Analysis of Flow Channel Geometry and Flow Configuration on the Thermal and Electrochemical Performance of an Anion Exchange Membrane Water Electrolyzer

This study investigates the impact of flow channel geometry on the performance and thermal management of the anion exchange membrane water electrolyzer (AEMWE) system. The research combines 3D numerical simulation with experimental analysis, evaluating parallel, mesh‐like, and serpentine channels across both coflow and counter‐flow operating configurations. The serpentine and straight channels were prone to localized hotspots and current density concentration, whereas the mesh channel demonstrated superior uniformity and effective heat dissipation capability. Counter‐flow operation showed a distinct performance improvement, effectively mitigating concentration polarization and localized heat accumulation compared to coflow. The simulated straight channel outlet temperature (328.3 K) was in close agreement with the experimental measurement (55.02°C), with an error of only about 0.51%, confirming the model's high accuracy. Experimental tests conducted across 60%–100% hydrogen production efficiency revealed that as efficiency increased, the stack outlet temperature rose from 53.55°C to 55°C. Correspondingly, heat loss increased from 0.36 kW at 60% efficiency to 0.75 kW at 100%. The results of this study provide a theoretical foundation and practical value for the future development of flow channel design optimization and thermal management mechanisms in AEMWE electrolyzers, enhancing their feasibility in green hydrogen applications.