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Design Testing and Construction of a Saltwater-Based Power Source Device

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 Journal of Academic Research 04:2(2019), pp. 21-31

Design, Testing, and Construction of an

Alternative Zn-Cu Electrolytic Cell Battery
Felipe B. Café III1, Jacob M. Cioco1, Leslie R. Conge1, Adrian U. Gadin, Nikko Ardel P.
Floretes, Walvies Mc L. Alcos
1
Students, College of Engineering, Samar State University, Philippines

Abstract: The paper presents the design, testing, and construction of a new energy source
derived from the ionized solution and electrodes. The design focused on the optimal salt-
liquid mixture as an electrolyte and the type of electrodes used to produce better energy
output. Included the design is the number of cells and the packaging set-up of the power
source device. It tested different liquids as electrolyte, including tap water, rainwater,
cooking oil, and human urine with NaCl as well as Coca Cola and Vinegar. Results
showed that the energy produced from different liquid-salt ratio and the size of the
electrodes used varied slightly. With the consideration of the device functionality,
manageability, total cost, and general appearance, a ten-cell zinc-cupper electrolytic cell
battery using salt-water- electrolyte produced 7.5 volts for 17 hours which can be
extended by replacing electrolyte. The prototype device can light an LED lamp or charge
a mobile phone.

Keywords: redox reaction, emergency power-source, small energy charging device, salt-
liquid electrolyte performance, zinc-copper electrodes, saltwater lamp

1. Introduction grid demand of 209.86 MW in 2015 was

The world needs more energy to
meet socio-economic development
requirements and enhance global living
standards to continue to improve (BP, 2019;
IPCC, 2012). In 2018, the global energy
demand rose by 2.3%, the fastest in the last
decade (IEA, 2019). By 2040 it is forecasted
that various sources of energy will increase
and still be widely used including the non-
renewables such as coal, gas, and oil (BP,
2019). Around 1.1 billion people (14% of
the global population) have no access to
electricity (IEA, 2017). Many of those
without access are found in rural areas, and
more than 95% of those living without
electricity are in countries in developing
Asia and sub-Saharan Africa (ibid). To date,
several communities still found on off-grid
and don't have access to electricity (ibid) to
light their homes or power, even small
devices. In the Philippines, an estimated off-
recorded (ADB, 2018). The need for energy
to even light the homes of the isolated
communities are too basic but many don't
have access. Efforts to address off-grid
communities are through the use of solar
panels, one of the easier to install or use.
In 2015, the solar-powered
electricity has reached around 227 GWe,
about 1% of all energy used globally (WEC,
nd). However, one of the disadvantages of
solar energy is the availability of the
sunlight requiring the user to have energy
storage to be of use when sunlight is
unavailable (Green Match, 2019; Renewable
Resources Co, 2016). For ordinary families
in many far-flung and off-grid communities,
lighting their homes during evenings is a
necessity. Most of these communities use
kerosene (or other similar) lamps and
candles. Candles and kerosene lamps
(gasera) are among the most common cause
JOURNAL OF ACADEMIC RESEARCH
of fires in households (PSA, 2018; BFP,
2015). In 2017, the Philippines listed a total
of 463 cases of fire attributed to candles and
gasera, about 40% lower than 2016 (PSA,
2018).
Aside from the risk of fire, higher
cost of usage and illumination quality,
candles and gasera’s (which burns kerosene
for light) are also not environmentally clean.
This potential risk was also one of the
reasons why many lamps have been created
using alternative sources of energy to
provide illumination to homes. In 2010, a
lantern powered a metal-air battery using
salt-water as an electrolyte catches the
attention of many. Today the said
technology is available in the market with an
energy output of 5volts and 160mA current
capable of lighting eight ultra-bright LEDs
(SALt, 2018). A metal-air battery
electrochemical cell uses an anode made
from metal and an external cathode of
ambient air usually with an aqueous or
aprotic electrolyte (Georgi, nd; 2006). The
metal-air battery described by SALt (2018)
uses the salt-water mixture as its electrolyte
to facilitate the flow of electrons from the
metal anode and an air cathode.
The archipelagic condition of the
Philippines provides far-flung, isolated
communities with vast resources (saltwater)
as the electrolyte of a metal-air battery. The
use of seawater is a cheaper alternative to
photovoltaic cells and another alternative
power source (Rao, Hoge, Zakrzewski, Shah
and Hamlen, 2013). On the other hand, salt
(among others) are valuable resources in far-
flung upland communities. If such resource
will be used for energy production, it may
compete with the flavoring of the food. This
raises the question of using other types of
liquid-salt mixture to serve as the
electrolyte. Also, the question of whether the
existing electrolytic battery power can be
Cafe et al. (2019)
Vol. 04 No.2
enhanced to improve voltage output to
increase its utility was explored in this
project.
2. Objectives
The paper presents the design,
testing, and construction of a novel energy
source from an ionized solution and metal,
specifically, it will;
2.1 Assess the output voltage and current
from different liquid-salt ratio using
the following liquids;
a. tap water and salt,
b. cooking oil and salt,
c. rainwater and salt,
d. urine and salt,
e. vinegar, and
f. soda
2.2 Determine the output voltage and
current considering the dimensions of
copper and zinc electrodes,
2.3 Determine the output volume and
current considering fuel-cell design
and connectivity,
2.4 Design and construct device enclosure,
and
2.5 Assess the acceptability of the
developed device considering cost-
effectiveness and utility.
3. Methodology
3.1. Research Design
The developed project was based on
an experimental study of what liquid-salt
mixture, size of copper and zinc and the fuel
cell design produced the needed output
power to light a LED lamp and charge a
device like a cellular phone. The battery was
developed using electrolytic cell technology.
A total of 26 set-ups and more than 130
experimental trials were conducted. The
optimal design of mixture and set-up was
22
JOURNAL OF ACADEMIC RESEARCH
used in developing the enclosure of the
device which was evaluated for its
acceptability using likert scale for utility and
a cost-benefit analysis was also conducted.
3.2. Testing and Evaluation
Electrolyte Design Mixture. The
alternative battery used the electrolytic cell
technology (Peshin, 2018; Bertrand, nd. )
wherein instead of using a salt bridge used a
salt-liquid mixture to maintain the neutrality
of water surrounding the electrodes. There
are a total of six types of liquid used in two
liquid-salt proportion. One set used 350 ml
of liquid and 4 tablespoons of salt while the
other set used 100 ml of liquid and 5
tablespoon of salt for tap water, cooking oil,
rainwater, and urine. On the other hand,
vinegar and soda (Coca-Cola) was not
mixed with any salt as these are already
ionized liquids. With the use of a digital
multimeter tester, the output voltage and
current were measured. The testing was
done at least three times from three different
set-ups.
Figure 1: Liquid-salt electrolyte performance
experimentation
Electrodes Size and Energy
Produced. The size of electrodes used was
tested; one using 100 x 33mm or 100 x 67
Cafe et al. (2019)
Vol. 04 No.2
mm copper and zincs. A total of five pairs of
copper and zinc were examined. The said
electrodes were immersed in a 350 ml to 4
and 5 tablespoons of salt. Using a digital
multimeter tester, the output voltage and
current were observed at least three times
from three similar set-ups.
Fuel Cell Set-up. The number of fuel
cell and the connectivity between cells was
studied. A total of nine set-ups were
developed to determine which set-up
produced a higher power output.
Acceptability of the Device. The
different mixes (especially the use of
different liquids) was examined for
acceptability. This considered the
manageability of the device considering the
liquid used. Cost-effectiveness was also
taken into consideration in the acceptability
evaluation.
Figure 2: (Top) Designing device’s enclosure
using 3D Builder App. (Bottom) Printing of the
metal battery enclosure using Flagforge 3D
printer
23
JOURNAL OF ACADEMIC RESEARCH
3.3 Design and construction of Enclosure
The optimal design of mixture, size
of electrodes, and the desired number of fuel
cell including its circuitry was the basis of
the enclosure design. The printed circuit
board (PCB) layouting utilized Proteus
application on PC to simulate the
performance of the designed circuit. The
enclosure of the metal-air battery was
constructed with the aid of a Flashforge 3D
printer and an acrylic glass for the lamp
enclosure.
Figure 3: PCB Layout Using Prosteus Application
3.4 Data Analysis and Presentation
Data were presented in tables, graphs
and pictures/images. Means, standard
deviation and frequency counts and relative
frequency values were used to summarize
the data gathered. A one-way ANOVA and a
post-hoc Tukey HSD test were performed to
determine the differences between groups.
Acceptability of the developed alternative
device based on an assessment of 35
potential device users was conducted. The
assessment was made in terms of overall
appearance, functionality/operability,
manageability, and cost.
Cafe et al. (2019)
Vol. 04 No.2
4. Results and Discussion
The end-goal of the project study is
to develop a prototype alternative liquid-
water-based power source utilizing the
electrolytic cell battery technology. In the
search for higher voltage and current output,
several alternative electrolyte, and metal as
electrodes were examined.
Electrical energy is produced in
many forms such as through combustion,
mechanical movement, and photosynthesis
(Battery University, 2017a). Electrical
energy generation of batteries is produced
by an electrochemical reaction between two
metals having different affinities (ibid) such
as zinc and copper. When the metals (the
electrodes) are exposed to a type of liquid
(usually acid) voltage is developed between
them as part of ion transfer (ibid). The
energy produced in the process comes from
the chemical change in dissolving the metal
into the acid termed as redox reaction
(Bewick et al., 2019; Bates, 2012; Bertrand,
nd).
4.1 Electrode Performance Assessment
The project utilized copper and zinc
as the battery electrodes. Sourced from junk
materials, it was prepared in two different
sizes to check its effect on power generation.
With the amount of electrolyte (water-salt
solution) remained the same, the produced
voltage and current differ slightly in terms
of value. Data shown in Table 1 suggests
that the size of electrodes influences the
amount of voltage generated significantly.
On the other hand, the current produced is
slightly different from each sample group
but the difference was not statistically
significant.
The battery tested generates
electricity through an electrochemical
24
JOURNAL OF ACADEMIC RESEARCH Vol. 04 No.2

Table 1. Anode-Cathode Size and Output Voltage

Anode Cathode Water/Salt voltage σ p-value (Tukey HSD)

Copper Zinc Ratio (g/g) v (b) (c) (d) (e)
Size (mm) Size (mm)
(a)100x67 100x33 350/60 0.7487 0.0006 0.622 *0.012 0.899 0.899
(b)100x33 100x67 350/60 0.7493 0.0006 0.102 0.283 0.622
(c)100x67 100x67 350/60 0.7507 0.0006 *0.004 *0.011
(d)100x33 100x33 350/60 0.7483 0.0006 0.899
(e)100x33 100x33 350/75 0.7487 0.0006
significant @ * 0.05 **0.01

Table 2. Anode-Cathode Size and Output Current

Anode Cathode Water/Salt current σ p-value (Tukey HSD)

Copper Zinc Ratio (g/g) A (b) (c) (d) (e)
Size (mm) Size (mm)
(a)100x67 100x33 350/60 0.5000 0.0100 0.899 0.735 0.735 0.899
(b)100x33 100x67 350/60 0.5033 0.0058 0.899 0.429 0.735
(c)100x67 100x67 350/60 0.5067 0.0058 0.195 0.429
(d)100x33 100x33 350/60 0.4933 0.0058 0.899
(e)100x33 100x33 350/75 0.4967 0.0058
significant @ * 0.05 **0.01

reaction. With elements involved having
larger surface area improves the reaction
process (Papiewiski, 2018; Susanto, 2017).
Increasing the surface area of anodes (zinc
or aluminum) and maintaining the distance
between electrodes increases current while
the higher surface area of the zinc anode in
the shorter distance with the cathode
generates higher voltage and current
(Susanto, 2017). In the study, the distance
between the electrodes was placed at the
shortest possible to produce a smaller sized
device. The little variation in the distance
has not significantly affected the amount of
current as shown in Table 1. On the other
hand, the voltage produced is slightly higher
but significantly different for set-up having
larger zinc electrode as shown in Table 2.
The size of the metal electrodes will
have some effects on the serviceability of
the battery. The metal electrodes corrode as
it reacts with the electrolyte solution which
makes larger sized electrodes longer time to
consume. However, the rate of corrosion
will depend on the kind of electrolyte
composition. In this paper, the zinc electrode
will corrode until it stops giving off
electrons to copper (Bates, 2012). This
means that larger electrodes will have a
longer life span.
4.2 Type of Electrolyte and Energy
Produced
An electrolyte is a chemical medium
which allows the transfer of electrical charge
between electrodes; commonly it is in forms
of salt, acids or other bases in liquid or dry
format (Bates, 2012; Battery University;
2017b; Schubert & Tsupova, 2017). In this
project, six different liquid was examined,
some mixed with salt to improve ionic
composition. Four were mixed with table
salt (NaCl) were the other two were used as
is. Voltage and current produced were

Cafe et al. (2019) 25

JOURNAL OF ACADEMIC RESEARCH Vol. 04 No.2

Table 3. Liquid-Salt and Output Voltage

Liquid Used Liquid/Salt voltage σ p-value (Tukey HSD)

Ratio (g/g) v (b) (c) (d) (e) (f)
(a) Tap Water 350/60 0.7500 0.010 0.864 0.899 0.899 **0.001 **0.001
(b) Cooking Oil 350/60 0.7433 0.006 0.899 0.581 **0.001 **0.001
(c) Rain 350/60 0.7467 0.006 0.864 **0.001 **0.001
(d) Urine 350/60 0.7533 0.006 **0.001 **0.001
(e) Vinegar 350/00 0.8100 0.010 0.864
(f) Coca Cola 350/00 0.8033 0.080
significant @ * 0.05 **0.01

Table 4. Liquid-Salt and Output Current

Liquid Used Liquid/Salt Current σ p-value (Tukey HSD)

Ratio (g/g) A (b) c (d) (e) (f)
(a) Tap Water 350/60 0.507 0.006 0.797 0.899 0.481 **0.001 **0.001
(b) Cooking Oil 350/60 0.513 0.006 0.481 0.082 **0.001 **0.001
(c) Rain 350/60 0.503 0.060 0.797 **0.001 **0.001
(d) Urine 350/60 0.497 0.006 **0.001 **0.001
(e) Vinegar 350/00 0.753 0.006 **0.001
(f) Coca Cola 350/00 0.650 0.001
significant @ * 0.05 **0.01

examined from six different battery set-up,
maintaining type, size and distance of
electrodes. Table 3 and 4 summarizes the
result of the tests. The battery with
electrolyte using tap water, rainwater, and
urine mixed with the same amount of salt
have produced not significantly different
voltage output of about 0.750, 0.747, and
0.753 volts respectively. The use of vinegar
and Coca Cola resulted in slightly higher
voltage output which is significantly higher
than water (tap and rain) and oil with salt
electrolyte as shown in Table 3.
Vinegar (Datu Puti brand) used in
the project likely consists 3.97% acetic acid
(Bacongco et al., nd) other brands ranges
from 5-21% CH3COOH (Helmenstine, 2019)
while its pH is around 2.5-2.7. Coca Cola
like vinegar is acidic with pH of 2.6-2.7
(Cotton, 2011) and probably 80-89% of it is
water. The acid in the two liquids makes it
qualify as an electrolyte for the battery. On
the other hand, urine is about 91-96% water
(Rose et al., 2015) and ammonium
bicarbonate is the dominant compound in it
(Pettersson, 1994). The addition of NaCl
was made to transform urine into an
effective electrolyte. As urine ages, urea is
biologically decomposed to ammonia which
releases unpleasant odor (Andreev, 2017)
making it unfavorable electrolyte.
The current observed to battery set-
up having vinegar and Coca Cola as
electrolyte is significantly higher than tap
water, rainwater, urine, and cooking oil. On
the other hand, the vinegar registered higher
voltage and current than the Coca Cola set-
up. Vinegar and Coca Cola will make the
battery expensive than tap water or
rainwater. The result observed did not
consider long-term changes in the energy
produced; chemical reaction changes with

Cafe et al. (2019) 26

JOURNAL OF ACADEMIC RESEARCH Vol. 04 No.2

Table 5. Circuit Output Using Different Connections

Output Voltage Output Current

Liquid/Salt No. of Type of
Liquid Used (v) (A)
Ratio (g/g) Cells Connection
ave. σ ave. σ
Tap Water 350/60 10 Series 7.503 0.006 2.507 0.012
Tap Water 350/60 6 Series-Parallel 1.650 0.010 1.353 0.006
Tap Water 350/60 8 Series 4.503 0.015 2.103 0.006
Tap Water 350/60 2 Series 1.493 0.006 0.853 0.006
Tap Water 350/60 2 Parallel 0.757 0.006 0.203 0.006

Figure 4. Circuit Diagram of 10-Cell Battery Figure 5. Perspective View of 10-cell Container

the changing chemical profile of electrolyte
as it is used.
The effect on the energy produced
versus the amount of salt added was
evaluated. The increase in the liquid-NaCl
ratio of 350/60 to 100/80 has resulted in an
increase in voltage and current significantly.
4.3 Fuel Cell Design
printing made use of Flashforge 3D printer
taking at least two hours to complete. The
device is comprised of three sections;
solution container, system circuitry, and the
load section (see Figure 6). The upper part is
the solution container (see Figure 5)
containing ten cells to hold ten separate
batteries in which are connected in series
(see Figure 4).

The produced energy from the tested

set-up was not sufficient to power a higher
luminosity lamp or charge a mobile phone
or the likes. The small energy produced
requires setting-up series of these cells to
provide more substantial energy. Various
configurations were tested and a ten-cell set-
up connected in series was more preferred.

4.3 Construction of Device Enclosure

The device enclosure was

constructed using a 3D printer; the rest of Figure 6. Main Device Enclosure
the device is made of acrylic glass. The

Cafe et al. (2019) 27

JOURNAL OF ACADEMIC RESEARCH Vol. 04 No.2

Below the solution container is 4.4 Device Acceptability Assessment

where the system circuits are found (see
Figure 6). It is also where the USB charging
port, the switch, battery, the LED indicator,
and the PCB are kept. On the other hand, the
lower portion of the device is an acrylic
enclosure which is transparent. It is where
the lamp will be located (see Figure 8).
Shown in Figure 7 is the block diagram of
the entire device.
Appearance. Table 6 shows a
summary of the assessment made about the
developed device. Its assessment made is
not based on any existing lamp or equipment
with similar capacity. Out of 35 respondents,
around 83% rated it as very good or
excellent. Overall, the device enclosure and
how it looks received a rating of 4.25.
Respondents critique was it seems fragile
and may fall-off during use. Improving the
rigidity of the device and the color choices
may further improve the rating.

Functionality. The device received

an excellent rating in terms of functionality.
It produced the desired/promised outcome
says the respondents. The device is capable
Figure 7. Block Diagram of the System
of lighting an LED lamp for more than 17
hours after which the solution needs to be
replaced.

Table 6. Circuit Output Using Different

Connections

Liquid Rating
Attribute
Used Ave. Interpretation
Overall - 4.25 Very Good
Appearance
Functionality - 4.51 Excellent
Device *Tap Water 4.40 Very Good
Management *Rainwater 4.31 Very Good
*Oil 3.22 Good
*Urine 2.06 Bad
Coca Cola 4.26 Very Good
Vinegar 2.94 Good
Cost *Tap Water 4.20 Very Good
Efficiency *Rainwater 4.20 Very Good
*Oil 3.23 Good
*Urine 4.49 Very Good
Coca Cola 3.43 Good
Vinegar 3.37 Good
Figure 8. The Alternative Salt-Water Zinc- Legend: 1.00 – 1.50 (Very Bad) 1.51-2.50 (Bad) 2.51-3.5
(Good) 3.51-4.5 (Very Good) 4.51-5.00 (Excellent)
Cupper Electrolytic Battery Powered Lamp and
Energy Source

Cafe et al. (2019) 28

JOURNAL OF ACADEMIC RESEARCH
Power Device Management. The
smell of the vinegar and more specifically of
the urine was the main issue raised by
respondents. These were the reason why
urine and vinegar as electrolyte material
received a low rating of Bad and Good
respectively. The other factor which made
the device receive a Bad score was the
hygienic aspect of urine.
Cost Efficiency. One major issue
raised by the potential user of the device was
the use of more expensive electrolyte such
as cooking oil, vinegar, and Coca Cola
(soda). The device costs around PhP
3,000.00, making it less appreciated by
possible users. The total cost of the device
may be further reduced when mas
manufactured.
5. Conclusion and Recommendation
5.1 . The device is capable of producing 7.5
volts which can run for 17 hours enough
to light an LED lamp and cost
approximately PhP 3,000.00.
5.2 The type of liquid, the amount of salt
mixture and the size of electrodes used
produced very small variations in the
output voltage and current. Differences
which will have little bearing on the
functionality of the device.
5.3 Among the different liquid (with salt)
used as an electrolyte, the more
preferred is the tap water and rainwater
due to availability and cost while the
least preferred are the urine and vinegar
because of its smell and hygienic
consideration.
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