜌𝑣𝑣) 𝜇 + 𝜇 −
𝜕𝑥 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑦
y-momentum

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 𝜕𝑢 𝜕𝑣 𝜕𝑤
Volumetric deformation is given by :- 𝑑𝑖𝑣 𝐮= + +
𝜕𝑥 𝜕𝑦 𝜕𝑧

By allocating stress equations in the x-momentum, the equation is

𝐷𝑢 𝜕𝑝 𝜕 𝜕𝑢 𝜕 𝜕𝑢 𝜕𝑣 𝜕 𝜕𝑢 𝜕𝑤
𝜌 =− + 2𝜇 + 𝜆𝑑𝑖𝑣 𝑢 + 𝜇 + + + + 𝑆𝑀𝑥
𝐷𝑡 𝜕𝑥 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥 𝜕𝑧 𝜕𝑧 𝜕𝑥
Navier-Stokes Equation Equation 1
𝐷𝑢 𝜕𝑝
𝜌 = − + 𝑑𝑖𝑣 𝜇 . 𝑔𝑟𝑎𝑑 . 𝒖 + 𝑆𝑀𝑥
𝐷𝑡 𝜕𝑥
Equation 2
𝐷∅ 𝜕(𝜌∅)
𝜌 = + 𝑑𝑖𝑣 (𝜌∅𝒖)
𝐷𝑡 𝜕𝑡

31
• By combining equation 1 and 2 to obtain governing equation of
compressible Newtonian fluid, the equation is
𝜕 𝜌𝑢 𝜕𝑝
• + 𝑑𝑖𝑣 𝜌𝑢𝒖 = − + 𝑑𝑖𝑣 𝜇 . 𝑔𝑟𝑎𝑑 . 𝒖 + 𝑆𝑀𝑥 Equation 3A
𝜕𝑡 𝜕𝑥
𝜕 𝜌𝑣 𝜕𝑝
• + 𝑑𝑖𝑣 𝜌𝑣𝒖 = − 𝜕𝑦 + 𝑑𝑖𝑣 𝜇 . 𝑔𝑟𝑎𝑑 . 𝒖 + 𝑆𝑀𝑦 Equation 3B
𝜕𝑡
𝜕 𝜌𝑤 𝜕𝑝
• + 𝑑𝑖𝑣 𝜌𝑤𝒖 = − 𝜕𝑧 + 𝑑𝑖𝑣 𝜇 . 𝑔𝑟𝑎𝑑 . 𝒖 + 𝑆𝑀𝑧 Equation 3C
𝜕𝑡

• The significant elements are identified and replaced as a common

variable  to represent as fluid properties for general transport
equation
𝜕(𝜌∅)
• + 𝑑𝑖𝑣 𝜌∅𝒖 = 𝑑𝑖𝑣 Γ𝑔𝑟𝑎𝑑∅ + 𝑺∅ Equation 4
𝜕𝑡
General Transport Equation

32
• From Equation 4, the Partial Differential Equation (PDE) of Momentum
Transport Equation can be acquired :-

• x-momentum equation
𝜕 𝜕 𝜕 𝜕𝑢 𝜕 𝜕𝑢 𝜕𝑝 Equation 5A
• (𝜌𝑢𝑢) + (𝜌𝑣𝑢) = 𝜇 + 𝜇 − +𝑆𝑢 0
𝜕𝑥 𝜕𝑦 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑥

• y-momentum equation
𝜕 𝜕 𝜕 𝜕𝑣 𝜕 𝜕𝑣 𝜕𝑝
• (𝜌𝑢𝑣) + (𝜌𝑣𝑣) = 𝜇 + 𝜇 − +𝑆𝑣 0 Equation 5B
𝜕𝑥 𝜕𝑦 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦 𝜕𝑦

• Continuity equation
𝜕𝑢 𝜕𝑣
• (𝜌𝑢) + (𝜌𝑣) = 0 Equation 6
𝜕𝑥 𝜕𝑦

33
actual dimension
Percentage error
= 14.44%

34
Mass balance calculation

35
 Row 2, vstar worksheet
Coefficient Formulae

Fw (𝜌𝑢)𝑤 + (𝜌𝑢)𝑝
2
Coefficient Formulae
Fe (𝜌𝑢)𝑒 + (𝜌𝑢)𝑝
(2Dw + Fw) Фw – (2Ds + Fs) Фs
2 Su
Fn (𝜌𝑢)𝑛 + (𝜌𝑢)𝑝 Sp
2 - (2Dw + Fw) – (2Ds + Fs)

Fs (𝜌𝑢)𝑠 + (𝜌𝑢)𝑝
2 d 𝐴
𝑎𝑝
Pe 𝐹
𝐷
Dw max [ 0, ( 1-0.1 |Pew| 5 ] + max [Fw, 0]
aw
De max [ 0, ( 1-0.1 |Pee| 5 ] + max [-Fe, 0]
ae
Dn max [ 0, ( 1-0.1 |Pen| 5 ] + max [-Fn, 0]
an
36
Ds max [ 0, ( 1-0.1 |Pes| 5 ] + max [Fs, 0]
a
Percentage error result

Percentage Error %
Initial Adding by column Adding by row
Uin (m/s)
2D (11 x 11) 2D (11 x 12) 2D(11X13) 2D(12X13) 2D(13X13)

10 24.43 20.17 12.26 0.38 0.39

5 8.39 2.08 2.13 0.93 0.90

2.5 1 0.94 1 0.31 0.27

1 1.44 0.24 0.29 0.07 0.06

0.5 2.73 0.13 0.17 0.04 0.04

37
pressure

MAGNITUDE OF VELOCITY

38
U-velocity

V-VELOCITY

39