HHO GENERATION APPLICATION

Nada Oman Badr, Basma Omar Abd EL-Hameed, Zuhair EL Sheshtawy, Ibrahim El bougdadiy, Mohamed Bayoumy
Pharos University, Alexandria EGYPT, nadabadr899@yahoo.com, basma-alex@hotmail.com, ZuhairEl-
Sheshtawi2015@yahoo.com,ibrahimelbogdady@yahoo.com, mohamedbayoumy93.mb@gmail.com
Supervisor: Dr.Tarek Belal, tarek.belal@pua.edu.eg
Supervisor: Dr.Sameh tawfeek, sameh_tawfeek@hotmail.com

Abstract- Alternate fuel is important and it should be used as II. THEORY

an assist fuel beside the fossil one. Actually we spend a lot of our
income for our vehicle fuelling. A)Principle
the hydroxy gas is an additional source of fuel. This gas was
Recently, using hydrogen as a supplement fuel for spark mixed with air before feeding into the combustion chamber.
ignition engines is one of the potential solution that is not brand
Hydroxy gas is also known as HHO, Brown‟s gas, Water
new. Hydrogen is not a fuel that occurs free in nature like fossil
fuel so we need electrolyzing procedure, as electrical energy is gas. HHO stands for Hydrogen-Hydrogen-Oxygen. As it
used to break water into H2 and O2. In principle, an electrolysis name implies the hydroxy gas consists with 2:1 particles of
cell consists of two electrodes, commonly flat metal or carbon hydrogen and oxygen.
plates, immersed in an aqueous conducting solution called the
electrolyte. HHO gas was produced by the electrolysis process is B) Equations:
injected into the intake manifold after the carburetor. We create We established a MATLAB programing to Simulate the
a MATLAB program to calculate the cycle with and without expected result and compare it to real results, to get an over
HHO, create the balance equation for H2 addition in combustion view of the engine, by using the following equations:
equation, the saving percentage of fuel reached 5%. This work
presents an investigation to the effect of Hydrogen Booster • General combustion equation of introducing hydrogen
System on fuel consumption of an internal combustion with hydrocarbon fuel (C6H6) with x=1.99.
engine .And how we achieved it. CaHb + 4𝑎+𝑏 2(2−𝑥) (O₂ + 3.76 N₂+x H₂) → a CO₂
+ [x*(4𝑎+𝑏2(2−𝑥))H₂O]+[3.76*(4𝑎+𝑏2(2−𝑥))N₂] (1)
Keywords:[Alternative fuel, HHO generator, Fuel saving,
Brown’s gas]
• The cylinder volume at any crank position Ɵ is:
Nomenclature and Abbreviation V= Vc + (πB2)/ 4(l +a -s) (2)
RPM: revolution per minute, Ɵ: crank angle, B: Cylinder
bore, P: pressure, VC: clearance volume, rC: compression ratio
• The equation rearrangement:
V/Vc = 1+1/2 (rC-1) [R+1-cosƟ-(2R- sin2Ɵ) 1/2] (3)
I. INTRODUCTION The MATLAB outputs for the vehicle specification and
conditions, present the relation between the pressure (p) and
Due to the ending stocks of fossil fuels, as well as
crank angle (Ɵ) as shown in figure (1), and to see the effect
instability of the political situation in the world, especially
of changing in the volume (V) with the pressure (p) as
in countries that are major crude oil suppliers, governments
shown in figure (2)
of countries poor in the resources are forced to seek
alternative sources of energy. Currently, the most common
fuel for admission of internal combustion engines is oil. As
a result of the Continuous increasing of fuels prices and
legislation imposing decrease of toxic exhaust gasses
emissions tends to expansion the power base of the
automotive industry through the introduction of alternative
fuels. Electrolysis of water can give us hydrogen in form of
oxy-hydrogen gas which can be used as an alternative fuel
for any internal combustion engine. Electrolysis of water
can give us hydrogen in form of oxy-hydrogen gas which
can be used as an alternative fuel for any internal
combustion engine.
Fig.1 The relation between the pressure (p) and crank angle (Ɵ)

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Military Technical College, Cairo, Egypt, July 25-28, 2016.
 In principle, an electrolysis cell consists of two electrodes,
commonly flat metal or carbon plates. A source of DC
voltage connected to the electrodes, as shown in figure (4)
so that an electric current flows through the electrolyte from
anode to cathode. As a result, water in the electrolyte
solution is decomposed into H2 which is released at the
cathode and oxygen at the anode. Since water itself is the
poor conductor of electricity an electrolyte like KOH is used
to increase the electric conduction.

In our project we used (304) S.S instead of (316) S.S as it is

easier and requires less cost to manufacture.

Fig.2 pressure (P)-volume (V) diagram.

III. EXPERIMENTAL WORK

A) Experimental Setup

Our project is accumulative work depends on data

measured and collected by the previous two graduated
classes from the mechanical department at pharos
university; their experimental results are summarized as
follows: Fig.4 Electrolysis Cell.
• Successfully manufacturing the HHO Generator.
TABLE I
• Different electrolytes-like NaOH, KOH, Tap Water, and HHO DRY CELL COMPONENTS
Sea Water-measurements have been conducted and components material Size(cm) NO.
results show that the best solution is KOH 6 g/lit Cover plates Artilon 22x22x1 2
concentration. Plates (304)stainless steel 18x18x0.06 11
gaskets Rubber (O-Ring) NBR 17x0.3 12
B) Experimental set-up line Diagram
Bolts Steel 0.8x11 4
Nuts Steel 0.8 8
Washer Steel 0.8 16
Valves Steel 0.8 5

Dry cell assembly

We used the bipolar arrangement as follow: cover plate,

gasket, S.S plate, gasket…, to the last S.S plate, then gasket,
Fig. (3) Line Diagram of the experimental set-up. and then cover plate. Gathering by four bolts one in each
edge to balance the pressure applied on the gaskets.
C) Manufacture of HHO-Generator

1. DRY CELL
It considered the main element in HHO-Generation
system, and there are two categories of cells; wet cell - and -
dry cell [refer to plates positioning with the
electrolyte],Data based on several experiments show that:
11 plates (316) S.S is the best choice to eliminate any heat
loss and inhibit the electrical conductivity to ensure good
water electrolysis process which uses an electric current to
dissociate the water molecules into H2 and O2 as follow:
Fig.5 dry cell assembly
2 H2O → 2 H2 + O2

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Military Technical College, Cairo, Egypt, July 25-28, 2016.
2. THE WATER TANK
Is used to contain the electrolyte (1 liter distilled water
with 6 gram KOH), we used a car water tank as it is
designed to stand with the operation conditions ,it must be
insulated well to prevent any leakage of the gases passes
through it.
3. The Bubbler
The bubbler will serve two purposes: cleaning the HHO
gas and act as a safety barrier.
D) Experimenting the unit in the lab
To make sure that the HHO-generator we have built-it-
up work well and produce the required amount of the
hydroxy-gas
Make sure that bubbler is installed above the water tank to
accomplish the gravity head needed for a correct “filtering”
of the HHO gas.
F) Experimental Work on the navy vehicle
This project is done with association and help of the
navy research center, we are very grateful to them for
giving us a vehicle to work on.
The Experiment consists of:
• The vehicle.
• HHO-Generator system [Dry-Cell, Tank, Bubbler,
pipes, electrical connection].
• Measuring devices [Taco-meter, and Digital Scale].

The Experiment procedures:

a) Use external petrol tank to be able to measure the

amount of the fuel consumption, we considered locating
the tank at a head allow the petrol to flow without any need
for pumping system.

Fig.8 experimenting the unit in lab.

E) INSTALLATION IN VEHICLE

1.Positioning the Dry-Cell

We needed to find a good place in the engine
compartment of the vehicle to locate the HHO-Generator.
Fig.9 the external petrol tank.
We installed the Dry-Cell as far away from the heat of the
engine as possible. The best place to install the dry-cell is
in the front of the car, in the space between grill and the
radiator to make it closer to the air entering the engine b) Measure the fuel consumption by observing the digital
compartment and it found to be the largest space available. scale during a specific period of time at a certain value of
the vehicle speed (RPM), using the Taco-meter to conform
2. Positioning the Water Tan that speed is maintained constant.
Make sure that water tank is installed with the same
care as described before for the Dry-Cell. The water tank
needs to be placed 20 cm above the HHO dry-cell to
accomplish the gravity head needed for the
water/hydrogen to flow into the generator. But in some
cases without too much space available for the installation
just makes sure that the bottom of the water tank is a little
bit higher than the top of the dry-cell.

3. Positioning the Bubbler

The bubbler will serve two purposes: cleaning the HHO
gas and acts as a safety barrier. In case of a flashback, the Fig. 10 using the Taco-meter.
bubbler acts as a safety barrier. If a flame reaches the
c) Measure the fuel consumption at a certain RPM before
bubbler and ignites the HHO that has accumulated at the
adding the hydroxy gas at different loads (1/3𝑙𝑜𝑎𝑑, 2/3𝑙𝑜𝑎𝑑,
top, the water column will prevent the HHO from going on
to the dry cell because the flame cannot skip from bubble to 𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑, 𝑎𝑛𝑑 𝑎𝑡 𝑛𝑜 𝑙𝑜𝑎𝑑)
bubble.

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d) The hydroxy gas enters to the combustion chamber A) Relations Between Fuel Consumption and load at
through the manifold with the filtered air where suction Different RPM
occurs, that make water to be extracted from the tank due to
the suction effect, then enters the combustion chamber and with HHO
causes damage to the engine. To avoid the suction effect we without HHO
used a valve as shown in figure (11) to increase the pressure 28.5

fuel consumption(g/min
and reduce the suction at the hydroxy gas inlet to the 28
27.5
manifold.
27
26.5
26
25.5
25
0 0.5 load 1 1.5
Fig.12 fuel consumption vs different load at (1100 RPM)

As shown in fig.12, the average fuel consumption at 1100

Fig.11 valve was used to avoid suction effect.
e) Adding the hydroxy gas at the same RPM and measure
the fuel consumption at different loads (1/3𝑙𝑜𝑎𝑑, 2/3𝑙𝑜𝑎𝑑,
𝑓𝑢𝑙𝑙 𝑙𝑜𝑎𝑑, 𝑎𝑛𝑑 𝑎𝑡 𝑛𝑜 𝑙𝑜𝑎𝑑)
f) Repeat steps (3 and 5) with different RPMs.
g) Compare the results before and after the hydroxy gas
RPM with different loads is reduced with HHO by 0.179%
less than the fuel consumption without HHO. This amount
of reduction in fuel consumption is not good enough, but we
know that the maximum warm up for any car don‟t take
more than few minutes, so this amount doesn‟t have high
effect in fuel consumption so we can neglect it.
with HHO without HHO
Linear (with HHO) Linear (without HHO)
28.5
fuel consumption(g/min)

28
addition. 27.5
27
26.5
26
IV. EXPERIMENTAL RESULTS 25.5
25
Even modern petrol engines are unfortunately not 0 0.5 load 1 1.5
burning petrol fuel to its full potential. The average petrol Fig.13 fuel consumption vs different load at (1400 RPM)
engine in a car is about 18% to 20% efficient. That leaves a
lot of room for improvement and HHO fuel is a good way
of improving the efficiency. The reason for this is simple; Fig.13, showing the average fuel consumption at 1400
the hydrogen is highly flammable and has a much higher RPM with different loads is reduced with HHO by 3.5%
heating value. less than the fuel consumption without HHO.
The hydrogen explosion is so fast that it fills the with HHO without HHO
combustion cylinder at least 3 times faster than the petrol Linear (with HHO) Linear (without HHO)
explosion and subsequently ignites the petrol fuel from all 28.5
fuel consumption(g/min)

directions instead of just a spark in one end of the 28

combustion cylinder, and this is preferred because the petrol 27.5
only has a short time in the combustion cylinder and if it‟s 27
not fully burnt in that short amount of time it goes out the 26.5
exhaust and is not benefitted from. 26
25.5
So we examined the effect of adding hydrogen to our 25
engine, also we studied the effect of variation in load, and 0 0.5 1 1.5
load
variation in RPM. We worked on different rpm 1100 Fig.14 fuel consumption vs different load at (2000 RPM)
rpm,1400rpm,2000rpm ,and at full load,1/3 load , and 2/3
load, and we got these results.

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 As shown in fig.14, the average fuel consumption at with hho without(hho)
2000 RPM with different loads is reduced with HHO by Linear (with hho ) Linear (without(hho))
4.3% less than the fuel consumption without HHO. 30
B) Relations Between Fuel Consumption and different

Fuel consumption(g/min)
25
loads
20
with hho without(hho)
Linear (with hho ) Linear (without(hho)) 15
30
Fuel consumption(g/min)

10
25 1000 1500 2000 2500
Car speed(RPM)
20
Fig.17 fuel consumption vs different (RPM) at 2/3 load
15
As shown in fig.17, at 2000 RPM the reduction in fuel
10
consumption with HHO is (6.35%), at another speed 1400
1000 1500 2000 2500
Car speed(RPM) RPM (1.85%), and at speed 1100 RPM reduction in fuel
Fig.15 fuel consumption vs different (RPM) at no load consumption is (0.216 %).

with hho without(hho)

As shown in fig.15, at 2000 RPM the reduction in fuel Linear (with hho ) Linear (without(hho))
consumption with HHO is (2.44%), at another speed 1400 30
RPM is (3.03%), and at speed 1100 RPM reduction in fuel Fuel consumption(g/min) 28
consumption is (0.07%). 26
24
22
20
with hho without(hho) 18
Linear (with hho ) Linear (without(hho)) 16
30 14
Fuel consumption(g/min)

12
10
25
1000 1500 2000 2500
Car speed(RPM)
20
Fig.18 fuel consumption vs different (RPM) at full load
15

10 As shown in fig.18, at 2000 RPM the reduction in fuel

1000 1500 2000 2500 consumption with HHO is (5.9%), at another speed 1400
Car speed(RPM) RPM (5.28%), and at speed 1100 RPM reduction in fuel
Fig.16 fuel consumption vs different (RPM) at 1/3 load consumption is (0.1 %) this amount of reduction in fuel
consumption not good but we know that maximum warm up
As shown in fig.16, at 2000 RPM the reduction in fuel for any car not increase than few minutes so this amount not
consumption with HHO is (2.49%), at another speed 1400 have bigger effect in fuel consumption we can neglect it.
RPM (3.846%), and at speed 1100 RPM reduction in fuel
From the previous data analysis, we found the reduction
consumption is (0.287%).
in fuel consumption is good at two speeds 1400 RPM with
3.5% and 2000 RPM with 4.3%.

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 V. SAFETY PRECAUTIONS REFERENCES
[1] „Internal Combustion Engine Fundamentals” John Heywood.
General steps [2] HHO generator. http://hhospecialists.com/vt~hho-hydrogen-
• Be sure to work outside, no smoking at any time during generators~hho-abstract~brgwtr-cors-vermont-05035.
the installation; make sure the engine is off and very [3] Dhananjay Babariya, Jay Oza, Bhavin Hirani, Gaurang Akbari “An
Experimental Analysis of S.I Engine Performance with HHO as A
importantly, not hot. Fuel” IJRET
[4] “Effect of Alternative Fuel on SI Engine‟s Performance”, PUA group of
• You must address the maintenance worker to Make Graduation project. Class2013
sure that the unit does not operate during maintenance [5] HHO calculation. http://www. jatit. Org /volumes /Vol31No2 /10 Vol3
and be warned of any hydrogen is stored in hoses since 1No2.pdf
[6] HHO. Overview. http://www. sciencedirect. com/science /article/pii/
the spark of hydrogen is considered shot S0360319910017830
[7] History of HHO generator. http://www. oxyhho.com/ ?History_Of
• Our HHO System does not store hydrogen; HHO Generator.
subsequently there is no fire hazard when installed [8] Installation.www.smart.cover.gr/manuals/DC1500C_english_2013.pdf
properly. [9] Material properties. http://www.aksteel.com /pdf/markets products
/stainless/austenitic/316_316l_data_bul
• However water electrolysis generates Hydrogen, an letin.pdf
[10] Safty.http://auto-hydrogen.com/what-is-hho/hho-safety-equip-defined
explosive gas, which means that you should never light
a match or smoke near or in front of the generators
output - the water tank could blow up.
• Be careful with the generator working when the car is
not moving. A small amount of hydrogen can
accumulate in the air intake of the motor and could
explode if you smoke or use an open flame near it.
• When testing the tank for pressure endurance, it is
recommended to test it using water not air (water is
more safe and the system runs on a low pressure,
leakage test only needs a hydrostatic Test) to avoid
bursting of tank and should be tested in a closed
container or behind a hard surface while wearing safety
equipment.

VI. CONCLUSION

In this project we tried to apply the HHO gas in a car

engine with 1600 to reach our goals:
• reducing fuel consumption by 5%
• Successfully manufacturing the HHO Generator
• Applying the HHO Generator(system) Inside a hood of
a car
• Successfully mixing HHO gas with the mixture of the
air and fuel with no circumstances.

ACKNOWLEDGEMENT

This paper is prepared by the combustion graduation

project group in the Department of Mechanical engineering
at Pharos University in Alexandria. Special thanks to Dr.
Tarek Belal, who supervised the project with Dr.Sameh
Tawfeek, and Eng. Saad for giving a help in the practical
work, we would like to thank PUA for providing us with
workshops and tools. And special thanks for The Navy
research center for offering us a vehicle to work on.

1st IUGRC International Undergraduate Research Conference,

Military Technical College, Cairo, Egypt, July 25-28, 2016.