In this paper, the development and testing of a Roots pump with a new rotor profile for hydrogen recirculation in the fuel cell system are presented. The design method of the rotor profile, port position, and structure of the pump is presented. A prototype of a three-lobe Roots pump with helical rotors was fabricated, and its performance was experimentally tested. The measured data show that the effect of the pressure difference on the flow rate and volumetric efficiency of the Roots pump is the most significant, while the effect of suction pressure is limited. It is concluded that the leakage rather than flow resistance is the key factor, which has a major influence on volumetric and isentropic efficiency. The comparison of the performance is also given by the measured results of the same Roots pump working with air, helium, and hydrogen. Finally, the successful integration of the Roots pumps into three PEM fuel cell systems is reported and the optimal operating parameters of the Roots pump in the systems under various loads are also presented. It is found that the performance of the Roots pump integrated into the fuel cell system is better than that measured with pure hydrogen on the test rig. The performance maps composed of all the measured data of the Roots pump are very helpful for the optimal design and operation of the fuel cell system.

The gas-water separator is an important auxiliary component of the hydrogen recirculation subsystem for the proton exchange membrane fuel cell (PEMFC) system. This study investigated three baffle separators with different structures used for a 75 kW PEMFC system by computational fluid dynamics (CFD) simulation and experimental validation. An Euler-Lagrange two-phase simulation model was established to investigate the gas-phase flow characteristics and the droplets trajectory and film distribution in separators. Moreover, an experimental bench was set up to test the overall performance of the separators. The results showed that the CFD model can predict the performance of the gas-water separator accurately. Through the comparison of air and mixed hydrogen, it was found that the density of the gas phase fluid has a great influence on the pressure drop. The local gas flow at the baffle bottom where the film fall directly is at high velocity in separator A, resulting in that the liquid film is broken easily to cause more fine droplets being entrained again into the outflow. Besides, thicker liquid film still formed in the top part of the separators A and B compared with separator C, which is not conducive for high separation performance. Thus, the separator C is preferred to be suggested for PEMFC systems.