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.

In this paper, the performance of a Roots pump for hydrogen recirculation in proton exchange membrane (PEM) fuel cell system is simulated based on CFD modeling. The Roots pump is in a three-lobe configuration with helical rotors, and it is developed specifically for fuel cell systems between 60 to 110 kW. A three-dimensional model of the Roots pump is established to predict the pump performance, including the flow rate and power consumption under various operating conditions. Extensive simulations were conducted and then verified experimentally by operating with working fluids of air and helium. Based on the validated CFD model, the contents of water vapor and nitrogen in the hydrogen recirculated are taken into account to evaluate the Roots pump performance numerically according to the actual conditions of the recirculating hydrogen at the stack outlet. It is shown that the volumetric efficiency and isentropic efficiency are improved with the increase fraction of water vapor and nitrogen. It is found that the performance of the Roots pump integrated in the PEM fuel cell system is between the performance of the pump working with air and helium. Finally, correlations of volumetric efficiency and isentropic efficiency are given based on the CFD results to show the general pattern of this kind of hydrogen pump. It is believed that these equations are very helpful to the design and operation control of the PEM fuel cell system.

Oil-free helical Roots air compressors which have great application potential in air circulation systems for high-power fuel cell systems, such as commercial fuel cell vehicles (FCVs), have the advantages of active adaptation, low cost, large flow rate and high reliability. In this study, a three-dimensional transient numerical simulation model of a helical Roots air compressor was established by considering all leakage clearances. In this study, hexahedral structured dynamic grids were generated in the working chamber and the rotating angle was updated at an increment of 1° to ensure the mesh quality of the entire solving domain. The accuracy of the simulation model was validated using experimental data, and the maximum deviation was less than 4.0%. Based on the simulated results, the pressure field and variation of the pressure field with the rotation angle are presented. It shows that the pressure fluctuation at the discharge side was larger than that at the suction side. The influence of various leakage clearance on the volumetric efficiency was analyzed comparatively. Additionally, the flow field characteristic of clearance was revealed. It is found that the rotor tip clearance was the major factor for the reduction of volumetric efficiency when the size was larger than 0.12 mm instead of the interlobe clearance. It is suggested that more attention should be paid to control the clearance size to ensure the performance of helical Roots air compressors.

Roots blowers are widely used in various fields, and their performances are extremely important for their application in the chemical industry. In this study, a Roots blower with a flow capacity of 90 m³/min was investigated using a computation fluid dynamics (CFD) approach, with emphasis on its performance. A previous-generation blower comprising two lobes was simulated, and the calculated volumetric efficiencies were compared with experimental data. After validating the CFD model, the performance of a Roots blower with two to six lobes was predicted. The effect of the sealing angle at the tip of the profile on the performance of the blower was also investigated. An optimized profile with three lobes and a sealing angle of 4° was selected. A new-generation Roots blower with the same capacity as that of the previous-generation was manufactured and tested. The volumetric efficiency improvements of 12.1%–18.2% could be achieved by profile optimization.

The air compressor is a key component in the polymer electrolyte membrane (PEM) fuel cell system and its performance has great impact on the electric power output from the system. Here, analysis was conducted firstly on the Roots-type compressor with fixed internal compression based on the volume reduction created by helical rotors. The built-in volume ratio variations with the wrap angle and the lobe numbers were calculated and discussed. Then a prototype of the Roots-type air compressor with 6 lobes was developed according to the outcomes of the research. The volumetric and isentropic efficiency of the prototype were measured under the discharge pressures from 0.11 MPa to 0.25 MPa while the rotation speeds from 10000 to 14000 rpm. Under the design conditions, the volumetric efficiency and isentropic efficiency of the Roots-type air compressor were 75.8% and 53.9% respectively. It was concluded that this kind of Roots-type air compressor is especially suitable for the fuel cell systems applied in the range extended electric vehicles.

A mechanical pre-cooling auto-cascade refrigeration (PACR) system was proposed, R600a single-stage vapor compression system was used to provide pre-cooling for R600/R170 auto-cascade refrigeration (ACR) system. Performance of PACR system under different operating conditions was discussed. The result showed that maintaining a constant outlet temperature of 30°C for the condenser and −45°C for the evaporator in a PACR system resulted in an optimal intermediate temperature that maximized coefficient of cooling performance (COP). At this time, the optimal intermediate temperature of R600/R170 was 0°C, the COP maximum value ( COP _max ) was 0.693 and exergy efficiency ( η _Ex ) was 20.9%. And as the evaporator outlet temperature decreases to −70°C, the optimal intermediate temperature decreases to −10°C. The cooling capacity ( Q _e ) of the low-temperature grade circulating refrigerant in the PACR system using R600/R170 at different evaporation temperatures was increased by 86.3%–108% compared to that of R134a/R23. COP _max was increased by 7.1% compared to that of R134a/R23 at the evaporator outlet temperature of −60°C.