Impact of HHO gas on diesel engine
performance and emissions
M. S. Gad
Faculty of Engineering,
Fayoum University
Fayoum, Egypt
+(2012) 22950756 m_m_sayed@cic-cairo.com
msm19@fayoum.edu.eg
Abstract—Green transportation will play
an important role in future such as: ground
and air applications. Hydrogen has a wide
variety of applications in spite of decreasing of
natural resources. Depletion of fossil petroleum
resources and continuous increase of fuel
consumption led to search about fuel saving
solutions. Hydroxy gas (HHO) was produced
by the electrolysis process. HHO gas was used
as an additive fuel. Effect of HHO on engine
performance and exhaust was investigated. A
constant flow rate of 0.42 liter per minute of
HHO gas was introduced through the intake
port of the engine. Tests were investigated at
different engine loads. HHO gas was enriched
with air in diesel engine, the thermal
efficiency was increased by 7% and specific
fuel consumption was reduced by 15% at full
load compared to diesel oil. HC emission was
reduced at an average of 25% with hydroxy
gas. CO emission was reduced at an average of
18% in comparison to pure diesel. NOx was
increased with hydroxyl gas addition at full
load condition by about 8% compared to pure
diesel. HHO gas was recommended as a good
additive to diesel oil in performance
improvement and emissions reductions.
Keywords: Hydroxyl (HHO), Electrolyzer,
Diesel engine, Performance, Emissions.
TABLE OF CONTENTS
1. INTRODUCTION ................................ 1
2. DESIGN AND CONSTRUCTION OF
HHO GENERATOR .......................... 3
3. EXPERIMENTAL SET UP.................... 4
4. RESULTS AND DISCUSSION ............... 5
5. CONCLUSIONS .................................. 7
REFERENCES ........................................ 8
BIOGRAPHY ....................................... 10
978-1-7821-2734-7/20/$31.00 ©2020 IEEE
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Mahmoud M. A. Sayed Tarek A. Mahmoud
Canadian International Department of Computer
College, Cairo, Egypt Engineering,
+(2010) 01028826 Military Technical
College, Cairo, Egypt
t.mahmoud@mtc.edu.eg
1. Introduction
The scientists try to improve environmental
conditions by using green transportation (ground
and air applications.) There are some applications
that deal with renewable energy and optimization
of environmental quality. The ready and limitless
availability of water makes HHO gas as an
alternative energy source.
One liters of water generates 1866 liters of HHO
gas. A 12 V DC battery supplied power to HHO
cell. The positive terminal of the battery is
connected with the anode of the cell and negative
terminal with the cathode. The amount of HHO
gas produced depends on the dimension of cell.
HHO gas was passed through the safety check
valve followed by fire arrester. Investigation of
performance and emission of karanja biodiesel
blends with diesel enriched with a constant flow
rate of HHO gas on comparison with neat diesel
was done. Constant flow rate of 0.73 LPM of
HHO gas through intake manifold gave promising
outcome than that of neat diesel. Improved results
are obtained for performance and emission except
for NOx emission [1].
Enrichment of intake air with hydroxy gas gave
promising results compared to neat diesel fuel.
Performance and exhaust emissions had improved
except NOx emission. Oxygen content in HHO
gas led to higher combustion efficiency is
obtained and yields better performance than pure
diesel [2]. HHO production rate was found to
benefit from large cell gap under same conditions
of electrolyte concentration, operating
temperature, and engine speed. The appropriate
production condition with low fuel consumption
and emission as compared to no fuel cell
condition were found to be: an anode-cathode cell
gap of 10 mm [3]. HHO gas improved the
combustion process.
 Using of HHO gas reduced CO, HC and smoke
emission to 15, 9 and 25%, respectively. CO, HC
and smoke emissions fall to 50, 40%, and 85%,
respectively when using biodiesel with HHO.
Applying HHO gas increased CO2 and NOx
concentrations by up to 6 and 10%, respectively.
The added hydrogen and oxygen improved carbon
perfect oxidation. NOx emissions were increased
due to the increased maximum combustion
temperature. HHO gas led to an increase in the
cylinder pressure [4].
Thermal efficiency increased by 13.28%
compared with diesel fuel. Output power
increased by 6% compared with diesel fuel.
Specific fuel consumption was reduced by 15% at
full load condition. HC emission was reduced at
an average of 33% with hydroxy gas. CO
emission was reduced by 23%. NOx was
increased with hydroxy gas enrichment at full
load condition. Exhaust gas temperature was
increased. Smoke emission was reduced by 8% as
compared to diesel oil. HHO is carbon free fuel
which results in less HC and CO emissions. The
decrease in specific fuel consumption is due to the
combined effect of hydrogen and oxygen which
helps in achieving complete combustion. With the
addition of HHO gas, some amount of diesel fuel
will be replaced by HHO gas which results in
decreased fuel consumption [5].
The main factors of using HHO gas were
decreasing the fuel consumption and the
environmental pollution reduction.
Transportations were considered a promising
application of HHO gas using 150CC engine.
Results showed reduction 14.8% in fuel
consumption, 33% reduction in CO and 27.4%
reduction in HC. There was an increase of 17.9%
in break power and 15.7% increase in thermal
efficiency were recorded [6]. Pure hydroxy
enriched intake air led to increase of output power
and torque outputs [7]. Hydroxyl (HHO) is a
gaseous fuel which contains a mixture of
hydrogen (H2) and oxygen (O2) gases and can be
obtained directly by electrolysis of water. The
flammability of HHO gas is much more compared
to diesel oil. Compact HHO generators are
designed to integrate them to internal combustion
engines to generate necessary amount of HHO
required. The torque of diesel engine increased by
19.1%; whereas there was a reduction in CO and
HC emissions, and specific fuel consumption by
averages of 13.5%, 5%, and 14%, respectively
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with HHO usage. There is a reduction in NOx
emission for HHO gas. CO emission was
decreased by 20% and fuel consumption reduced
from 20% to 30% with HHO utilization [8, 9].
The introduction of HHO gas increases engine
torque, power and thermal efficiency, while
simultaneously reducing the formation of NOx,
CO and HC emission.
HHO gas production rate by electrolysis depends
on many factors such as electrode material,
geometrical parameters, type and concentration of
electrolyte and amount of current passed. HHO
gas has been improved to improve engine
performance and emissions. Additional
equipments such as water tank, electrolyzer,
bubbler unit and flame arrester were added [10].
There are two different types of HHO cells: wet
cell and dry cell. HHO dry cell uses the
electrolysis process in order to produce HHO gas
from water, which is ionized by adding NaOH as
the electrolyte. HHO dry cell was used because of
its smaller size and ease to install in engines [11].
The increment of catalyst mass fraction in water
directly increases the HHO flow rate. HHO
system used as enrichment of diesel fuel led to
increase of output power. HHO gas gave better
performance and emission because of extra
oxygen, high burning velocity, and carbon free
content [12]. HHO gas as secondary fuel as a
performance and emission improver was used in
diesel engines. HHO addition improved output
power, and specific fuel consumption by 3.18%,
and 17.4%, respectively compared to diesel fuel.
CO emission was decreased by HHO gas addition
[13, 14].
Water electrolysis used DC current) to split water
into protons, electrons, and gaseous oxygen in the
anode (positive electrode) and hydrogen in the
cathode (negative electrode) in the electrolyzer.
HHO gas was cheaply produced from water
electrolysis. The required voltage for splitting a
molecule of water is approximately 1.23 V. Two
metallic electrodes (as anode and cathode) were
immersed in aqueous solution of electrolyte and
catalyst. NaOH, KOH or NaCl were used for
HHO production. KOH has been widely used in
electrolyzer for a long time due to better
conductivity. Hydrogen and oxygen remained in
their monoatomic state (a single atom per
molecule) and thus there is no atomic bond
needed to be broken. HHO gas can have more
 energy because these bonds are never made. HHO
is an unstable state of H2O vapor. This hydrogen
molecule acts as a fuel and oxygen molecule helps
to burn the fuel. The heating value of hydrogen is
high and for the presence of oxygen the proper
combustion can be assured [15]. HHO addition in
diesel engine led to increase in output power and
torque by 3.81% and 2.79%, respectively and
reduction in specific fuel consumption to 2.78%.
HHO gas has a significant amount of water vapor
which participates in combustion process and
reduced combustion temperature [16].
HHO system with diesel fuel yields higher engine
torque output compared to pure diesel. High
burning velocity and low ignition energy of
hydroxy air block the fuel to be fast and
completely burnt at high speeds. A control unit
has been used to obtain appropriate electrolysis
voltage and current. Uniform and improved
mixing of hydroxy and oxygen content of HHO
stimulate combustion which has a major effect on
specific fuel consumption. Wide flammability
range, high flame speed and short quenching
distance of hydroxy yield diesel fuel to be
combusted completely under high speed
conditions. Wide flammability range, oxygen
content and absence of carbon make HHO gas
produced adequate combustion and reduction of
HC and CO emissions [17].
Diesel engine was tested under different loads and
with HHO flow rate from 1 LPM up to 3.3 LPM.
An increase in thermal efficiency of 11.06% at
full load and 3.3 LPM of HHO, while a reduction
of 4.15% was obtained at part rated load and 1
LPM of HHO. At high loads, CO, HC and smoke
emissions decreased. Four factors such as space
between electrodes (2 mm and 3 mm), electrolyte
type (NaOH and KOH), electrolyte concentration
(20% and 30%) and electrodes surface roughness
(smooth and rough). The best configuration (with
316L stainless steel electrodes) was with KOH at
30% and with rough electrodes spaced 3 mm. A
dry cell electrolyzer provided HHO gas of 0.375
LPM. Applied voltage and current, catalyst
amount (NaOH), number and area of electrodes
and stacks. There were improvements in thermal
efficiency, specific fuel consumption and exhaust
emissions [18-25]. An electrolyzer consisted of 7
serial plates at the anode, 3 mm gap and 5%
solution of NaOH. There was 14% reduction in
fuel consumption, 22% reduction in HC and 23%
reduction in CO for 2 LPM of HHO [26]. Dry cell
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HHO generator has been installed to the test
engine. The test gave the result such that the fuel
consumption has been reduced by 6 - 12% with an
HHO gas supply of 1 LPM along with the engine
air intake [27].
This work takes the light on HHO gas dry cell
design and fabrication application. Diesel engine
(4-stroke) was used to test the effect of
enrichment of fixed rate of HHO gas on engine
performance and emissions. HHO gas was
produced by electrolysis process using NaOH
catalyst in an electrolyte. HHO dry cell was
designed and fabricated to produce 0.42 liter per
minute. Performance parameters such as specific
fuel consumption, thermal efficiency and exhaust
gas temperature were studied. Exhaust emissions
such as CO, HC and NOx emissions were
recorded. All performance and emissions
parameters in case of HHO addition were
compared to diesel oil.
2. DESIGN AND CONSTRUCTION OF
HHO GENERATOR
The electrolyzer is a cell which breaks water
down into hydrogen and oxygen gasses by
passing an electric current through the water.
Sodium hydroxy (NaOH) as catalyst and distilled
water are used to prepare electrolyte (10% m/m).
The electrolyte was transferred to the HHO
system reservoir and filled the HHO reactor. The
reactor consists of 8 plates. A battery of 12 V and
40 A was used as power supply. A hydroxy gas
flow meter was used to measure HHO production
rate. The reactor produced 0.42 L/min hydroxy
gas was 40 A. The rubber gaskets ensure a good
sealing of any plate to touch the neighbor plate
and guarantee the water and gas existence inside
the generator. The plates have down small holes
for equalizing the water level in the cells and
to permit the electrons to flow under voltage
drop. Two acrylic end cover plates with thickness
15 mm one of them has inlet water hole and the
other has outlet gas hole, bolts, washers, nuts,
fittings, bubbler, connectors, non-return valve,
hoses and tank. The water tank ensures
continuous feeding of electrolyte to the generator.
A bubbler is a container partially filled with
water and HHO gas is fed through its bottom
and avoid backfires from reaching the
electrolyzer and drying and purification of HHO
gas from water vapor. Non-return valve between
the electrolyzer and bubbler is safety essential in
the backfire case.
 The plates are fabricated from stainless steel 3. EXPERIMENTAL SET UP
316L with dimension 80 x 80 x1 mm. A bubbler The experimental setup for diesel engine
is located above the electrolyzer to supply it with supplemented with hydroxy gas through dry
water electrolyte mixture for the electrolysis cell hydroxy (HHO) gas generator as shown in
process. HHO bubbles escaped to the surface of Fig.2. Hydroxy gas at constant flow rate is passed
the water in the bubbler passes to the flashback into intake manifold.
arrestor. The electrolysis of water produces a
mixture of hydrogen oxygen and their ions. The readings were taken for different engine
speeds and full load. Four-stroke single cylinder
The potential difference to be applied across the diesel engine technical specifications are
electrodes depends on the amount of gas summarized in Table 1.
generated per unit time. The reactions taking
place at the electrodes are R1, R2 and R3. Table 1 The tested diesel engine specifications
Engine parameters Specifications
Engine Model DEUTZ FIL511
Bore 100 mm
Stroke 105 mm
Displacement 824 cm
Type of injection direct
Using Faraday’s First law to calculate the Type of cooling Air
theoretical maximum production of HHO gas as
shown: An AC generator of 4.5 kW maximum power is
directly coupled to determine the engine brake
power. The engine has been equipped to measure
fuel consumption and engine speed.

Where: The engine receives air through an air box fitted

V = volume of the gas [L], with an orifice for measuring the air consumption.
R = ideal gas constant = 0.0820577 [L x atm/ (mol
Fuel consumption rate has been determined using
x K)],
I = current [A], a glass burette and stop watch.
T = temperature [K],
F = Faraday’s constant = 96485 Coulombs/ mol, The engine speed has been measured using a
p = ambient pressure [atm], digital tachometer. The engine has been warmed
z = number of excess electrons (2 for H2, 4 for O2). up before taking all readings. When the engine
reached its stable condition, the experiments have
Fig. 1 demonstrates HHO cell which adapts with been started and measurements recorded. Firstly,
diesel engine. the engine is operated with diesel fuel.

Then, the engine has been run with fixed

production rate of 0.42 liter per minute of HHO
gas. For every operating condition, the engine
speed was measured; the engine load was taken at
full load.

Exhaust gas analyzer of MRU DELTA 1600-V

model was used to measure exhaust emissions
such as CO, HC and NOx.

Fig.1 HHO cell adaption with diesel engine.

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 Fig.3 Effect of NaOH concentration and supply
current on HHO productivity

1. Diesel engine 10. Piezo pressure Every square inch of plate area of dry cell
transducer produced needs 0.54 Amp. Every current supply
2. AC generator 11. Charge amplifier of 1 Amp., produced 0.064 liter per minute. The
3. Diesel tank 12. Data acquisition increase in supply current of the battery led to
card increase oh HHO gas production as shown in
4. Biodiesel tank 13. Personal computer
5. Burette 14. Exhaust gas Fig.4. Electrolyzer using NaOH catalyst produced
analyzer
more HHO gas with the same amount of catalyst
6. Air surge tank 15. Smoke meter
7. Orifice 16. Exhaust gas temp. about NaCl and KOH.
thermocouple
8. Pressure differential 17. Proximity switch Because hydrogen and oxygen contents of NaOH
meter produces more HHO gas against NaCl. HHO
9. Intake air temperature 18. Cardan shaft production rates at different mass fractions of
thermocouple catalysts were shown in Fig.4.

Fig.2 Schematic diagram of the experimental

setup

4. RESULTS AND DISCUSSION

4.1 EFFECT OF CATALYST
CONCENTRATION ON
PRODUCTIVITY
Sodium hydroxide, Sodium Chloride and
potassium hydroxide are the best additives
choices as catalysts. The percentage of the
catalyst is a main factor in evaluating the cell
current. The gas production increases with
catalyst concentration until the limit of 28 %
(weight). Any increase in the concentration
produces a reduction in gas production. Dry cell
design can vary in shape or size depending on
the amount of the output gas needed from the
cell. The gas output was measured and a quantity
of 0.25 liter per minute for each liter of engine
size was used. As NaOH catalyst mass fraction
increased, HHO productivity increased due to the
thermal conductivity increase of the electrolyte
as shown in Fig.3.
HHO
Fig.4 Effect of catalyst concentration on HHO
productivity.
4.2 SPECIFIC FUEL CONSUMPTION
Figure 5 shows the variation of specific fuel
consumption with engine speed. When diesel
oil enriched with hydroxy gas, there is
reduction in specific fuel consumption. The
reduction was due to uniform mixing of hydroxy
gas with air as well as oxygen. Hydroxy gas
assisted diesel fuel during combustion process
and yields better combustion. HHO gains a high
flame speed, high diffusivity and wide
flammability.
The addition of hydroxy gas would help the fuel

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 to be burned faster and more complete
combustion. Improved mixing of hydroxy, air
and oxygen content of HHO has a positive
impact on specific fuel consumption.

The enhancement resulting from the heat energy

liberated from HHO burning resulted in higher
combustion efficiency. Decrease of specific fuel
consumption with HHO gas was about 15%
about diesel oil.

Fig.6 Thermal efficiency of diesel oil with HHO

gas

4.4 EXHAUST GAS TEMPERATURE

Fig. 7 shows the exhaust gas temperature for diesel
and HHO gas enrichment. There was better
combustion for addition of hydroxy gas in to the
engine. Because of high residence time
associated due to high auto ignition temperature
of hydroxy gas, more charge gets accumulated
inside the cylinder contributes to increase the
Fig.5 Effect of diesel oil with HHO gas on exhaust gas temperature. Decrease of exhaust gas
specific fuel consumptions. temperature with HHO gas was about 7% about
diesel oil.
4.3 THERMAL EFFICIENCY
Figure 6 shows the brake thermal efficiency
for diesel and with addition of hydroxy gas.
The thermal efficiency of diesel engine when
enriched with hydroxy gas is higher than diesel
due to increase in calorific value of overall
mixture in the combustion chamber. The high
value of thermal efficiency can be attributed to
better mixing of hydroxy gas with air which
results in better combustion.

The brake thermal efficiency at full load is

maximum at when enriched with hydroxy
Fig.7 Exhaust gas temperature of diesel oil with
gas .The thermal efficiency increased by average
HHO gas.
of 15% compared to baseline diesel.

The addition of HHO gas in diesel engine 4.5 CO EMISSION

improved the brake power of the engine due to The variation of carbon monoxide (CO) emission
the hydrogen present in HHO gas. Increase of with hydroxyl gas enrichment is shown in Fig. 8.
thermal efficiency with HHO gas was about 15% The average reduction of 13.5% is gained of CO
about diesel oil. emission.

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 It is due to the absence of carbon in hydroxy gas.
HHO- diesel fuel burn more completely than pure
diesel operation. Utilization of HHO gas with
interior oxygen content enriches the engine
combustion process and decreases of CO
emission. The diatomic of bonds in HHO gas
atomic structure with high start response without
propagation delay of ignition owing to reaction
surface travel time ensures complete and
efficient fuel burning and results in the
reduction of emission percentages. HHO gained
a higher flame speed and high flammability,
addition of hydroxy would help fuel to be burned
faster and more complete. Lower CO emission in Fig.9 HC emissions of diesel oil with HHO gas.
diesel oil with HHO gas was due to the absence
of carbon in the hydrogen structure. Decrease of 4.7 NOX EMISSION
CO emission with HHO gas was about 18% about The variation of oxides of nitrogen for all fuels
diesel oil. with respect to the engine speed was shown in
Fig.10. The formation of oxides of nitrogen is
due to the peak combustion temperature, the
oxygen concentration in the combustion
chamber and the residence time of high
temperature gas in the cylinder. The
enrichment of hydroxy gas increased the
calorific value as compared to diesel, causes
temperature rise in the combustion chamber
hence causing increase in NOx emission. NOx
formation is related to oxygen concentration,
reaction temperature and residence time.
Increase of NOx emission with HHO gas was
Fig. 8 Effect of diesel oil with HHO gas on CO emission. about 8% about diesel oil.

4.6 HC EMISSION
The unburned hydrocarbons (HC) emitted with
emission gases due to the incomplete
combustion. Figure 9 shows HC is decreased
as the engine speed is increased. HC percentage
for engines blending HHO gas with air and fuel
mixture was lower than diesel oil. HC was
decreased due to the increase of the fuel
oxidation; as oxygen is already exist with
sensible percentage in HHO gas emission. As
the hydroxy carbonless, burning of hydroxyl
with diesel leads to lower hydrocarbon levels
and because of high cylinder temperature. Fig.10 Effect of diesel oil with HHO gas on NOx
The short quenching distance and wide emission.
flammability range of hydroxy leads to less HC
emission. Oxygen index of hydroxy yields 5. CONCLUSIONS
better combustion which diminishes HC Green transportation will play an important role
emission. The combined effect of hydrogen and in future such as: ground and air applications. A
oxygen in HHO gas helps in achieving dry HHO cell electrolyzer was designed and
complete combustion. Decrease of HC emission fabricated with NaOH-water solution for
with HHO gas was about 25% about diesel oil. production of HHO. Constant flow rate of 0.42
liter per minute of HHO gas through intake

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 manifold gave promising outcome than diesel
oil. The increment of the mass fraction of
catalyst in the water directly increases the HHO
flow rate. A single cylinder four stroke diesel
engine used hydroxy gas enrichment and
results in significant improvement in
performance parameters such as specific fuel
consumption, thermal efficiency and exhaust gas
temperature and reduction in exhaust emissions
such as CO, HC and NOx. Thermal efficiency of
diesel engine increased by about 15% and
specific fuel consumption reduced by about
15% when enriched with hydroxy gas. Exhaust
gas temperature was decreases due to the effect
of HHO gas. Decrease of exhaust gas
temperature with HHO gas was about 7% about
diesel oil.CO emission was decreased by 18%
under the effect of HHO addition in diesel
engine. There was decrease in HC emission for
HHO with diesel oil by 25% compared to diesel
oil. Increase of NOx emission with HHO gas
was about 8% about diesel oil. Improved results
are obtained for performance and emission
characteristics except for NOx emission. HHO
gas gives the better performance and emission
characteristics because of its better combustion
characteristics such as extra oxygen, high
burning velocity, and carbon-free content.
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