Solutions

Fuel Cell System Modeling

Design and validate fuel cell systems with GT-SUITE, from air and hydrogen flow to cooling and power management.

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Solution Overview

Range Of Capabilities

Combining industry leading productivity tools and collaboration features with advanced multi-physics modeling capabilities, GT-SUITE can be used throughout the entire product development process.

GT-SUITE integrates flow, thermal, chemical, and electrical solutions to enable complete modeling of the Balance of Plant and Vehicle Systems, such as air compression and humidification, hydrogen storage and recirculation, cooling systems, power management controls, and more.

The flexible range of fidelity provides an ideal simulation environment for system design, component selection, and controls optimization.

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Application Highlights

Modeling the Complete Fuel Cell System

  • Model any fuel cell system configuration using GT-SUITE’s object-oriented model building architecture, without being constrained by predefined topologies
  • Design and evaluate all key balance-of-plant components, including fuel cell stacks, compressors, pumps, humidifiers, ejectors, heat exchangers, and tanks, within a single integrated environment
  • Optimize water management, thermal regulation, stoichiometry, and pressure control simultaneously, reflecting the coupled nature of real system behavior
  • Perform drive-cycle analysis to develop power management strategies and size battery systems, ensuring drivability, fuel economy, and reliability across real-world operating conditions
  • Operate at the right combination of fidelity and computational speed to capture critical transient phenomena, including flooding, starvation, and hot spots
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Advanced Modeling Capabilities

GT-SUITE supports higher-fidelity analysis with real-time simulation, hardware-in-the-loop testing, degradation modeling, and multi-domain co-simulation for the most demanding fuel cell development needs.

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Multi-Technology Platform: PEMFC, SOFC, and Electrolysis

One platform for the full technology spectrum, from automotive fuel cells to stationary power and hydrogen production.

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Predictive Electrochemistry and Degradation Modeling

Predict long-term catalyst and membrane degradation from a measured polarization curve, and see peak performance and lifetime reliability in one model.

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Full Vehicle and Drive Cycle Integration

Connect the stack to powertrain, electrical, and cooling systems for complete drive cycle simulation, including altitude and temperature effects.

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Real-Time Capable and XiL Compatible

Move from system-level simulation to controller validation with HiL/SiL-ready models, no rebuilding required.

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3D-to-1D Model Generation with GEM3D

Convert 3D CAD geometry into high-fidelity 1D models with GEM3D, capturing flow field effects without manual modeling.

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Ready-to-Use Component Templates for Balance of Plant

Pre-built templates for humidifiers, ejectors, compressors, and heat exchangers, plus a built-in fluid library for any configuration.

Fuel Cell System Modeling FAQs

Frequently asked questions about fuel cell system modeling and simulation.

  • Can GT-SUITE model the full fuel cell system, or just the stack?

    The complete fuel cell system, from individual cell and stack through the full balance of plant and integrated vehicle or power system, lives in one environment with GT-SUITE. Air and hydrogen handling, cooling circuits, water management, and power management controls all work together, with no need to stitch together separate tools.

  • What if I do not have detailed stack data from my supplier?

    GT-SUITE is built to handle this. You can start from a measured polarization curve if that’s what’s available, or use physical MEA property inputs if you have more detail. The example models are a practical starting point that scales to your stack size and refines as supplier data becomes available.

  • How does GT-SUITE handle water management?

    In more depth than most system-level tools. Water production, condensation in channels and pipes, liquid separation and purging, and two-phase flow effects are all modeled. Crossover of water, nitrogen, hydrogen, and oxygen is also captured, which matters for membrane hydration and long-term performance.

  • We are developing controls — Can GT-SUITE support that work?

    Yes. Real-time modeling and XiL compatibility mean the same model supports both system design and hardware-in-the-loop testing. GT-SUITE includes an out-of-box cathode stoichiometry controller, and the Fuel Cell Model Builder provides a working balance of plant model with controllers already in place.

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