基于CFD的氢系统中冷器在不同工况与流动对齐条件下的传能强化热液性能分析

Abstract Thermal management in hydrogen fuel cell systems is critically important for system efficiency and durability, and the optimization of intercoolers directly affects the performance of these systems. In this study, the thermal–hydraulic performance of crossflow water-cooled intercoolers used in hydrogen fuel cell systems was comprehensively investigated using a three-dimensional computational fluid dynamics (CFD) approach under various fin geometries, placement configurations, and operating conditions. Parametric analyses were carried out for triangular and I-shaped fin structures, arranged in vertical and horizontal configurations, at air inlet temperatures of 353 K and 373 K, and air velocities ranging from 1 to 12 m/s, spanning laminar to transitional flow regimes. The numerical model was validated against experimental data available in the literature, and the mean absolute percentage error was calculated as 10.4 %. The results revealed that, at an air inlet temperature of 373 K, the I-shaped fin configuration with vertical placement exhibited the highest total heat transfer ( Q̇ ) and heat flux ( q″ ) values across all flow regimes. At high Reynolds ( Re ) numbers within the transitional regime, this configuration provided approximately 35 % higher heat transfer performance compared to the triangular fin structures. Nusselt ( Nu ) number, Stanton ( St ) number, and enthalpy values also improved with increasing Re number in a similar manner. In terms of the trade-off between heat transfer and pressure drop, the horizontally placed I-shaped configuration offered the highest j/f ratio, especially in the laminar flow regime, thus representing an advantageous alternative in terms of energy efficiency. Thermal efficiency analyses indicated that systems operating at an air inlet temperature of 373 K achieved on average 20–30 % higher heat transfer rates compared to those operating at 353 K. The data obtained demonstrated that optimizing fin geometry and placement configuration can significantly enhance system performance in the thermal management of hydrogen fuel cell systems.