CONTENTS

TOPICS PAGE NO

1. ABSTRACT.……………………………………………………………………………...3

2. INTRODUCTION………………………………………………………………………..4

3. LITERATURE REVIEW……………………………………………………………….5

4. PARTS NEED FOR HYDROGEN GENERATOR…………………………………..8

5. PROPERTIES OF HYDROGEN……………………………………………………….9

5.1 ATOMIC STRUCTURE………………………………………………………………………..9

5.2 PHYSICAL PROPERTIES…………………………………………………………...12

5.2.1 STATE………………………………………………………………………………………………....12

5.2.2 ODOR, COLOR AND TASTE………………………………………………………………………...14

5.2.3 TOXICITY……………………………………………………………………………………………..15

5.2.4 DENSITY AND RELATED MEASURES ………………………………………................................15

5.2.5 LEAKAGE……………………………………………………………………………………………..18

5.3 CHEMICAL PROPERTIES …………………………………………………………..19

5.3.1\REACTIVITY…………………………………………………………………………………………..19

5.3.2 ENERGY………………………………………………………………………………………………..20

5.3.3 FLAMMABILITY…………………………………………………………………………...................21

5.3.4 HYDROGEN EMBRITTLEMENT……………………………………………………………………21

6. EXPERIMENTAL CALCULATION BY ORSAT APPARATUS………………….22

7. ADVANTAGES……………………………………………………………………….....26

8. DISADVANTAGES……………………………………………………………………...26

9. SAFETY PRECAUTION………………………………………………………………..27

10. DESCRIPTION OF DIFFERENT PARTS ………………………………………….28

1
 9.1. CONTACT BREAKER……………………………………………………………………...28

9.2 .LED…………………………………………………………………………………………..28

9.3. BUBBLER ………………………………………………………………………………......29

11. DESIGN FEATURES USED IN THE GENERATOR………………………………30

12. BRIEF DESCRIPTION ON PARTS NEED FOR MAKING GENERATOR…….31

13. BUBBLER CONNECTIONS CLOSE UP…………………………………………….32

14. CONSTUCTION OF BUBBLER ……………………………………………………..47

15. HOW THE GENERATOR IS CONNECTED TO THE ENGINE………………….50

16. HOW TO POWER THE HYDROGEN GENERATOR …………………………….50

17. SETTING UP THE WATER IN THE GENERATOR……………………………….51

18. INSTALLING THE GENERATOR…………………………………………………..52

19. OUTPUT HOSE AND BUBBLER…………………………………………………….55

20. ADDITIONAL STUFF…………………………………………………………………59

21. THE COMPLETE INSTALLATION PICTURE…………………………………… 60

22 CONCLUSIONS................................................................................................................60

23 GROUP WORK ACTIVITIES…………………………………………………………61

24. REFERENCE…………………………………………………………………………...61

2
 1. ABSTRACT
A hydrogen generation apparatus according to the present invention includes: a

hydrogen generator configured to generate a fuel gas through a reforming reaction by using a

raw fuel; a combustor configured to heat the hydrogen generator; an on-off valve configured

to open/block a gas passage through which the gas that is sent out from the hydrogen

generator is supplied to the combustor; a combustion air supply device configured to supply

combustion air to the combustor; an ignition device provided at the combustor; and a

controller.

In a case where flame extinction has occurred at the combustor during generation

of a hydrogen-containing gas in a start-up process, the controller performs an ignition

operation of the ignition device with the on-off valve kept opened.

Fig.1 [Circuit diagram of hydrogen generator booster]

3
2. HYDROGEN GENERATOR BOOSTER
INTRODUCTION

The Hydrogen Generator is a piece of equipment which when installed correctly

can increase the mpg performance of a car or motorcycle, or truck and reduces the harmful

emissions dramatically.

It does this by using some current from the cars battery and alternator to

fracture water into a mixture of hydrogen and oxygen gasses called HHO hydroxy gas which

is then added to the air which is being drawn into the engine.

The HHO gas improves the quality of the fuel burn inside the engine cylinders,

this can increase the engine power, cleans old carbon deposits off the inside of an old engine,

reduces the unwanted exhaust emissions or smog and can improve the miles per gallon that

your vehicle gets. Provided that the fuel computer does not try to pump excess fuel into the

engine when it detects the much extra oxygen in the exhaust and the improved quality of the

exhaust.

This hydrogen generator is easy to make and the components don‘t cost much.

The hydrogen output the generator is very good as it produces 1.7 to 2.0 litres of HHO gas

per minute at a manageable amp current load. This is how to make and use it.

4
3.LITERATURE REVIEW

We need to stop burning fossil fuels. If we do so, it leaves us with two problems,
namely, a way to generate power to run our electrical equipment and heat or cool our homes,
and a way to power our vehicles. In this document, we will consider the question of
powering vehicles.
There are two main options.
The first is to achieve a reduction in the amount of fossil fuel burnt. The second is to
eliminate the use of fossil fuel altogether. Both have been achieved. As an example of the
first option, consider a car powered by a petrol (gasoline) engine. In the average car, only
35% or so of the fuel is burnt in the cylinders of the engine, the remaining 65% burns in the
catalytic converter or is pushed, unburnt, out of the exhaust pipe as major pollution.

Reducing the fuel used:

It is possible to reduce the amount of fuel used, by utilising any or all of the following:
1. Improving the quality of the burn.
2. Reducing the amount of fuel in the cylinder.
3. Introducing water vapour into the cylinder.
4. Improving the quality of the spark.
5. Improving the streamlining of the vehicle

1). The burn quality can be improved dramatically by replacing some or all of the air drawn
into the engine, by a mixture of hydrogen and oxygen. This can be done by sacrificing a
small amount of engine power to drive an electrolyser to split water into the hydrogen/oxygen
mix needed, passing it through a safety ‗bubbler‘ and feeding the gas into the air intake of the
engine. This causes a dramatic improvement to the burn, increases the power of the engine,
reduces the pollution and improves the miles per gallon achieved.
2). The fuel mix can be made leaner. If more air is used, the engine will run hotter. If a
hydrogen/oxygen (―hydroxy‖) mix is used, then there is a general improvement all round. If
the vehicle has computer control of the fuel/air mix, it is necessary to add an extra circuit to
prevent the computer injecting more fuel to offset the leaner mix required, and the companion
document D17.pdf explains in considerable detail how to do this.

5
3). Adding water vapour to the air intake can give a 25% improvement in the miles per
gallon.
4). If the power of the spark is increased by adding extra circuitry to the electrical system,
the fuel burn is improved. However, this tends to lead to greater plug wear. The
―Firestorm‖ plug gives a major improvement in burn quality

5) the car, and/or other passive devices can give a major improvement in fuel consumption
through reduced the car, and/or other passive devices can give a major improvement in fuel
consumption through reduced wind pressure.

If using hydroxy gas to improve the burn quality and improve the mpg of a vehicle, no
timing adjustments are normally necessary. However, all recent cars in the USA are fitted
with an Electronic Control Unit and if nothing is done about that, a decrease in mpg may
actually occur as the Controller may start pumping more fuel into the engine when it sees a
change in the quality of the exhaust

Stanley Meyer.

On 17th December 1995, the Channel 4 television series ‗Equinox‘ ran a programme
which included an interview with Stanley Meyer of Ohio, USA. I watched Stan demonstrate
a new method of separating water into its components of hydrogen and oxygen. His method
is some 17 times more efficient than conventional electrolysis. With conventional
electrolysis, the temperature of the water (plus additives to help the process) rises
substantially during the process. With Stan‘s method, the water temperature does not rise at
all and no additives are needed. This strongly suggests that his method utilises zero-point
energy to provide the extra power needed to break down the water. Zero-point energy shows
a temperature drop as the current increases.

Stan received several patents covering his process, including US 4,798,661;

4,936,961; 4,826,581; 4,798,661 and 4,613,304. His first patent was very difficult to obtain
as the US Patent Office said it was impossible to do and demanded to see a working model.
Stan gave them a demonstration but even then, they took a further three years of stalling
before they issued the patent.

6
Henry Puharich.

Henry also used a pulsed signal to split water molecules in an efficient manner. His
technique is rather different in that he starts with a modulated audio sine-wave signal and
uses half-wave rectification to cut off the negative voltage components

Paulo Mateiro.

It is reported that water has been efficiently split by Paulo Mateiro, using the most
simple electrodes possible, with only 4.8 Volts from a 555 timer circuit. Different
frequencies from 200Hz to 1,100Hz have been used and for the cell in the test, the optimum
was 923Hz. The current was 300mA and the hydrogen production was so great that the
bubbles were almost tossing the water out of the top of the

Kiyoshi Inoue (Tokyo).

Kiyoshi has been granted US Patent 4,184,931 for an efficient pulsed electrolysis
system. His recommendation is for a pulse waveform which has an ―on‖ period of from 5
to 50 microseconds (500 microseconds at a push) and an ―off‖ time of 2 to 30 times the ―on‖
time. His circuit provides independent adjustment of both the ―on‖ and ―off‖ times (a
simple circuit to do this is in the electronics tutorial section of this set of documents).

Rothman Technologies.

Since 2003 Rothman Technologies of Canada have been running a 12HP petrol motor
on hydrogen produced by a chemical process. This is a cheap process in which metal is
consumed and so, although of great interest, this is not a ‗free-energy‘ engine. A recent
patent application by William Brinkley proposes a system where aluminium pipes are
consumed by a 25% solution of Potassium Hydroxide heated to 180 degrees Fahrenheit.
William remarks on the non-polluting nature of the system, but this is not really so in that a
very large amount of energy has to be put into producing the aluminium metal in the

7
smelting and refining process, and the pollution is just moved from the end user to the
industrial plant.

Francis Cornish of the UK has a system where electrolysis of water is combined with a
chemical process consuming aluminium wire. The system works well, but I have
reservations about using consumables which tie you to industrial manufacturing, also
concerns about the reliability of mechanical feed systems when they are being used by non-
technical people (most car drivers). There is also the issue of removing and recycling the
chemical residue generated by the process.

4 .PARTS NEED FOR HYDROGEN GENERATOR:

Part, Quantity, Comment:

 4-inch diameter PVC pipe, 12-inches long 1, this Forms the body of the generator.
 4-inch diameter PVC pipe end-cap 1, this Closes the bottom of the generator.
 4-inch diameter PVC pipe screw cap 1, this makes the top of the generator
 90-degree Quick Connect Outlet fitting 1 3/8" O.D. Tube x 14" NPT (from Hardware
store)
 Level indicator Nylon barbed tube fitting 2 1/4" Tube x 1/8" NPT (from your local
hardware store Lowes or home depot)
 Quarter-inch I.D. Poly sight tube 8‖ Water-level indicator tubing (from Hardware
store)
 Stainless steel switch covers 16 these make plate assembly
 components or stainless steel sheet metal flat pieces from eBay or steel yard
 Stainless steel straps 12-inches long 2 The electrical connections to the plates or
stainless steel utensils like spoons or forks from cooking supply stores or dept. stores
will work
 3/4" Inside Diameter Clear poly tube 12-inch From your local hardware store or

Lowes home depot

 5/16‖ stainless steel bolts 1.25‖ long 2 Electrical strap connection to the top cap.

 5/16‖ stainless steel nuts & washers 6 each To fit the steel bolts in the cap top.

 5/16‖ diameter nylon threaded rod 8‖ min.

 Nylon Threaded Rod 5/16"-18 Thread. 2 needed

8
  5/16‖ inch nylon washers 1.6 mm thick 1-pack Nylon 6/6 Flat Washer 5/16", pack of

100

 5/16‖-18 s/s jam nuts (1/4" thick) 20 needed

 90 degree Bubbler Fittings 2 1/4" Barbed Tube 1/2" NPT.

 Check valve 1 1/4" tube, aquarium shop or from your local Hardware store

 PVC glue 1 tube Same colour as the PVC pipe if possible

 5/16" Neoprene sealing washer 2 needed from the local Hardware store
 Tool dip – tool coating, it‘s a liquid plastic used to dip tool handles in, sold at all
hardware stores,
 Optional: Light Emitting Diode 1 10 mm diameter, red, with panel mounting clip
 Quarter-watt resistor 1 470 ohm (code bands: Yellow, Purple, Brown)

5. PROPERTIES OF HYDROGEN

5.1 ATOMIC STRUCTURE:

Hydrogen is by far the most plentiful element in the universe, making up 75% of the mass
of all visible matter in stars and galaxies. Hydrogen is the simplest of all elements. We can
visualize a hydrogen atom as a dense central nucleus with a single orbiting electron, much
like a single planet in orbit around the sun. Scientists prefer to describe the electron as
occupying a ―probability cloud‖ that surrounds the nucleus some-what like a fuzzy, spherical
shell. In most hydrogen atoms, the nucleus consists of a single proton, although a rare form
(or ―isotope‖) of hydrogen contains both a proton and a neutron. This form of hydrogen is
called deuterium or heavy hydrogen. Other isotopes of hydrogen also exist, such as tritium
with two neutrons and one proton, but these isotopes are unstable and decay radioactively.

Most of the mass of a hydrogen atom is concentrated in its nucleus. In fact, the proton is
more than 1800 times more massive than the electron. Neutrons have almost the same mass
as protons. However, the radius of the electron‘s orbit, which defines the size of the atom, is
approximately 100,000 times as large as the radius of the nucleus! Clearly, hydro-gen atoms
consist largely of empty space. Atoms of all elements consist largely of empty space,
although all others are heavier and have more electrons.

9
 HYDROGEN MOLECULE (H2)

Electron Probability Cloud

Nuclei

Fig.2. [Atomic Structure of a Hydrogen Molecule]

A proton has a positive electrical charge, and an electron has a negative electrical
charge. Neutrons do not carry a charge. Together, the charges associated with the proton and
electron of each hydrogen atom cancels each other out, so that individual hydrogen atoms are
electrically neutral.

Chemically, the atomic arrangement of a single electron orbiting a nucleus is highly

reactive. For this reason, hydro-gen atoms naturally combine into molecular pairs (H2 in-stead
of H). To further complicate things, each proton in a hydrogen pair has a field associated with
it that can be visualized and described mathematically as a ―spin‖. Molecules in which both
protons have the same spin are known as ―ortho-hydrogen‖. Molecules in which the protons

10
have opposite spins are known as ―Para hydrogen‖. Over 75% of normal hydrogen at room
temperature is ortho-hydrogen.

This difference becomes important at very low temperatures since orthohydrogen

becomes unstable and changes to the more stable Para hydrogen arrangement, releasing heat
in the process. This heat can complicate low temperature hydrogen processes, particularly
liquefaction.

COMPOSITION OF OTHER FUELS:

It is natural for us to compare hydrogen to other hydrocarbon fuels with which we are
more familiar. All hydrocarbon fuels are molecular combinations of carbon and hydrogen
atoms. There are thousands of types of hydrocarbon com-pounds, each with a specific
combination of carbon and hydrogen atoms in a unique geometry.

fIg.3. [Chemical Structure of Common Fuels]

The simplest of all hydrocarbons is methane, which is the principal constituent of natural
gas. (Other components of natural gas include ethane, propane, butane and pentane as well as

11
impurities.) Methane has the chemical formula CH4, which means that each molecule has
four hydrogen atoms and one carbon atom.

Other common hydrocarbons are ethane (C2H6), propane (C3H8) and butane (C4H10). These
are all considered light hydrocarbons since they contain less than five carbon atoms per
molecule and therefore have low molecular weight (a carbon atom is almost 12 times as
heavy as a hydrogen atom).

Gasoline is composed of a mixture of many different hydro-carbons, but an important

constituent is heptane (C7H16). Gasoline, diesel, kerosene, and compounds found in asphalt,
heavy oils and waxes, are considered heavy hydrocarbons as they contain many carbon atoms
per molecule, and therefore have high molecular weight.

The lightest hydrocarbons are gases at normal atmospheric pressure and temperature.
Heavier hydrocarbons, with 5 to 18 carbon atoms per compound, are liquid at ambient
conditions and have increasing viscosity with molecular weight. Other chemical fuels include
alcohols whose molecules com-bine an oxygen/hydrogen atom pair (OH) with one or more
hydrocarbon groups. Common alcohol fuels are methanol (CH3OH) and ethanol (C2H5OH).

5.2 PHYSICAL PROPERTIES

5.2.1 STATE

All substances exist on earth as either a gas, liquid or solid. Most substances will
change from one of these states to another depending on the temperature and pressure of their
surroundings. In general, a gas can be changed into a liquid by reducing its temperature, and
a liquid to a solid by reducing its temperature further. To some extent, an increase in pressure
will cause a substance to liquefy and solidify at higher temperature than would otherwise be
required.

The transition from liquid to gas is known as boiling and the transition from liquid to
solid as freezing. Accordingly, each substance has a characteristic boiling temperature and
freezing temperature (at a given pressure). The opposite transitions, from gas to liquid and
solid to liquid, are known as condensation and melting respectively.

12
 The condensation temperature is the same as the boiling temperature and the melting
temperature is the same as the freezing temperature. The process of condensation is also
known as liquefaction and the process of freezing is also known as solidification.

Boiling and freezing temperatures are most meaningfully compared relative to

―absolute zero‖. Absolute zero (0 ºR; 0 K; –459.69 ºF; –273.15 ºC) is the lowest temperature
in the universe at which all molecular motion stops.

Hydrogen has the second lowest boiling point and melting points of all substances,
second only to helium. Hydrogen is a liquid below its boiling point of 20 K (–423 ºF; –253
ºC) and a solid below its melting point of 14 K (–434 ºF; –259 ºC) and atmospheric pressure.
Obviously, these temperatures are extremely low. Temperatures below –100 ºF (200 K; –73
ºC) are collectively known as cryogenic temperatures, and liquids at these temperatures are
known as cryogenic liquids.

The boiling point of a fuel is a critical parameter since it defines the temperature to
which it must be cooled in order to store and use it as a liquid. Liquid fuels take up less
storage space than gaseous fuels, and are generally easier to transport and handle. For this
reason, fuels that are liquid at atmospheric conditions (such as gasoline, diesel, methanol and
ethanol) are particularly convenient.

The boiling point of a pure substance increases with applied pressure—up to a point.
Propane, with a boiling point of –44 ºF (–42 ºC), can be stored as a liquid under moderate
pressure, although it is a gas at atmospheric pressure. (At temperatures of 70 ºF (21 ºC) a
minimum pressure of 111 psig (7.7 bar) is required for liquefaction). Unfortunately, hydro-
gen‘s boiling point can only be increased to a maximum of -400 ºF (–240 ºC) through the
application of approximately 195 psig (13 bar), beyond which additional pressure has no
beneficial effect.

13
 5.2.2 Odour, Colour and Taste
Pure hydrogen is odourless, colourless and tasteless. A stream of hydrogen from a
leak is almost invisible in daylight. Com-pounds such as mercaptans and theophany‘s that are
used to scent natural gas may not be added to hydrogen for fuel cell use as they contain
sulphur that would poison the fuel cells.

Hydrogen that derives from reforming other fossil fuels is typically accompanied by
nitrogen, carbon dioxide, carbon monoxide and other trace gases. In general, all of these
gases are also odourless, colourless and tasteless.

5.2.3 Toxicity
Hydrogen is non-toxic but can act as a simple asphyxiate by displacing the oxygen in the
air.

Asphyxiation
Oxygen levels below 19.5% are biologically inactive for humans. Effects of oxygen
deficiency may include rapid breathing, diminished mental alertness, impaired muscular
coordination, faulty judgement, depression of all sensations, emotional instability and fatigue.
As asphyxiation progresses, dizziness, nausea, vomiting, prostration and loss of
consciousness may result, eventually leading to convulsions, coma and death. At
concentrations below 12%, immediate unconsciousness may occur with no prior warning
symptoms.

In an enclosed area, small leaks pose little danger of asphyxiation whereas large leaks
can be a serious problem since the hydrogen diffuses quickly to fill the volume. The potential
for asphyxiation in unconfined areas is almost negligible due to the high buoyancy and
diffusivity of hydro-gen.

Inhaled hydrogen can result in a flammable mixture within the body.

Inhaling hydrogen can lead to unconsciousness and asphyxiation.

Other Gases Accompanying Hydrogen

Gases that accompany hydrogen when reforming other fossil fuels, such as nitrogen,
carbon dioxide, carbon monoxide and other trace gases, can also act as asphyxiates by dis-

14
 placing oxygen. In addition, carbon monoxide is a poisonous gas that is a severe health
hazard.

Carbon Monoxide
The affinity of haemoglobin (in the blood) for carbon monoxide is 200–300 times
greater than its affinity for oxygen. As a result, inhalation of carbon monoxide quickly
restricts the amount of oxygen in the bloodstream and asphyxiation en-sues. Asphyxiation
can continue for some time after a victim is moved to fresh air.

Depending on levels and duration of exposure, the symptoms may include headache,
dizziness, heart palpitations, weakness, confusion, or nausea, leading to convulsions, eventual
unconsciousness and death. With repeated long-term overexposures, carbon monoxide can
damage the central nervous system and possibly lead to hardening of arteries. Since carbon
monoxide is odourless, colourless and tasteless, there is no warning of its presence other than
the symptoms it causes.

Published exposure limits vary somewhat depending on the regulating body. Typical
values state that exposure to carbon monoxide becomes a health hazard when it exceeds the
time weighted average of 25 molar ppm over 8 hours, or 100 molar ppm over 15 minutes. An
exposure of 1200 ppm poses immediate danger without warning symptoms.

Carbon monoxide is poisonous.

Carbon monoxide is flammable over a very wide range of concentrations in air (12.5
– 74%). As a result, even small leaks of carbon monoxide have the potential to burn or
explode. Leaked carbon monoxide can concentrate in an en-closed environment, thereby
increasing the risk of combustion and explosion. The auto ignition temperature of carbon
monoxide is 609 °C (1128 °F). Carbon monoxide has almost the same density as air and will
therefore not diffuse by rising. Carbon monoxide burns with a characteristic blue flame.

5.2.4 Density and Related Measures

Hydrogen has lowest atomic weight of any substance and therefore has very low density
both as a gas and a liquid.

15
Density
Density is measured as the amount of mass contained per unit volume. Density values
only have meaning at a specified temperature and pressure since both of these parameters
affect the compactness of the molecular arrangement, especially in a gas. The density of a gas
is called its vapour density, and the density of a liquid is called its liquid density

Substance Vapour Density (at 68 Liquid Density (at

ºF; 20 ºC, 1 atm) normal boiling point, 1
atm)

3
Hydrogen 0.005229 lb/ft (0.08376
3 4.432 lb/ft3 (70.8 kg/m3)
kg/m )

3 3 3
Methane 0.0406 lb/ft (0.65 kg/ 26.4 lb/ft (422.8 kg/m )

3 3
Gasoline 3 3
0.275 lb/ft (4.4 kg/m ) 43.7 lb/ft (700 kg/m )

Table 1- [Vapour and Liquid Densities of Comparative Substances]

Specific Volume
Specific volume is the inverse of density and expresses the amount of volume per unit
3 3
mass. Thus, the specific volume of hydrogen gas is 191.3 ft /lb (11.9 m /kg) at 68 ºF (20 ºC)
3 3
and 1 atm, and the specific volume of liquid hydrogen is 0.226 ft /lb (0.014 m /kg) at –423 ºF
(–253 ºC) and 1 atm.

16
Specific Gravity
A common way of expressing relative density is as specific gravity. Specific gravity is
the ratio of the density of one substance to that of a reference substance, both at the same
temperature and pressure.

3 3
For vapours, air (with a density of 0.0751 lb/ft ; 1.203 kg/m ) is used as the reference
substance and therefore has a specific gravity of 1.0 relative to itself. The density of other
vapours are then expressed as a number greater or less than 1.0 in proportion to its density
relative to air. Gases with a specific gravity greater than 1.0 are heavier than air; those with a
specific gravity less than 1.0 are lighter than air.
3
Gaseous hydrogen, with a density of 0.00523 lb/ft , has a specific gravity of 0.0696 and
is thus approximately 7% the density of air.

3 3
For liquids, water (with a density of 62.4 lb/ft ; 1000 kg/m ) is used as the reference
substance, so has a specific gravity of 1.0 relative to itself. As with gases, liquids with a
specific gravity greater than 1.0 are heavier than water; those with a specific gravity less than
1.0 are lighter than water.

3
Liquid hydrogen, with a density of 4.432 lb/ft , has a specific gravity of 0.0708 and is
thus approximately (and coincidentally) 7% the density of water.

Hydrogen Content
Even as a liquid, hydrogen is not very dense. Ironically, every cubic meter of water
(made up of hydrogen and oxy-gen) contains 111 kg of hydrogen whereas a cubic meter of
liquid hydrogen contains only 71 kg of hydrogen. Thus, water packs more mass of hydrogen
per unit volume, be-cause of its tight molecular structure, than hydrogen itself. This is true of
most other liquid hydrogen-containing com-pounds as well; a cubic meter of methanol
contains 100 kg of hydrogen and a cubic meter of heptane contains 113 kg. Hydrocarbons are
compact hydrogen carriers with the added advantage of having higher energy density than
pure hydrogen.

When used as vehicle fuel, the low density of hydrogen necessitates that a large volume of
hydrogen be carried to provide an adequate driving ranges.

17
5.2.5 Leakage
The molecules of hydrogen gas are smaller than all other gases, and it can diffuse
through many materials considered airtight or impermeable to other gases. This property
makes hydrogen more difficult to contain than other gases. Leaks of liquid hydrogen
evaporate very quickly since the boiling point of liquid hydrogen is so extremely low.

Hydrogen leaks are dangerous in that they pose a risk of fire where they mix with air
. However, the small molecule size that increases the likelihood of a leak also results in very
high buoyancy and diffusivity, so leaked hydrogen rises and becomes diluted quickly,
especially out-doors. This results in a very localized region of flammability that disperses
quickly. As the hydrogen dilutes with distance from the leakage site, the buoyancy declines
and the tendency for the hydrogen to continue to rise decreases. Very cold hydrogen,
resulting from a liquid hydrogen leak, be-comes buoyant soon after is evaporates.

In contrast, leaking gasoline or diesel spreads laterally and evaporates slowly

resulting in a widespread, lingering fire hazard. Propane gas is denser than air so it
accumulates in low spots and disperses slowly, resulting in a protracted fire or explosion
hazard. Heavy vapours can also form vapour clouds or plumes that travel as they are pushed
by breezes. Methane gas is lighter than air, but not nearly as buoyant as hydrogen, so it
disperses rapidly, but not as rapidly as hydrogen. For small hydrogen leaks, buoyancy and
diffusion effects in air are often overshadowed by the presence of air currents from a slight
ambient wind, very slow vehicle motion or the radiator fan. In general, these currents serve to
disperse leaked hydrogen even more quickly with a further reduction of any associated fire
hazard.

18
 When used as vehicle fuel, the propensity for hydrogen to leak necessitates special care
in the design of the fuel system to ensure that any leaks can disperse with minimum
hindrance, and the use of dedicated leak detection equipment on the vehicle and within
the maintenance facility

5.3 Chemical Properties

5.3.1 Reactivity
High reactivity is characteristic of all chemical fuels. In each case, a chemical reaction
occurs when the fuel molecules form bonds with oxygen (from air) so that the final, reacted
molecules are at a lower energy state than the initial, unreacted molecules.

As the molecules react, the change in chemical energy state is accompanied by a

corresponding release of energy that we can exploit to do useful work. This is true in both a
combustive reaction (as in an internal combustion engine where the energy is released
explosively as heat) or in an electrochemical reaction (as in a battery or fuel cell where the
energy is released as an electrical potential and heat).

This chemical energy release is analogous to that which occurs when water flows from
a high level to a low level. The water at the high level has potential energy that is released as
it falls to the low level. This energy can be harnessed to do useful work, such as turning a
turbine.

Once at the low level, the energy is spent and it cannot do further work at that level. In
order to do further work, it must either fall to an even lower level, or be raised back to the
high level through some external agency that inputs energy.

5.3.2 Energy
Energy Content
Every fuel can liberate a fixed amount of energy when it reacts completely with oxygen
to form water. This energy fuel‘s higher heating value (HHV) and lower heating value
(LHV). The difference between the HHV and the LHV is the ―heat of vaporization‖ and
represents the amount of energy required to vaporize a liquid fuel into a gaseous fuel, as well
as the energy used to convert water to steam

19
 Higher Heating Value (at 25 ºC Lower Heating Value (at 25 ºC
and 1 atm) and 1 atm)
Fuel

Hydrogen
61,000 Btu/lb (141.86 kJ/g) 51,500 Btu/lb (119.93 kJ/g)

Methane 24,000 Btu/lb (55.53 kJ/g) 21,500 Btu/lb (50.02 kJ/g)

Propane 19,600 Btu/lb (45.6 kJ/g)

21,650 Btu/lb (50.36 kJ/g)

Gasoline 19,000 Btu/lb (44.5 kJ/g)

20,360 Btu/lb (47.5 kJ/g)

Diesel 19,240 Btu/lb (44.8 kJ/g) 18,250 Btu/lb (42.5 kJ/g)

[Table 2- Heating Values of Comparative Fuels]

The higher and lower heating values of comparative fuels are indicated in Table 1-3.
Although the terms HHV and LHV do not apply to batteries, the energy density of a lead acid
battery is approximately 46 Btu/lb (0.108 kJ/g).

Gaseous fuels are already vaporized so no energy is required to convert them to a gas.
The water that results from both a combustive reaction and the electrochemical reaction
within a fuel cell occurs as steam; therefore the lower heating value represents the amount of
energy available to do external work.

Both the higher and lower heating values denote the amount of energy (in Btu‘s or
Joules) for a given weight of fuel (in pounds or kilograms). Hydrogen has the highest energy-
to-weight ratio of any fuel since hydrogen is the lightest element and has no heavy carbon
atoms. It is for this reason that hydrogen has been used extensively in the space pro-gram
where weight is crucial.

20
 Energy Density
Whereas the energy content denotes the amount of energy for a given weight of fuel,
the energy density denotes the amount of energy (in Btu‘s or Joules) for a given volume (in
3 3
ft or m ) of fuel. Thus, energy density is the product of the energy content (LHV in our case)
and the density of a given fuel.

The energy density is really a measure of how compactly hydrogen atoms are packed
in a fuel. It follows that hydro-carbons of increasing complexity (with more and more
hydrogen atoms per molecule) have increasing energy density. At the same time,
hydrocarbons of increasing complexity have more and more carbon atoms in each molecule
so that these fuels are heavier and heavier in absolute terms.

On this basis, hydrogen‘s energy density is poor (since it has such low density)
although its energy to weight ratio is the best of all fuels (because it is so light). The energy
density of comparative fuels, based on the LHV, is indicated in Table 1-4. The energy density
3 3
of a lead acid battery is approximately 8700 Btu/ft (324,000 kJ/m ).

5.3.3 Flammability
Three things are needed for a fire or explosion to occur: a fuel, oxygen (mixed with the
fuel in appropriate quantities) and a source of ignition. Hydrogen, as a flammable fuel, mixes
with oxygen whenever air is allowed to enter a hydro-gen vessel, or when hydrogen leaks
from any vessel into the air. Ignition sources take the form of sparks, flames, or high heat.

Flashpoint
All fuels burn only in a gaseous or vapour state. Fuels like hydrogen and methane are
already gases at atmospheric conditions, whereas other fuels like gasoline or diesel that are
liquids must convert to a vapour before they will burn. The characteristic that describes how
easily these fuels can be converted to a vapour is the flashpoint. The flashpoint is defined as
the temperature at which the fuel produces enough vapours to form an ignitable mixture with
air at its surface.

If the temperature of the fuel is below its flashpoint, it can-not produce enough vapours
to burn since its evaporation rate is too slow. Whenever a fuel is at or above its flashpoint,

21
vapours are present. The flashpoint is not the temperature at which the fuel bursts into flames;
that is the auto ignition temperature.

The flashpoint is always lower than the boiling point. For fuels that are gases at atmospheric
conditions (like hydro-gen, methane and propane), the flashpoint is far below ambient temperature
and has little relevance since the fuel is already fully vaporized. For fuels that are liquids at
atmospheric conditions (such as gasoline or methanol), the flash-point acts as a lower flammability
temperature limit.

5.3.4 Hydrogen Embrittlement

Constant exposure to hydrogen causes a phenomenon known as hydrogen
embrittlement in many materials. Hydrogen embrittlement can lead to leakage or catastrophic
failures in metal and non-metallic components.

The mechanisms that cause hydrogen embrittlement effects are not well defined.
Factors known to influence the rate and severity of hydrogen embrittlement include hydrogen
con-centration, hydrogen pressure, temperature, hydrogen purity, type of impurity, stress
level, stress rate, metal composition, metal tensile strength, grain size, microstructure and
heat treatment history. Moisture content in the hydrogen gas may lead to metal embrittlement
through the acceleration of the formation of fatigue cracks

6. EXPERIMENTALCALCULATION BY ORSAT APPARATUS:

The main components of the apparatus are:

 Burette used to measure volume of the flue gas sample.
 Bottle with coloured water, used as a driving medium by application of hydrostatic
force.
 Two or three absorption bottles with capillary tubes where the individual
components of the flue gas are absorbed.
 Block of valves providing access to individual absorption bottles.
 Three-way valve allowing connecting the burette to the incoming flue gas line or to
the ambient air.

22
The general working principle is as follows:
 Certain amount of dry flue gas is delivered to the burette
 Flue gas is pumped to consecutive absorption bottles where individual flue gas
components are absorbed. After absorption of each component, the volume of
remaining gas mixture is verified, thus allowing determining volumes of individual
components.
 Each apparatus at the Thermodynamics Laboratory has two absorption bottles:
 Bottle filled with potash lye (3), which absorbs carbon dioxide
 Bottle filled with pyro Gallic acid solution (4), which absorbs oxygen.

After CO2 and O2 are absorbed, CO content may be determined using an Ostwald‘s diagram
for the specific fuel. It could also be determined using a third reagent.

Fig no.4.[ORSAT APPARATUS]

23
PROCEDURE:
 Open the atmospheric valve and collect the red solution in burette up to 100ml and
close the valve.
 Now collect the exhaust gas of an automobile enters to the burette by closing
atmospheric valve and solution valves.
 Now raise the outside beaker up to the level of 100ml in burette, so that the exhaust
gas be outside the burette.
 Now open the solution valve & allowed to mix with first solution up to 1 minute.
Now lower the outside beaker and match with the level. Now calculate the difference
reading in the burette. Suppose initial burette reading is 100ml and after balancing the
burette the reading is 96 ml. then 100-96=4ml is of co2 is present.
 Similarly continue the experiment for 2nd & 3rd solution and calculate the content of
CO & O2.

CHEMICALS REQUIRED:

1.NaoH 2.KOH 3.CUCL 4.pyro Gallic

acid
5.Concent.HCL 6.Methyl Orange 7.concent.H2SO4 8.H2O

24
6.1. Exhaust gas Analysis (Without Hydroxy gas)

Initial After Final Absorbent Value of Absorbent Value of Absorbent Value of

Burette exhaust Burette Reading CO reading CO2 reading O2
Reading gas Reading for CO absorbed for CO2 absorbed for O2 absorbed
(ml) entering (ml) in burette In In In In in
(ml) (ml) burette(ml) burette(ml) burette(ml) burette(ml) burette(ml)

100 54 46 52 52-46=6 50 48-46=2 54 50-46=4

6.2. Exhaust gas Analysis (With Hydroxy gas)

Initial After Final Absorbent Value of Absorbent Value of Absorbent Value of

Burette exhaust Burette Reading CO reading CO2 reading O2
Reading gas Reading for CO absorbed for CO2 absorbed for O2
absorbed
(ml) entering (ml) in burette In In In In
(ml) (ml) in
burette(ml) burette(ml) burette(ml) burette(ml)
burette(ml)

100 48 52 49.5 49.5- 48.5 48.5- 54.5 54.5-

48=1.5 48=0.5 48=6.5

TABLE NO-4

6.3. Fuel Consumption Time Analysis:

Petrol in (litre) HHO Gas Time Consumption

1litre Without use of HHO gas 1hour 20minutes
1litre With use of HHO gas 1hour 35 minutes

TABLE NO-5

25
7. ADVANTAGES
1) They improve gas mileage.

2) They slowly clean out carbon deposits out of your engine.

3) The added hydrogen/oxygen produced acts like a catalysis to your fuel, a more complete
burn and slightly cooler. The cell creates a clear clean more combustion able air, right into
your air stream, so it is the safest addition of any added voltage gas to a car or truck, on the
planet.

4) Add a FREE 120 octane booster to your air/fuel mix.

5) The ortho hydrogen and ortho oxygen created breaks apart the hydro-carbon chain of
molecules, leaving a much cleaner emission.

6) Increases horsepower.

7) Will NOT damage your engine, all your doing is adding more combustion air to the air
intake.

8.DISADVANTAGES
1) Hydrogen is a dangerous substance to handle. It‘s molecules are small enough to permeate
through materials generally thought to be suitable for containing gases.

2) It can make metals brittle.

3) It is considered a ‗green‘ fuel because when it is burnt with oxygen, it does not produce
carbon dioxide. While this is true, it is not the whole picture.

4) Hydrogen burnt with oxygen produces a flame inconveniently hot and in mobile
applications, we have to carry the oxygen around as well as the hydrogen. Unfortunately, the
flame temperature can be lowered conveniently by burning the hydrogen in air, which also
dispenses with the need to carry the oxygen around.

26
5) Burning hydrogen in air or an oxygen/air mixture produces nitrous oxide which is a major
pollutant - and if you do that, it is no longer a ‗green‘ fuel (although it produces less pollution
than petrol & diesel).

9.SAFETY PRECAUTION
Before getting into the details of how to construct the booster, you must be aware
of what needs to be done when using a hydrogen generator of any design. Firstly, hydroxyl
HHO gas is highly explosive.
If it wasn‘t, it would not be able to do its job of improving the gas mileage your
vehicle is getting; hydroxy gas needs to be treated with care and caution. It is important to
make sure that it goes into the engine as designed and nowhere else. It is also important
that it gets ignited inside the engine and nowhere else.
To make this happen, a number of common-sense steps need to be taken.
Firstly, the hydrogen generator must not make hydrogen gas when the engine is not running.
The best way to arrange this is to switch off the electricity going to the booster.
It is not enough to just have a manually-operated dashboard On/Off switch as it
is almost certain to be forgotten one day. And the generator will be left on making gas while
the engine is off Instead, the electrical supply to the booster is sent through the ignition
switch of the car. That way, when the engine is turned off, we can be sure that the hydrogen
generator is turned off.
So as not to put too much amp load through the ignition switch, and to allow for
the possibility of the ignition switch being on when the engine is not running, instead of
wiring the hydrogen generator directly to the switch, it is recommended that you wire a
standard automotive relay across the oil pressure sending unit and then the relay carry the
amp load electricity. The fuel pump is powered down automatically when the key is off, and
so this will also shut off the hydrogen generator.
An extra safety feature is to allow for the (very unlikely) possibility of an electrical
short-circuit occurring in the Hydrogen generator or its wiring. This is done by putting a fuse
or contact-breaker between the battery and the new wiring you are installing as shown in the
sketch.

27
 Fig.5 [ BLOCK DIAGRAM OF A HYDROGEN GENERATOR]

10.DESCRIPTION OF DIFFERENT PARTS :

As shown above the fig., the hydrogen generator contains a number of metal plates
and the electricity passing through the water inside the generator between the plates, causes
the water to fracture into HHO GAS.
 CONTACT BREAKER:
We can choose to use a contact-breaker, and a light-emitting diode (―LED‖)
with a current limiting resistor of 680 ohms in series with it, this can then be wired directly
across the contacts of the circuit breaker.

 LED:
The LED can then be mounted inside the car within view of the driver. As the
contacts are normally closed, they short-circuit the LED and so no light shows. If the circuit-
breaker is tripped, the LED will light up to show that the circuit-breaker is working. The
current through the LED is so low that the hydrogen generator is switched off when the
contact breaker opens.

28
 Fig.6. shows a bubbler, a gas pipe, and a water level indicator

 BUBBLER:
A very important safety item is the bubbler; the bubbler has a container with
some water in it. The bubbler has the HHO gas coming in at the bottom and bubbling up
through the water.
A bubbler is a very simple, very cheap and very easy and should be installed. It
also removes electrolyte fumes from the gas before it is passes into the engine.

29
 The HHO gas collects above the water surface and is then drawn into the engine
through an outlet pipe above the water surface. To prevent water being drawn into the
hydrogen generator when the hydrogen generator is off and cools down, a one-way valve is
placed in the pipe between the booster and the bubbler.
If the engine happens to produce a backfire, then the bubbler stops the flame fire
from going back through the tubing hose and igniting the gas being produced in the
generator. If the generator is made with a tightly-fitting lid rather than a screw-on lid, then if
the gas in the bubbler catches fire and burns back thru, it will just blow the lid off the bubbler
and Stop the flame.
We can notice that the wires going to the plates inside the electrolyser are both connected
well below the water line inside the generator.
This is to stop the possibility of a connection working loose while driving and
causing a spark in the HHO gas filled region above the surface of the water, and this volume
is kept as low as possible to aid in this cause.
11. DESIGN FEATURES USED IN THE GENERATOR

[PARTS OF HYDROGEN GENERATOR]

[Fig no-7]

30
12. A BRIEF DESCRIPTION ON PARTS NEED FOR MAKING

GENERATOR:

The hydrogen generator is made from a length of 4-inch diameter PVC pipe, two
caps, several metal plates, a couple of metal straps and some other various parts. Assembly is
fairly straight forward, and this hydrogen generator can be built by anybody.
There is a plastic tube added to the outside of the hydrogen generator, to show the
level of the water inside the generator, so you don‘t have to unscrew the cap.
Another nice thing is the compact see thru bubbler which is connected to the
generator side and shows the gas flow coming from the generator. The main PVC pipe length
can be adjusted to fit the space you have next to the engine.

Two different types of bubbler are shown:

Fig.8 [ PVC PIPES]

31
12.Bubbler connections close up :

[Fig.9]
The generator uses cheap, standard electrical stainless steel wall switch plate covers
from lowest or home depot or any hardware store and stainless steel straps, now you can cut
stainless strips from sheet metal 304 or 316L works well, or you can cut from the handles
stainless steel forks or spoons, buy them from any super market or kitchen supply store.

32
 Fig.10 [ELECTRICAL COVER PLATES]

The electrical cover plates are bolted together in a group of eight closely-
spaced pairs. That need to drill the holes out to a larger size to fit the nylon bolts, the next
step is optional, it‘s a lot of extra work for just a little more hydrogen, but we can chose to do
it if we wish. Just hold the plates down dent them using a centre-punch and hammer.
These indentations bring up the gas output from 1.5 lpm to 1.7 lpm as
the both increase the surface area of the cover plate and provide spots where from which the
gas bubbles can leave the cover more easily. The more dents the better.
The active surfaces of the plates - that is, the surfaces which are 1.6 mm apart from each
other, need to be Prepared with sand paper. To do this, these surfaces are scored in an X-
pattern using 36-grade coarse sandpaper.
When we done this, it creates small sharp-edged bumps covering the
entire side of each of these plates. This type of surface helps the HHO hydrogen bubbles
leave the surface as soon as they are formed.
It also increases the usable surface area of the plate by about 40%.
Now we have found fingerprints on the plates of any generator plates seriously slows down
the gas production this happens because we reduce the working area of the plate quite allot.
We need to avoid all fingerprints (by wearing clean rubber gloves) or clean the plates of all
grease and dirt, use a good solvent and then, wash that off afterwards with distilled water.

33
Wearing rubber gloves is the better choice; cleaning chemicals are not a good thing to be
applying to these stainless steel surfaces.

[Fig.11]

34
 Fig.12 [INDENTATIONS MADE ON STAINLESS PLATE ]

As shown in the above fig.. are the hand tools used to make the indentations on
the stainless plates. The active plate surfaces that is, the plate surfaces that are 1.6 mm apart –
are indented and then sanded.
The stack of the prepared stainless plates is hung inside a Tube cut from a 4-
inch (100 mm) diameter PVC pipe. The pipe is changed to a suitable container by using PVC
glue to secure an end-cap on one end of the pvc pipe and a screw-cap fitting glued onto the
other end.
The container then has the gas-supply pipe fitting elbow fitted to the cap top,
which is drilled with a pair holes to allow the connecting straps for the stainless steel plate
assembly to be bolted to the cap, as shown here:

35
 Fig.13

Fig .14 [TOP CAP OF BOOSTER WITH TREAD]

36
 we need to make sure the stainless straps are tightly connected to the electric
wiring, the stainless cap bolts are both located in the stronger thicker portion on the
horizontal part of the cap, and bolted securely on both sides.
A gasket from a piece of rubber or some silicone sealant is a good choice to
seal the outside of the cap. If available, a steel washer with built in rubber face will also
work.

Fig.15 [Complete fig. of Generator Booster]

As the stainless steel strap which connects the hydrogen generator plates to the
negative terminal of the power supply connects to the center section of the stainless plate
assembly, it is necessary to bend it inwards slightly. The angle used for this is in not
important, but the strap should be vertical when it reaches the stainless electrical plates.

37
 Fig.16 [STAINLESS WALL PLATE]

The picture above shows the stainless wall plates and how the bubbler is attached to the side
of the generator with super-glue or GOOP. It also shows the different pipe connections.
The stainless steel switch-cover plates are 2.75 inch x 4.5 inch (70 mm x 115
mm) in size and their two mounting holes need to be drilled out to 5/16 inch (8 mm) diameter
in order to take the plastic bolts used to hold the plates together to make as an assembly.
After a year of constant usage, these plates are shiny and not corroded thanks
to proper use of stainless parts two stainless steel straps that were made are used to attach the
plate assembly to the screw cap of the booster.
These straps are taken from the handles of cooking utensils or stainless strap
steel that you cut, and they connect to three of the plates as the outside strap travels across the
bottom of the plate assembly, clear of the plates, and connects to both outside plates as can be
seen in both the above photographs and the diagram below.

38
 Fig.17 [STRAP FORMATION BY PLATES]

The plates are bolted in position by two plastic bolts which run through the
mounting holes in the stainless plates.
The arrangement is to have a small 1.6 mm gap between each of eight pairs of
plates. These gaps are created by putting plastic washers on the plastic bolts between each
pair of plates.
The spacing is important is must be the 1.6 mm gap between the plates as this
spacing has been found to be The best at the electrolysis hydrogen production. The way that
the battery is connected is unusual in that it leaves most of the plate unconnected.

39
 Fig.18 [STEEL PLATE ASSEMBLY]

These plate pairs are called neutral plates and they do produce gas despite looking as if they
are not electrically connected. Stainless steel nuts are used between each pair of plates and
these form an electrical connection between Side by side plates.
The plate assembly made in this way is cheap, easy to construct and both
compact and robust. We can also constructs a plate assembly out of stainless steel flat
pieces, such as stainless sheet metal, or corrugated stainless metal, We can also buy stainless
plates off eBay for this, just take a look at a couple of possibilities in these pictures.

40
Fig.19 [PLATES BIENG MADE]

Fig.20

41
Fig.21 [PLATES ARE BEING DEEPED IN THE ELECTROLYTIC SOLUTION]

Fig.22 [TESTING FOR ELECTROLYSIS PROCESS]

42
Fig.23 ,24 [BOOSTER BEING MADE FOR ELECTROLYSIS POCESS]

43
 Fig.25

The electrical straps are bolted to the screw cap at the top of the generator and this
both positions the plate assembly securely and provides electrical connection to the bolts on
the outside of the cap while maintaining an airtight seal for the holes in the top screw on cap.

Another thing is that the stainless steel straps coming from the screw cap to the plate
assembly, they need to be insulated so that electrical current does not leak between them
through the electrolyte water.

44
 Fig.25 [COMLETE ASSEMBLY OF PLATES]

The same needs to happen to the section of the strap which runs underneath the

plates. This insulating is best done with shrink wrap or tool plastic dip tool. dip works very

well, but if neither of these choices can be used by us, then the insulating can be done by

wrapping the straps in electrical tape.

If we use this method, the tape needs to be wrapped tightly around the straps,

being stretched slightly as you go along, The section running underneath the covers is

insulated before the array is assembled.

45
 Fig.26

The PVC housing for the generator has two small angle pipe fittings attached to

it and a piece of clear plastic tubing attached between them so that the level of the water

inside can be checked without removing the screw cap.

The white tube on the other side of the generator is a bubbler which is glued or

wire tied directly to the side of the generator using super-glue or wire ties in so that a single

combined generator/bubbler.

If space is limited we can mount the bubbler in a separate location. The bubbler

position is shown here, spread out before gluing or tieing in place as this makes the method of

attachment a little easier to view.

46
 Fig.27

13. CONSTUCTION OF BUBBLER:

The half-inch diameter 90 degree elbows at the ends of the one inch diameter
bubbler tube have their threads coated with silicone before being pushed into position. This
allows both of them to serve as pressure-relief pop-out fittings in the seldom seen event of the
gas being ignited.
This is an added safety feature of the generator. This generator is operated
with a mix of Potassium Hydroxide also called KOH or Caustic Potash. We can also use
baking soda if we prefer, most people have baking soda around the house, KOH will last
longer and produce less brown water.
To get the right amount in the generator, fill the generator to its normal liquid
level with distilled water and add the Hydroxide or baking soda a little at a time, until the
current through the booster is about 4 amps below the working current of 20 amps. This
allows for the generator heating up when it is working and pulling more amps because the
electrolyte water is hot. The amount of KOH is typically 2 teaspoonful‘s.
It is very important to use distilled water as tap water has impurities in it
which make a mess which will clog up the generator. Also, be very careful handling
potassium hydroxide as it is highly caustic. If any gets on you, wash it off immediately with

47
large amounts of water, and if necessary, use some vinegar which is acidic and will offset the
caustic splashes. Baking soda does not have this problem.

The completed booster usually looks like this:

Fig.28 BOOSTER

OR

Fig.29

14. HOW THE GENERATOR IS CONNECTED TO THE ENGINE:

The final step is how the generator is connected to the engine. The normal mounting

for the generator is close to the carb or throttle body so that a short section of tubing can be

48
used to connect the generator to the intake of the vehicle engine. We can hose to connect to

the air box where the air filter is, or into the intake tubing.

The closer we get it to the throttle plate the better it is, because for safety

concerns, we want to reduce the volume of HHO gas lingering around in the intake system.

We can drill and tap a 1/4" (6 mm) NPT fitting into the plastic inlet tubing with a
barbed end for connecting the 1/4" (6 mm) hose.
The shorter the length of tubing to the air intake of the engine, the better it
is. Again, for safety concerns, we want to limit the amount of unprotected HHO hydrogen
gas.

If a long run of 3 feet (1 meter) or more must be used due to space limits, then it
would be a good idea to add a second bubbler at the end of the tube, for additional fire safety.
If we do this, then it is better to use a larger diameter outlet hose, chose 3/8"or 5/16‖ (10 mm
or 8mm).
The normal mounting for the generator is close to the carb or throttle body so that
a short section of tubing can be used to connect the generator to the intake of the vehicle
engine. We can choose to connect to the air box where the air filter is, or into the intake
tubing.
The closer we get it to the throttle plate the better it is, because for safety
concerns, we want to reduce the volume of HHO gas lingering around in the intake system .
We can drill and tap a 1/4" (6 mm) NPT fitting into the plastic inlet tubing with a
barbed end for connecting the 1/4" (6 mm) hose. The shorter the length of tubing to the air
intake of the engine, the better it is. Again, for safety concerns, we want to limit the amount
of unprotected HHO hydrogen gas.
If a long run of 3 feet (1 metre) or more must be used due to space limits, then it
would be a good idea to add a second bubbler at the end of the tube, for additional fire safety.
If you do this, then it is better to use a larger diameter outlet hose, chose 3/8"or 5/16‖ (10 mm
or 8mm).

49
15.HOW TO POWER THE HYDROGEN GENERATOR
 Use wire and electrical hardware capable of handling 20 amps DC, no less.
Overkill is better in this case, It is recommended to use parts that can handle 30
amps.
 Run the power through the ignition circuit, so that it only powers up when the
engine is on.
 A 30 amp relay should be used to prevent damaging the ignition circuit and or
switch, the switch is not designed for an extra 20 amp load.
 Make sure to use a properly rated fuse, 30 amps is best.
 Use a toggle switch for further operational control. Also can add this safety
feature, run an oil pressure switch to the relay as well, so the unit operates only
when the engine is actually started and running
 It is very important that everything is tight, solder is better than, crimping.
 Any loose connections can cause heat and this could lead to a fire, so make sure
that connections are of good quality , and be sure to check them every so often to
make sure they have not worked loose

16. SETTING UP THE WATER IN THE GENERATOR

 Fill the generator with distilled water and baking soda or KOH.
 Clean it more often using baking soda First.
 Fill the generator with distilled water about 2" from the top.
 Add a teaspoon of KOH or NaOH, or baking soda to the water and then slip the top
into place.
 Do not tighten it up for now, leave the top loose and resting in place.
 Connect 12V power supply to the connectors and monitor the amp draw of the
generator.
 Striving for 16 amps flowing when the generator is cold. As the water heats up over
time, the amp load draw will increase by about 4 amps until it reaches around 20
amps, and this is why you are trying for 16 amps when the generator is cold.
 If the amp draw is too high, pour out some of the water inside and add just a little
more distilled water.

50
  If the current is too low, add a small amount of baking soda or koh until the 16 amps

is reached.

 Overfilling the generator will cause some of the electrolyte water solution to be
forced up the output tube, so a water level tube was added to the outside of the
generator to allow us to see the electrolyte water solution level inside of the
generator.

 The generator usually needs to be topped off once a week, depending on how often
you have it turned on. Add distilled water, then check the current amp draw again.
 Notice that a drop in amps over the course of a several water refills, and this is
normally what happens.

 Some of the baking soda or KOH escapes the generator suspended in water Vapour
droplets, so every so often you may need to add a little more baking soda or KOH.

 The water in the bubbler acts to clean the contaminant out of the HHO gas also, we
suggest installing an amp meter so you can watch the amp current being used as the
generator is being operated.

17. INSTALLING THE GENERATOR:

 Select a ventilated area in the engine compartment or around the front bumper
in front of the radiator to install the generator every car or truck is different so
look it over well, we need to choose the best place to mount it.
 It must be mounted with the top pointing upwards. Large hose clamps work
very good for this, but do not over tighten them or the PVC may lose shape or
possibly crack.
 Hold the weight of the generator from the bottom with a bracket made from
strap metal, then use two hose clamps to hold the generator in place, one close
to the top and one close to the bottom. We can‘t install the
Generator inside of the car or truck for safety reasons.

51
18. OUTPUT HOSE AND BUBBLER:

The bubbler on the side of the generator should be filled about 1/3 to 1/2 full of

water - tap water is fine for the bubbler. The check valve before the bubbler is there to

prevent the bubbler water from being sucked back inside of the generator into the generator

when it cools and the gases inside contract.

Make sure the bubbler water level is always correct. Failure to do so could result
in a backfire event. That water inside the bubbler is water shield between the stored HHO gas
in the generator and the intake of your engine.
Install the output hose from the bubbler as close to the carburettor/throttle body.
by making a connection point into the intake tube/air cleaner. make the use as short as
possible to reduce the amount of HHO gas that it contains. I recommend using the same type
of 1/4" poly hose that is used on the unit. .
we will need an efie device or oxygen sensor adjuster, also a map sensor adjuster will work
well also.

52
This is an Efie device example:

Fig.30 [EFIE DIVICE]

53
HERE IS AN ANOTHER EFIE DEVICE EXAMPLE:

Fig.31,32

54
HERE IS A MAP SENSOR ADJUSTER WITH NEW HYDROGEN GENERATOR

Fig.34 [MAP SENSOR ADJUSTER]

19.ADDITIONAL STUFF

some people find the plate cell layout of the hydrogen Booster, rather
difficult to understand, so this additional section is just to try to explain the how
it work, The hydrogen generator plate arrangement is laid out in this way for a
good reason.

55
 This is mainly because the sets are squeezed inside in this manner to
create more hydrogen two identical sets of plates into one pvc generator as
shown here:

Fig.35

This arrangement is two identical sets of plates positioned back to-back.

Let‘s just take a look at just one of the two sets of stainless steel plates. Here,

we have just the electrical Positive linked to the electrical negative by a set of

four pairs of stainless plates in a daisy chain (the technical term is: connected

"in series" or "series connected").

Easily the most electrically efficient way for doing this is to exclude
all possible current flow paths through the electrolyte water by sealing off
around the edges of all the stainless plates and forcing the current to flow

56
through the plates and only through the plates.so we use a clever spacing of the
stainless plates:

Fig.36 [ The Picture Shows How The Plates Are Connected. ]

57
 The red lines show paths of unwanted current flow which produce
almost no HHO gas. This lost current flow is opposed by the useful current flow
across gap "A" in the diagram.
To assist the flow across the 1.6 mm gap "A", the waste flows as
long as possible. This is done by the gap "B" being made as large as possible.

The voltage applied to the cell (13.8 volts when the engine is
running) divides equally across the four plate pairs, so there will be 1/4 of that
voltage (3.45 volts) across each stainless plate pair.
If we look again at the original diagram, we will see that there are
two of these sets of four plate pairs, positioned back-to-back in the generator.
Each of these acts separately, except for the fact that there are additional
electrical current leakage paths through the electrolyte water between the
stainless plates of one set and the plates of the second set.
There is a steady voltage drop across the assembly of plates, that they
are connected in pairs in the middle due to the metal-to-metal connection
created by the steel nuts between the plates: It is often difficult for some to
understand of how the voltage drops across a chain of resistors (or matrix of
plates).

58
 Fig.37

The voltages are relative to each other, so each plate pair thinks that it
has a negative electrical connection on one plate and a positive connection on
the other plate.
20. THE COMPLETE INSTALLATION PICTURE:

Fig.38

59
 21. CONCLUSION
The new generation of hydrogen generators comes with extremely high
purity devices, that are safe and that present no danger to the environment. They
are the best alternative to gas cylinders, and they are simple to use anywhere. The
hydrogen generator just needs to be plugged in the electrical supply and it is ready
to go.

The hydrogen generator need of course a source of distilled water, or just

water at some models, to produce hydrogen, because it separates the hydrogen
from the oxygen in the water, thus producing highly pure hydrogen for weeks.

These hydrogen generators can generate hydrogen that is 99.99..% pure,

giving over 1000 cc/min, and they do not require changing their cylinders. The
safety of the hydrogen generators has been certified.

How the hydrogen generator works may vary from manufacturer to

manufacturer, for example some models use a solid polymer electrolyte to separate
oxygen from hydrogen, which makes them more safe than other models that use a
caustic liquid electrolyte. After the hydrogen is generated it passes through a
palladium membrane that lets only 99.99% pure hydrogen pass through, thus
insuring the gas' purity.

In conclusion, the latest generation of hydrogen generators brings some

series of improvements that makes it extra reliable, with almost no need of
maintenance or downtime
The best way of increasing the safety and lowering the costs in the
laboratory is to acquire a hydrogen generator, and we can be sure that the

60
investment is worth it, because we will no longer have to buy hydrogen cylinders,
so the hydrogen generator will pay for itself in a year or two.

22. GROUP WORK ACTIVITIES:

Our group consists of six members. This project is fully divided between the team
members. It was under guidance of Er.Kasinath Panda, lecturer, mechanical
engineering department,G.I.E.T,gunupur. It was a total group work done under
complete verification. The data were collected from different sources.

23. REFERENCE:

1)http://www.wikipedia.com/hydrogen generator booster.

2)http://www.answers.com

3)http://www.Automobile engineering.

4)http://www.google.com/hydrogen generator booster

TECHNICAL SUPPORT:

ONGC Chief Engineer Mr.Pradep Kumar Panigrahi (Phd.in Marine Engineering)

61