Efficient thermal management is critical for sustaining the performance and durability of Proton Exchange Membrane Fuel Cells (PEMFCs), where excessive operating temperatures accelerate material degradation and reduce power output. Previous studies have explored various cooling channel designs; however, limited research integrates zigzag multi-fin geometries with both computational and experimental validation for fin width optimization under high-velocity cooling. This study presents a combined Computational Fluid Dynamics (CFD) simulation using ANSYS Fluent and experimental investigation of a multi-fin multi-channel cooling system for PEMFCs. The effects of fin widths (0.3–1.0 mm), inlet flow velocities (0.6–3.0 m/s), and cooling media (air, 20% ethylene glycol (EG) solution) were analyzed with respect to cathode surface temperature, power density, and cooling efficiency. Results show that a 0.3 mm fin width with 3.0 m/s inlet velocity reduced the cathode temperature by ~13 K and increased power density by ~40%. The optimized zigzag configuration improved heat transfer uniformity, achieving cooling efficiencies up to 67.0%. Experimental validation confirmed the CFD results with less than 3% deviation. The findings highlight the potential of optimized multi-fin designs to enhance PEMFC thermal stability and electrical output, offering a practical approach for advanced fuel cell thermal management systems.

For the separation process in liquid-liquid mixture such as ethanol-water mixture, a sieve tray distillation columnis an alternatif for affordable process and maintenance. However to date, this sieve tray system is still currentlyhaving a lower Murphee efficiency and smaller interfacial area, as compared to other tray system, that is, either abubble cap or valve tray. Therefore it is of important to optimize the performance of sieve tray distillation bymeans of adding the wire mesh packing on that tray, as being the aim of the present study. This study isconducted by using a batch sieve tray distillation system, where the wire mesh packing is added on the third traythat is calculated from the top of the column, to avoid flooding inside the column. Here the resulting fermentedmolasses of containing a 10% volume of ethanol is used as a mixture distillation feed. The height of the wiremesh packing being studied is varied as 5 cm, 3 cm, and 2 cm. Our results showed that the Murphee efficiencyobtained by the variation of the packing height of 5 cm, 3 cm, 2 cm and without packing were 73.5%, 66.27%,56.86%, and 46.7% respectively, and were increased by subsequent level of the packing height. Thecorresponding hydrodynamic properties of this appended packing sieve tray distillation by means of theinterfacial area were 11.88 cm2/cm3, 0.48 cm2/cm3, and 0.32 cm2/cm3, while its pressure drop measured from thewater manometer height were 38.33 cm H2O/m, 30 cm H2O/m, 10 cm H2O/m for the packing height of 5 cm, 3cm, 2 cm height, respectively. The increasing of the performance of appended packing sieve tray distillation bymeans of the Murphee efficiency is explained by the increasing of the interfacial area for vapour-liquid than thetray itself. This preliminary study is expected to be a pioneer study of strategy to increase the performance ofconventional sieve tray distillation that is known as a kind of affordable distillation process.