Project report on

DESIGN & MANUFACTURING OF PLASTIC

GRANULATOR FOR RECYCLING 3D PRINTED
WASTE

SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR THE MINI PROJECT

BY

AMAN KUMAR

SAYYAM KANTHARIA

SAAHIL BHATTACHARYA

SAURABH PARABH

UNDER THE GUIDANCE OF

PROF. HETAL PUROHIT

DEPARTMENT OF MECHANICAL ENGINEERING

NEW HORIZON INSTITUTE OF

TECHNOLOGY &
MANAGEMENT
ANAND NAGAR, KAVESAR, OFF GHODBUNDER ROAD, THANE
(WEST), MAHARASHTRA 400615
UNIVERSITY OF MUMBAI
2022 - 2023
 DECLARATION

We here by declare that the project entitled “DESIGN &

MANUFACTURING OF PLASTIC GRANULATOR FOR
RECYCLING 3D PRINTED WASTE ” submitted by us to the MUMBAI
UNIVERSITY for partial fulfillment of the requirement for the mini project in the
field of MECHANICAL ENGINEERING is a record of bonafide work carried
out by us under the guidance of Prof. Hetal Purohit. We further also declare
that, this written submission represents our ideas in our own words, we have
adequately cited and referenced the original sources. We have adhered to all
principles of academic honesty and integrity and have not mis-presented or
fabricated or falsified any idea/ data/ facts/ source in our Project Report
submission. We understand that any violation of the above will be caused for
disciplinary actionby the institute and can also evoke penal action from the
sources which have thus not been properly cited or from whom proper
permission has not been taken when needed.

AMAN KUMAR

SAYYAM KANTHARIA

SAAHIL BHATTACHARYA

SAURABH PARABH

DATE : / / 2023
 CERTIFICATE

This is to certify that the project titled “ DESIGN & MANUFACTURING

OF PLASTIC GRANULATOR FOR RECYCLING 3D PRINTED
WASTE” is a bonified work of “ AMAN KUMAR , SAYYAM
KANTHARIA , SAAHIL BHATTACHARYA , SAURABH PARABH”
submitted to the University of Mumbai in partial fulfillment of the
requirement for “MINI PROJECT” in “Third year of Engineering in the
subject of Mechanical Engineering” for the Academic Year 2022 – 23

Prof. Hetal Purohit

( Project Guide )

Dr. Satish Silaskar Dr. P. D. Deshmukh

( Head of Mechanical ( Principal )
Engg. Department )

DATE : / / 2023
 PROJECT REPORT APPROVAL FOR T. E.

This project report entitled “ DESIGN AND MANUFACTURING

OF PLASTIC WASTE GRANULATOR FOR 3D PRINTED WASTE ” by “
Aman kumar, Sayyam Kantharia, Saahil B h a t t a c h a r y a , Saurabh
Parabh ” is approved for the Degree of Mechanical Engineering.

EXAMINERS:

1.

2.

DATE : / / 2023

PLACE : THANE
 ACKNOWLEDGEMENT

We sincerely express our deep gratitude to our guides Prof. Hetal Purohit,
Department of Mechanical Engineering for their valuable guidance and
encouragement during this work. We wish our sincere thanks to Dr. Satish Silaskar,
Head of Mechanical Engineering Department for their valuable guidance and
suggestions.
We are also thankful to Prof. (Dr.) P. D. Deshmukh, principal and otherstaff
members of Mechanical Engineering Department who are involved in making this
part of the project successful.
Last but not least, we would also like to acknowledge our family members and
friends for their contribution,continuous support and encouragement in the
completion of the project.

AMAN KUMAR

SAYYAM KANTHARIA

SAAHIL BHATTACHARYA

SAURABH PARABH

DATE : / / 2022
 CONTENTS

SR. NO NAME OF PARTICULARS PAGE NO

1 Introduction 1

1.1 General Overview 1

1.1.1 Global Warming Due to Greenhouse Gases 1

1.1.2 Percentage of Air Pollution Caused Due to 2

Various Sources
1.2 Introduction to Oxyhydrogen Generator 3

1.2.1 Types of Oxyhydrogen Generator 4

2 Aim & Objective 7

2.1 Problem Statement 7

2.2 Objective of the Project 8

2.3 Scope of the Project 9

3 Literature Review 10

3.1 Summary of Literature Review 10

4 Methodology 15

4.1 Sequential Flow Chart 15

5 Principle of Working 18

5.1 Production Method of Hydrogen 18

5.1.1 Steam Methane Forming 18

5.1.2 Electrolysis 19

5.1.3 Coal Gasification 20

5.2 Working Principle of Project 21

6 Design of Oxyhydrogen Generator 22

 6.1 Major Components 22

6.2 List of Components 27

6.3 Schematic Diagrams of The Generator 30

6.3.1 Series Configuration 30

6.3.2 Parallel Configuration 30

6.4 Drafting of Oxyhydrogen generator 31

6.4.1 Assembly Of Oxyhydrogen Generator (Parallel 31

Connection)
6.4.2 Details Of Oxyhydrogen Generator (Parallel 32
Connection)
6.4.3 Assembly Of Oxyhydrogen Generator (Series 33
Connection)
6.4.4. Details Of Oxyhydrogen Generator (Series 34
Connection)
7 Manufacturing & Assembly 35

7.1 Manufacturing Processes of components with its 35

Specifications
7.2 Stepwise Procedure for the assembly 40

7.2.1 Assembly Procedure for Parallel Configuration 40

7.2.2 Assembly Procedure for Series Configuration 41

7.3 Cost Estimation 41

7.3.1 Raw Material Cost 42

7.3.2 Manufacturing/ Fabrication Cost 43

8 Experimentation & Data Analysis 44

8.1 Need of Experimentation 44

8.2 Specifications of the Setup 45

8.3 Actual Experimental Setup 46

8.4 Experimental Procedure 46

 8.5 Results Obtained 48

8.5.1 8.5. For Parallel Configuration with Tap Water 48

1.1
8.5. For Series Configuration with Tap Water 49
1.2
8.5.2 8.5. For Parallel Configuration with Distilled 50
2.1 Water
8.5. For Series Configuration with Distilled 51
2.2 Water
8.6 Health & Safety Considerations 51

9 Conclusion 54

10 Future Scope 55

References
 List of Figures

SR. NO NAME OF PARTICULARS PAGE NO

1 Introduction 1

1.1.2 Percentage of air pollution caused due to various 2

sources
1.2.1.1 5
Wet cell Oxyhydrogen generator
1.2.1.2 6
Dry Cell Oxyhydrogen Generator
5 Principle of working 19

5.1.1 Formation of steam 19

5.1.3 Coal gasification process 20

5.2 Electrolysis Process 21

6 Design of Oxyhydrogen Generator 22

6.1.1 Stainless steel plates 23

6.1.2 Plexiglass Lid 23

6.1.3 Separator cover 24

6.1.4 Rubber Gasket 24

6.1.5 Threaded Screw & Nut: 25

6.1.6 Screw Insulation Tube: 25

6.1.7 Gas Chamber 26

6.1.8 Pneumatic Hose and fittings 26

6.1.9 Neutral plate 27

6.3.1 Series configuration 30
 6.3.2 Parallel configuration 30

6.4.1 Assembly Of Oxyhydrogen Generator (Parallel 31

Connection)
6.4.2 Details Of Oxyhydrogen Generator (Parallel 32
Connection)
6.4.3 Assembly Of Oxyhydrogen Generator (Series 33
Connection)
6.4.4 Details Of Oxyhydrogen Generator (Series 34
Connection)
7 Manufacturing and assembly 35

7.1.1 Electrode plate Before and After Manufacturing 35

7.1.2 Cover plate Before and After Manufacturing 36

7.1.3 Separator Before and After Manufacturing 36

7.1.4 Rubber Gasket Before and After Manufacturing 37

7.1.5 Neutral plate Before and After Manufacturing 37

7.1.6 Nut and Bolt 38

7.1.7 Insulation Tube 38

7.1.8 Gas Chamber Before and After Manufacturing 39

7.1.9 Rechargeable battery 40

8 Experimentation & Data Analysis 44

8.1.1 Experimental Setup 44

8.3 Actual experimental setup 46

8.4 Gas over water method 47

 List of Tables
SR. NO NAME OF PARTICULARS PAGE
NO
1 Introduction 1

1.1 Major Constituents of Combustion Gases in Fuels 1

Causing Air Pollution
6 Design of Oxyhydrogen Generator 23

6.1 List of Components 27

7 Manufacturing & Assembly 35

7.1 Material Cost 42

7.2 Manufacturing Cost 43

8 Experimentation & Data Analysis 44

8.1 Result for parallel connection oxyhydrogen generator 48

(tap water with KOH)
8.2 Result for series connection oxyhydrogen generator (tap 49
water with KOH)
8.3 Result for parallel connection oxyhydrogen generator 50
(distilled water with KOH)
8.4 Result for series connection oxyhydrogen generator 51
(distilled water with KOH)
 ABSTRACT

This study analyses a waste plastic granulator system to accelerate the

deployment of distributed recycling by providing low-cost feedstocks of
granulated post-consumer waste plastic. 3D printed products and waste into
polymer feedstock for recycling bots of fused particle/granule printers. The
experimentally measured power use is only a minor contribution to the overall
embodied energy of distributed recycling of waste plastic.The device’s technical
specifications are quantified in terms of power consumption (380 to 404 W for
PET and PLA, respectively) and particle size distributions.

The experimentally measured power use is only a minor contribution to the

overall embodied energy of distributed recycling ofwaste plastic. The resultant
plastic particle size distributions were found to be appropriate for use in both
recycle bots and direct material extrusion 3D printers. t: In order to accelerate
deployment of distributed recycling by providing low-cost feed stocks of
granulated post-consumer waste plastic, this study analyzes an open source
waste plastic granulator system. It is designed, built, and tested for its ability to
convert post-consumer waste, 3D printed products and waste into polymer
feedstock for recyclebots of fused particle/granule printers.

The experimentally measured power use is only a minor contribution to the

overall embodied energy of distributed recycling of waste plastic. The resultant
plastic particle size distributions were found to be appropriate for use in both
recyclebots and direct material extrusion 3D printers. Simple retrofits are shown
to reduce sound levels during operation by 4dB-5dB for the vacuum. These
results indicate that the open source waste plastic granulator is an appropriate
technology for community, library, maker space, fab lab, or small business–
based distributed recycling .

Keywords : Greenhouse gas , HHO Generator , Electrolysis process , Enhanced

Combustion , Efficient HHO Generator etc.
 CHAPTER 1:

Introduction

1.1. General overview:

Plastic recycling is a huge aspect of the open-source mindset and is a valuable tool that can
help cut down on resource waste and pollution. Plastic waste is one of the most abundant,
but underused resources on the planet; even though plastic is easily recyclable by nature it
often ends up only serving as pollution for the planet once it is used once. So, in this
project, we aim to shred thermoplastic waste and reduce plastic waste. It is designed in
terms of its use user-friendliness cutting operations, structural design and ease of
manufacturability The peer-reviewed business literature now recognizes this potential
shift in manufacturing, which is brought on not only by the open-source sharing of 3D
printer designs but now more importantly because of millions of freely shared digital
designs of other products that are 3D printable.

Any level of consumer from scientific research funders to arthritis patients can earn a high
return on investment manufacturing with commercial polymer 3D printing filament based
on downloaded substitution values. However, commercial 3D printing filament is still
sold for roughly an order of magnitude more than the cost of the raw materials of virgin
plastic pellets. This has reduced adoption of AM at the prosumer level.

There are two methods to overcome this artificial cost barrier for wider spread distributed
manufacturing: use distributed recycling to make filament and skip the entire process of
fusing filament into a 3D printed object by printing directly from polymer granules,
shards or particle. Many research groups and companies have demonstrated that pre-
consumer and post-consumer waste polymers can be recycled into 3D printing filaments,
including

• polylactic acid (PLA)

• acrylonitrile butadiene styrene (ABS)

14
• high-density polyethylene (HDPE)

• polypropylene (PP)

• polystyrene (PS)

• polyethylene terephthalate (PET)

• linear low-density polyethylene(OLD)

• Low density polyethlene.

15
 a) Quality of the electrical wiring, etc

Figure 1.2.1.1. Wet cell Oxyhydrogen generator

1.1.1.2. Dry cell Oxyhydrogen generator:

In Dry cell HHO gas generator electrode is not fully dipped in electrolyte liquid and
electrolytes only used for filling the gaps present between the electrodes themselves. A
typical dry cell consists of a container, few plates (neutral, positive, negative, and end
plates), wires, pipes, DC power supply, bubbler, flashback arrester, rubber seals, fasteners,
etc. The plates are separated by rubber seals to avoid the leakage of water. Dry cell is
configured based on the number of plates and their connection. For example, -n n n n n n+
termed as 8 plates cell in series configuration with 7 water compartments. Whereas a series
parallel cell can be configuring as - n n n +n n n- which means two 5 plates series cells in
parallel configuration. It should be noted that the spacing (defined by thickness of the
rubber seal) between the two adjacent plates has a significant impact on the HHO
production, therefore, precise measure must be taken during the design and the salient
physical parameters which are vital for HHO gas production using dry cell are :
1. Material of the plates.
2. Thickness of the plates.
3. Spacing between the plates.
4. Cross-section area of the plates.

16
5. Number of neutral plates.
6. Number of electrodes.
7. Type of electrolyte.
8. Amount of electrolyte.
9. Quality of the electrical wiring, etc.

Figure. 1.2.1.2. Dry Cell Oxyhydrogen Generator

17
 CHAPTER 2:

Aim and objective

2.1. Problem Statement:

World demand for energy is very high relative to the supply amount from the traditional
sources especially fossil fuel which is considered the start point of the world crisis. The
sources of fossil fuel are limited and by the present state of its usage it will deplete in near
future. Also, burning petroleum fuel results in decreasing its save amount, environmental
pollution, global warming with climate change and health thread impacts. The cost of
petroleum products is high and hence is unaffordable to most people in most developing
countries. Major pollutants causing acid rains are the by-products of combustion. How
much we try to compensate with an alternative fuel for our cars like cars working with
electric motors, solar panels, but the bottom line is that weare still lagging in the technical
aspect compared to petroleum fuels. So not to compete with petroleum fuelsbut to help
petroleum fuels to exist longer life in turn help to survive this ever-demanding automobile
industry Faced with the ever-increasing cost of conventional fossil fuels, researchers
worldwide are working overtimeto cost-effectively improve internal combustion engines
(ICE) fuel economy and emission characteristics. In recent years, many researchers have
focused on the study of alternative fuels which benefit enhancing the engine economic and
emissions characteristics. The main pollutants from conventional hydrocarbon fuels are
unburned/partially burned hydrocarbon (UBHC), CO, oxides of nitrogen (NOx), smoke,
and particulate matter.

18
2.2. Objective of the Project:

The primary goal is to reduce the harmful emissions and increase the milage of the engine
by integrating the designed Oxyhydrogen generator. To achieve this goal, the following
objectives have been identified:

1. To develop a cost-effective renewable energy-based system such as

Oxyhydrogen Generator.

2. To make HHO gas as user friendly as the conventional fuels like gasoline,

diesel etc.

3. To find the best approach for production and extraction of HHO gas.

4. To analyze the capability of HHO gas in various industries such as manufacturing,

medical etc.

5. To analyze the behavior of HHO gas with different engines.

6. To make innovative approach for integrating the Oxyhydrogen generator with the
existing system withoutany complexity.
7. To enhance the mechanical performance parameters of the engine such as
mileage, thermal efficiency,engine torque etc.
8. To cut down the dependency on the expensive fossil fuels.

9. To reduce the emission of harmful exhaust gases such as CO, NOx, HC etc. which
contributes to greenhouse effect (Pollution free environment).
10. To reduce the ill effects arising partial combustion of fuel such as detonation
and knocking whichhampers the life of the engine.

19
2.3. Scope of the project:
1. In near future HHO gas replace the conventional fuel.

2. Economy will be achieved by the end users as the fuel cost is less.

3. Harmful emissions from the engine drastically reduces as the complete combustion takes
place.

4. Using HHO gas, engines will have higher thermal & brake power efficiency by consuming
less fuel.

5. Life span of the engine increases as there will be no carbon scaling inside the chamber.

6. Dependency on fossil fuels reduces and use of renewable energy will be encouraged.

7. A balance between the greenhouse gas will be maintained leading to reduction in global
warming.

20
 CHAPTER 3:

Literature review

The main purpose of literature of review is to give an overview on HHO generator (Oxy –
Hydrogen Generator), its importance, process of production of hydrogen i.e., Electrolysis process
carried out in HHO generator and its fabrication etc.

[1]
Ajayi and et al. , researchers have successfully fabricated HHO generator which includes a
closed container containing six electrode rods and an aqueous electrolyte with electrodes being
connected to two terminals of the battery. The generator housing is fabricated with low density
plastic with Perspex for rigid support. The current supplied to the generator is 60 amps for 30 mins
and volume of HHO gas produced during electrolysis is calculated using Faradays Law. It was
found that 27.379 litters of HHO gas was produced in during the above-mentioned run time. One
main advantage of hydrogen is the ease of storing, shipping, and using. This means that other
foreign countries having little space for solar and wind equipment will still be able to take
advantage from carbon free energy.

Yadav and et al.[2] researchers describe the two different methods of oxyhydrogen gas generation
and their implementation on the engine. The resonance is produced inside water molecules
between the electrodes by DC pulses (typically square wave output). This causes enormous
electrical force to break the bond between the hydrogen and the oxygen and they freed as gas
molecules which are magnetically coupled to each other. In this study instead of using plastic
container a 304 stainless steel container of same capacity is used which itself acts as cathode
during the process of electrolysis. It was observed that presence of water in the combustion
chamber decreases the temperature of combustion chamber, reduces detonation, and does not allow
deposition of carbon on the cylinder wall. Electrolysis of water is the beneficial method which is
used to produce high quality hydrogen gas. In the water electrolysis process water is split up into
hydrogen and oxygen by means of electric current, this process is also described as a hydrogen
generation. This Process consist of three main components Two conducting electrodes, Container
having suitable electrolyte and Power source. The electrolyte used a type of chemical substance
containing free ions which carries electric current. In an electrolyser, an electrolyser separates into
cathode and anode. Due to the various types of ionic species and electrolyte material they conduct,
different electrolysers work
21
in different ways. In recent research which is done on hydrogen and wind systems based on the
electrolysis of water with energy generated using wind is used to generate the electricity required
by this method which uses a renewable source of energy in the form of wind energy. In this regard,
sources which includes energy generated using wind are used as a renewable energy option. Using
this technique, renewable energy-based electricity can be converted to hydrogen, which is also
considered as environment friendly method.

De silva and et al. [3], author describes the research done on the production of HHO gas using dry
cell HHO generator. The electrolyte-catalyst combination used is distilled water and potassium
hydroxide (KOH). Two separate implementations were carried out using two and three electrodes
respectively to evaluate the effect of distance between the plates as well as the number of
electrodes used. It has been concluded that the most convenient and efficient design methodology
for optimal generator is three electrodes with minimum plate distance.

Kassaby and et al. , author describes the experiments conducted on Skoda Felicia 1.3 GLXi
[4]

gasoline engine with and without HHO generator at engine speeds 1500rpm, 200rpm and 2500rpm.
In addition, the emissions were measured using TECHNO TEST exhaust gas analyser TE488. The
optimized parameters were number of plates, distance between the plates and type and quantity of
the electrolytes. It was found that 6 g/L of KOH as catalyst gives highest efficiency at different
motor speeds compared to 4 g/L of NaOH. HHO gas to the fuel/air mixture has positive impact on
octane rating of gasoline fuel. Therefore, the engine compression ratio can be raised and more gain
in the thermal efficiency can be obtained. The results shows that engine thermal efficiency was
improved by 10%, reducing the fuel consumption up to 34%. The concentrations of NOx, CO and
HC gases has been reduced to almost 15%, 18% and 14% respectively.

Kumar and et al. , author describes about fabrication of the optimal hydrogen generator using
[5]

stainless steel 216K electrodes, low density polyethylene (LDPE) container, SMPs and sodium
hydroxide as electrolyte. The different materials for successful fabrication were considered during
the design and their favourable properties were stated.

Sudarmanta and et al. , Dry cell HHO gas generator performance optimization was done by
[6]

varying the duty cycle of pulse width modulation, PWM on the Sinjai spark ignition engine port
injection, 2-cylinder 650 cc with gas inlet mechanism using a venturi. Variations performed on

22
HHO gas generator is the duty cycle of PWM, i.e.,20%, 40%, 60%, 80% and 100% (or the same
as non PWM). Sinjai engine performance optimization done on setting ignition timing for
minimum advance for best torque, MBT mechanism. The results show that optimum performance
of HHO gas generator is generated by PWM system with 40% duty cycle with parameters such as
specific energy input of 33,121 MJ/kg, generator efficiency of 20,064% and generator temperature
can be maintained below 60 0C. Application of HHO gas generator in point above on standard
ignition timing Sinjai engine produce in an increase of performance such as torque, power, BMEP
and thermal efficiency respectively of 2.27%, 2.76% and 3.05% and a decrease of bsfc 7.76 %.
Retarded ignition timing is adjusted to MBT can increase performance such as torque, power,
thermal efficiency, respectively 6.55%, 7,65%, 15,50% and a decrease of bsfc 22,06 %.

Jeremiah and et al. , hydroxy gas was produced by the electrolysis process using different
[7]

electrolytes such as KOH. NaOH, and NaCl with various electrode design in a leak proof
plexiglass reactor. The testing was carried out 0n TVS Sper XL, air cooled 69.9 cc gasoline engine.
Results showed that constant flow rate at low engine speeds (critical speed 2800rpm) has
adverse effects on engine parameters. The solution to this was found by designing a Hydroxy
Electronic Control Unit (HECU) which decrease the flow rate of the HHO gas by decreasing
voltage and current
automatically. Increase in engine torque by an average of 19% and reduction in CO and HC gases
were recorded as 13.5% and 5% respectively. For 100ml gasoline consumption without HHO
vehicle covered 4.8Km while with HHO gas the distance covered was 7.2 km.

Joy and et al. , author describes the two different approaches to feed the HHO gas into the
[8]

engine produced by the wet cell HHO generator. The wet cell design is more complicated,
expensive, and complicated to fabricate. But since effectiveness and rate of HHO gas produced is
higher the design was selected to further optimization. Miles per gallons (MPG) comparison with
and without HHO was tabulated which shows 25% decrease in fuel consumption. The physical
parameters which are consider for production of HHO gas using wet cell type are Material of the
electrodes, Number of electrodes, Spacing between the electrodes, Type of electrolyte, Amount of
electrolyte, Quality of the electrical wiring, etc.

Nabil and et al. [9], author investigated the engine performance and gas emission for two different
engines: 150CC old engine with carburettor and 1300CC new engine with Electronic Control Unit

23
(ECU). According to the required amount of HHO gas and available electric power source the
number of cells and stacks are determined; also, the effective area of the plates is calculated. In this
study, different generators are designed, fabricated, and tested; 5, 7, 9 plates single stack
generators, 13 plates two stacks (2 negative and 1 positive plates) generator and 19 plates 3 stacks
(2 negative and 2 positives plates) also 7 plates single stack generator was tested with different
electrolyte concentrations (sodium hydroxide, NaOH). It is observed that, a directly proportion
relationship between the electrolyte temperature and the cell amperage, which is considered
generator obstacle. The increased current through the cell causes the generator to become hotter
which is a closed loop results in bad efficiency. The generator with 5 plates has abnormal
behaviour due to the cell voltage has 3V which is very large value compared to the standard cell
voltage that results in high temperature and amperage. It is suggested that the face area of the
plates between 2 to 4 in2 per ampere of current. Results showed reduction 14.8 % and 16.3 % in
fuel consumption, 33 % and
24.5 % reduction in CO, 27.4 % and 21 % reduction in HC and obvious reduction in the exhaust
gases temperature for 150CC and 1300CC engines respectively. Also, 17.9 % and 22.4 % increase
in brake power and 15.7 % and 22.4 % increase in thermal efficiency were recorded for 150CC
and 1300CC respectively. Heavily dependent on fossil fuels for energy, the transportation sector
contributes to a staggering 20 percent of carbon dioxide emissions globally. Hydrogen powered
vehicles could be the answer to this problem, as fuel cell vehicles, which use hydrogen gas to
power an electric motor, emit only heat and water as by-products.

H. Alrafie and et al [10]

, In this study, Oxyhydrogen (HHO) gas produced by electrolysis
process using Potassium hydroxide (KOH) was introduced as a supplementary fuel into a four-
cylinder, four -stroke Compression Ignition (CI) engine. In the first part, the throttle of the
engine is held to its full, half and quarter position. The field voltage (brake load) is varied to
obtain different engine speeds. In the second part, the field voltage of the electric dynamometer is
held constant while the throttle of the engine is varied. Power, torque, Brake Specific Fuel
Combustion (BSFC) and efficiency improvements depend on the HHO gas flow rate supplied to
the engine and can be enhanced by 14.2, 4.8, 10.6 and 8.8 percent, respectively. A curve that
relates engine speed with the optimum HHO gas flow rate was plotted to maximize the
enhancement of the engine performance. Optimum HHO gas flow rate depends on the engine
speed; being 1.4 L/min at low speeds, and increases with speed increase to reach 2.1 L/min at
intermediate speeds, while at high
24
speeds, to maximize the enhancement of power and torque, it is recommended to mix diesel with
HHO flow rate of 3.0 L/min.

Tresna Dewi and et al. [11]

in this research study author approached structural design approach
for HHO generator. Design steps are divided into Electrolysis Reactor and Bubbler Tube Design.
Electrolysis reactor is made of an acrylic tube with 40 cm height and 20 cm diameter, and it
consists of auxiliary chambers, which are feed chamber, 5-liter capacity positioning on top of
hydrogen reactor with a casing close designed based on the reactor tube design. The number of
cathodes and anodes that are made of stainless steel are 42, with 6 cm width and 11 cm in length
and will be placed inside the electrolysis reactor and connected. Electrode cells configuration is
decided using HHO calculator. Electrode consists of stainless steel plates of 6 stacks and seven
plats of cathodes and anodes in parallel connection. Stainless steel used in this research is type
316. Based on the result and discussion above, we can conclude that water electrolysis device
was designed to produce HHO gas using stainless steel electrode 316 with s i x stacks, where
each stack gas a coupling electrode with surface contact 66 mm2.The current efficiency of the
hydrogen generator is 89.13 %. The highest volume of resulted gas from electrolysis process is
0.9250 LPM at the 0.05M solution concentration in 15A. Chromatography gas analysis showed
that the average hydrogen content in sample products are 65.432 %; oxygen 33.106%; and
nitrogen 1.444.

Kaimkhani A. and et al. [12]

In this study, a comparison of dry cell and wet cell to produce the
HHO gas was conducted. The HHO gas can be as a supplementary fuel in the existing I.C.
engines to reduce their dependency on the fossil fuels. The physical and operational parameters
for both cells were compared and critically discussed. The impact of heat generation on both cell
and their relevant safety issues were particularized. The HHO production from both fuels was
compared. It can be concluded now that dry cell is far much better than the wet cell as it produces
more HHO gas as compared to wet cell for the same input conditions. Its terms of working and
maintenance, the dry cell are more reliable and suitable than the wet cell. The safety features of
dry cell are more promising than the wet cell.

25
 CHAPTER 4

Methodology

Table 4.1 Sequential Flow Chart

26
4.1. PROBLEM STATEMENT:

In this step Thrust areas were studied and problems existed were marked out. With proper
survey, effects of problem identified were studied. Identified problem was further studied,
understood, and need to solve the problem was discussed.

4.2. LITERTURE SURVEY:

In this step of literature review we have done a survey of scholarly sources (such as books,
journal articles, and theses) related to a specific topic or research question. It is often written
as part of a thesis, dissertation, or research paper, in order to situate our work in relation to
existing knowledge. A literature review consists of an overview, a summary, and an
evaluation of the current state of knowledge about a specific area of research. It may also
include a discussion of methodological issues and suggestions for future research. Existing
work done by research scholars was interpreted, various books related to topic were studied
and need of new design was initiated.

4.3. NUMBER OF POSSIBLE SOLUTION:

In this step number of possible solution were find out after so much research. A large
number of research paper and information related to problem statement were compile
together to find out the various possible solution.

4.4. FINALISING THE SOLUTION:

After finding out various possible solution, the most efficient and economical solution is
chosen and finalized for further research.

4.5. DESIGN OF COMPONENTS:

We have done design of each part of oxyhydrogen generator for fulfilling following
purposes:

A. To select proper materials and best suited shapes,

B. To select the dimensions based on the loads on machines and strength of the material,

C. Specify the manufacturing process for the manufacture of the designed components.

27
4.6. ASSEMBLY PROCEDURE:

In this step the manufactured components are assembled with proper care and procedure.

4.7. DETAILED MODELLING AND ASSEMBLY OF HHO

GENERATOR:

In this step we have done 2-D drawings of each device components and their 3D modeling
on Creo parametric software.

4.8. FABRICATION OF PROTOTYPE:

In this step, fabrication of prototype take place in the CAD model is converted into real
manufactured product by using various processes.

4.9.TESTING OF PROTOTYPE:

After fabrication, manufactured product is check for its proper function by conducting the
experiments on the device.

4.10.RESULTS AND CONCLUSION:

After experimentation and testing of product, results are taken and calculated further. After
final results made, conclusions were concluded in this final step.

28
 CHAPTER 5:

Principle of working

5.1 Production Methods of Hydrogen:

Hydrogen has become one of the most useful alternatives to fossil fuels today due to its
properties such as great range of flammability, minor quenching distance, minimal ignition
source energy, great diffusivity, and low density. Since hydrogen is one of the many
elements in the environment, it is easily available. Hydrogen is not available in its pure form
in nature (atmosphere). However, it can be produced from hydrogen-containing compounds
such as fossil fuels, hydrogen sulphide, biomass, and water. To acquire hydrogen, it must
first be separated from the other elements in the combination. The following are ways for
producing hydrogen. Due to their lower cost compared to other methods, steam methane
reforming and coal gasification are the current industrially established processes for
hydrogen production.

5.1.1 Steam Methane Forming

Over 90% of the world’s hydrogen is produced using the steam methane reforming
process. Under a 3–25 bar pressure (1 bar = 14.5 psi) in the presence of a catalyst,
methane combines with steam to form hydrogen, carbon monoxide, and a trace
amount of carbon dioxide. Methane steam reforming is an endothermic reaction,
which means it requires heat to complete the process. Most of the hydrogen generated
in the world today is derived from natural gas. The process of steam–methane
reforming for hydrogen production is like that of producing other fuels like ethanol,
propane, or even gasoline. The first stage is to generate carbon monoxide and steam,
which are then combined with a catalyst to produce morehydrogen. In a final
production stage known as “pressure swing adsorption”, car- bon dioxide and other
impurities are removed from the gas stream, leaving essentially pure hydrogen.
Reaction of steam–methane reforming:

Heat + H2O + CH4 + → CO + 3H2 (1)

29
Reaction between water and gas:

H2O + CO → Heat (few amount) + H2 + CO2(2)

Figure 5.1.1. Formation of steam

5.1.2 Electrolysis

Electrolysis is a viable method for generating carbon-free hydrogen from renewable and
nuclear energy. The process of splitting water into hydrogen and oxygen using
electricity is known as hydrogen generation. An electrolyte separates to the anode and
the cathode in an electrolyser. Because of the varied types of electrolyte material and
ionic species they conduct, different electrolysers work in different ways. Recently,
research has been done on hydrogen wind systems based on the electrolysis of water
with wind energy to generate the electricity required by this method using a renew-able
wind source. In this regard, sources including wind energy are used as a renewable
energy option. Using this technology, renewable energy-based electricity can be
converted to hydrogen, a carbon-free energy carrier that does not emit greenhouse gas.

30
5.1.3. Coal Gasification :

Coal is made up of two parts: carbon-based matter (the decomposed remnants of

prehistoric plants) and mineral stuff (which comes from the ground from which the coal
is dug). Carbon-based matter is made up of five primary components: carbon, hydrogen,
oxygen, nitrogen, and Sulphur. To comprehend gasification, we must first comprehend
combustion. The full oxidation of a fuel such as coal, which generates heat and carbon
dioxide, is known as combustion. Carbon dioxide is a non-combustible product of the
burning process because it cannot be further oxidized. However, coal is not fully oxidized
during gasification. Coal is instead treated with a substance known as a gasification
agent. It requires heat input to proceed. Becausethe resultant gas is not completely
oxidized, it can be burnt as a fuel.

Figure 5.1.3. Coal gasification process

31
5.2. Working Principle of Project

Electrolysis of water is the best method of producing high purity hydrogen gas on demand.
The most important element of the generator is the electrolyzer cell where the electrolysis
reaction takes place. The cell consists of two electrodes (an anode and a cathode), which are
separated by the ion exchange membrane. To produce the highest purity of hydrogen up to
up to 99.95% purity, a platinum catalyst is used at the electrodes.

Figure 5.2. Electrolysis Process

When a continuous voltage is applied to the electrodes on the electrolyser cell, the
following reactions takes place. At the anode (the positively charged electrode), the
water molecules lose two electrons, forming an oxygen molecule and four hydrogen
ions.

Anode: 2H2O - 4e = O2 + 4 H+

The oxygen that is produced in this half of the reaction is safely vented to
atmosphere from the back of the generator. The four hydrogen ions that have been
produced then attracted by the negatively charged cathode and collect four
electrons reducing them to two hydrogen molecules.

Cathode: 4H+ + 4e = 2H2

32
 CHAPTER 6
Design of Oxyhydrogen Generator
Generally, HHO dry cell generator is composed of metal plates, stainless steel is preferred due to
its good electrical, thermal, and physical properties, specifically stainless steel 316L is used in this
study, with certain number and dimension determined according to the design and the application.
Stainless steel is anti-corrosive metal with melting point 1375-1400 oC. The plates are connected to
the electric DC power source such that, for one stack generator, one plate has positive charge
(anode), one plate has negative charge (cathode) and the reminders are neutral. Numbers of neutral
plates is determined according to the design to divide the source voltage equally between cells with
reasonable value. Every two successive plates formed a closed compartment with the aid of rubber
gasket. 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. Rubber has thickness tolerance under
pressure force with final thickness 2mm is reasonable to satisfy a convenient current resistance and
suitable space permitting the HHO gas to escape freely in the required direction. The plates have
down small holes for equalizing the water level in the cells and to permit the electrons to flow
under voltage drop with small friction and heat generated. Also, there are upper large holes
permitting the gas to vent, these hole in uppermost to increase the surface area of contact with
water and to speed up the gas out. If the plate design has a rectangular shape, then the smaller edge
length is oriented to be the path of HHO gas. Generator has accessories: two acrylic end cover
plates with thickness 12mm both has inlet water hole and the other has outlet gas hole, bolts,
washers, nuts, fittings, connectors, hoses, and tank.

6.1. Major components:

Oxyhydrogen generator can be simply a one-cell unit or have as many as needed to produce the
required quantityof HHO gas. Electric current is the driving force that creates electrolysis in such
generator. It separates chemically bonded compounds in water by passing an electric current
through them. By adding an electrolyteto the water, the electrolysis process can be enhanced. An
electrolyte is any substance containing free ions that behaves as an electrically conductive medium.
Catalyst would be the correct term because of the function it performs to speed up the production
of HHO gas.

33
6.1.1. Stainless steel plates:
Plates are designed and can be fabricated of Stainless Steel 316L grade which are 100mm x
100mm x 1mmin size. Such 7 plates are used to which forms 6 gas compartments and are
connected in series such thatthere are 5 neutral plates and one positive and negative plate
respectively. One mounting hole is drilled atone corner to hold the plates together to make an
assembly.

Figure 6.1.1. Stainless steel plates

6.1.2. Plexiglass Lid:

Two plexiglass lid of dimensions 125mm x 125mm x 10mm are used to which serves the purpose
of end lids/covers. Plexiglass is a transparent, lightweight and has high impact resistance.

Figure 6.1.2. Plexiglass Lid

34
6.1.3. Separator cover:
A cover is fabricated of the size 100mm x 100mm x 1mm which covers the separator and
forms thecompartment between them. The cover is made with same material as the separator.

Figure 6.1.3. Separator cover

6.1.4. Rubber Gasket:

Rubber gaskets are placed between each side of the stainless-steel plates and plastic separator
to avoid anyleakages in the assembly. The dimensions of the gasket are 100mm x 100mm x 1mm.

Figure 6.1.4. Rubber Gasket

6.1.5. Threaded Screw & Nut:

Material used for nuts and bolts is Mild steel because of its anti-corrosive properties which are
inherent to the metal, it will not lose this resistance if scratched during installation or use

35
 Figure. 6.1.5. Threaded screw and nut

6.1.6. Screw Insulation Tube:

The hexagonal screws are inserted in a screw insulation tube of size 8mm in diameter to avoid
any electrical shocks while handling.

Figure 6.1.6. Screw Insulation Tube

36
6.1.7. Gas Chamber:

Gas outlet port is made from ABS material having High rigidity, Good impact resistance, even at
low temperatures and Good insulating properties.

Figure 6.1.7. Gas Chamber

6.1.8. Pneumatic Hose and fittings.

Pneumatic hose of 8mm diameter is used to connect the inlet and outlet ports of the generator
to thestorage tanks.

Figure 6.1.8. Pneumatic Hose and fittings

37
6.1.9. Neutral plate:

Neutral plate which is involved in electrolysis process is made of stainless steel material having
grade ‘SS 316L’ because of it is the superior choice for superior choice for high corrosion and
high temperature applications, best toughness, higher durability and better resistance to chemicals
and chlorides like salt.

Figure.6.1.9. Neutral plate

6.2. List of components:

Sr.No. Part Name Material Picture Quantity

1. Electrode Plates Stainless Steel 10

(SS 316L)

2. Neutral Plates Stainless Steel 6

(SS 316L)

38
3. End Cover Plates Plexiglass 4

4. Gas separator Plexiglass 6

5. Gas separator cover Plexiglass 1

6. Threaded Bolts Mild Steel 22

with Insulation

7. Nut Mild Steel 44

39
8. Containers Acrylic 3

9. Pneumatic Fittings Rubber 10

10. Pneumatic Hose Rubber 2

11 Gasket Rubber 25

12 Gas chamber Port Acrylic 6

Table 6.2. List of components

40
6.3. Schematic Diagram Of the Generator:

6.3.1. Series Configuration:

Figure 6.3.1 Series configuration

6.3.2. Parallel Configuration:

Figure 6.3.2 Parallel configuration

41
6.4. Drafting Of Oxyhydrogen Generator:

6.4.1. Assembly Of Oxyhydrogen Generator (Parallel Connection) :

Figure 6.4.1. Assembly Of Oxyhydrogen Generator (Parallel Connection)

42
6.4.2. Details Of Oxyhydrogen Generator (Parallel Connection) :

Figure 6.4.2. Details Of Oxyhydrogen Generator (Parallel Connection)

43
6.4.3. Assembly Of Oxyhydrogen Generator (Series Connection) :

Figure 6.4.3. Assembly Of Oxyhydrogen Generator (Series Connection)

44
6.4.4. Details Of Oxyhydrogen Generator (Series Connection ) :

Figure 6.4.4. Details Of Oxyhydrogen Generator (Series Connection)

45
 CHAPTER 7

Manufacturing and Assembly

7.1. Manufacturing process of components with its specifications:

7.1.1. Electrode Plate:

Electrode plate which is involved in electrolysis process is made of stainless-steel material having
grade ‘SS 316L’ because it is the superior choice for high corrosion and high temperature
applications, best toughness, higher durability and better resistance to chemicals and chlorides like
salt. There is total 10 electrode plates are used out of which 8 are used in parallel connection and 2
are used in series connection. The size of the raw steel plates before manufacturing was
100X100X1 mm and all the cutting of sides was done by laser cutting and it is available at low cost
with high accuracy as compared to other processes, so it was preferred. The dimension of the
finished plates after processing is shown in the fig below. Each steel plate (electrode plate) has 3
holes of radius 5mm and one hole of 2.25 mm. There is a inside cut of rectangular shape of
dimensions 93X10 mm through which water will travel from one plate to other. The electrode plate
will be responsible for the electrolysis process. It carries the current and voltage needed for the
generation of hydrogen and oxygen gas.

Figure 7.1.1. Electrode plate Before And After Manufacturing

7.1.2. Cover Plate:

The cover plate acts a casing of the generator by holding tightly all the steel plates and other parts
at their respective places. There are 2 cover plates facing each other of material plex-glass lid
because of High impact resistance, excellent dimensional stability, lightweight and excellent
chemical resistance properties. Its size before manufacturing process was 125*125*10 mm and

46
after processing the dimensions are shown in figure. The cutting of sides was done by laser cutting
process. Then after laser cutting, 11 holes of radius 4mm , 2 holes of radius 2.25 mm and 2 holes
of radius 5mm was made by drilling process.

Figure 7.1.2. Cover plate Before And After Manufacturing

7.1.3. Separator:
Separator used in Dry Cell HHO generator is made of Acrylic materialbecause of lightweight,
good impact resistance, outstanding thermal insulator properties. Its function is to keep the
produced gas from mixing with each other in the generator. It is only present in parallel
connection. It acts a barrier for the gas produced i.e. oxygen and hydrogen and forced this gas to go
through their respective outlet ports. It is arranged in middle of 8 plates so that 4 electrodes will get
positive current and will produce oxygen and other 4 electrodes will get negative current and will
produce hydrogen gas. The dimension of plate before processing was 100X100 mm and after laser
cutting, the dimensions is shown in figure

Figure 7.1.3. Separator Before And After Manufacturing

47
7.1.4. Gasket:
Gaskets used in Dry Cell Oxyhydrogen having parallel connection is made of rubber because it
has a property of mechanically sealing the microscopic gap between two mating surfaces or joints.
Also, it has excellent wear resistance and good bonding strength. The gasket’s material is rubber.
It has been made by cutting with hands and the dimensions are as shown in figure.

Figure 7.1.4. Rubber Gasket Before And After Manufacturing

7.1.5. Neutral plate:

Neutral plate which is involved in electrolysis process is made of stainless-steel material having
grade ‘SS 316L’ because of it is the superior choice for superior choice for high corrosion and high
temperature applications, best toughness, higher durability and better resistance to chemicals and
chlorides like salt. These plates of total number 6 are used in series connection which is arranged
in between positive and negative electrode. The final dimensions of the gasket used are shown in
fig. They are not connected to the supply. By using neutral electrodes between the anodes and
cathodes, produces the electric current reduction and effective area increase without affecting the
flow rate production.

Figure 7.1.5. Neutral plate Before and After Manufacturing

48
7.1.6. Nut and Bolt:
Material used for nuts and bolts is Mild steel because of its anti-corrosive properties which are
inherent to the metal, it will not lose this resistance if scratched during installation or use. Its
function is to fasten all the parts tightly together at their respective places. Total 11 bolts and 22 in
parallel connection and same number in series connection are used in the assembly. The
dimensions of the bolt and nut are shown in figure

Figure 7.1.6. Nut and Bolts

7.1.7. Insulation tube:
Insulation tubes used in Dry Cell Oxyhydrogen having parallel connection is made of rubber
because of low thermal conductivity, low electrical conductivity, higher thermal expansion etc.
The material for tube is rubber which is a good insulation material. Its main function is to reduce
the leakage of electric current while passing through electrodes.

Figure 7.1.7. Insulation Tube

7.1.8. Gas chamber:

The plate is used for the transmission of produced gas between the electrodes and also for the
water. There is total six gas chamber plates are used in parallel connection and zero plate in series
connection. One plate is situated between each two electrode plates to collect and transmit the

49
produced gas to the outlet of the generator. The material selected for gas chamber plate is acrylic
and it is cut or process through laser cutting.

Figure 7.1.8. Gas Chamber Before and After Manufacturing

7.1.9. Rechargeable Battery:

The battery used in this project is a rechargeable sealed lead acid VRLA battery rating 12V-
12.AH. This type of battery is excellent for rechargeable purpose. A rechargeable battery or
storage battery is a group of one or more electrochemical cells. They are known as secondary cells
because their electrochemical reactions are electrically reversible. Rechargeable batteries come in
many different shapes and sizes, ranging anything from a button cell to megawatt systems
connected to stabilize an electrical distribution network. Several different combinations of
chemicals are commonly used, including: lead– acid, nickel cadmium (NiCd), nickel metal hydride
(NiMH), lithium ion (Li-ion), and lithium ion polymer (Li-ion polymer).

TECHNICAL SPECIFICATIONS:

• Dimensions: 90*34*23 mm
• Rated Capacity: 4V 1.5Ah
• Charging Time: 4 Hr

50
 Figure 7.1.9. Rechargeable battery

7.2. Stepwise procedure of an assembly:

7.2.1 Assembly procedure of HHO generator (Parallel connection) :
1. The assembly operation begins after the components have been manufactured. The
following are the shorter forms:
(a) electrodes (el) (b) gasket (gs) (c) gas chamber (gc)
2. Plates are arranged in the following order: cover plate - gs–el-gs-gc–gs–el–gs. This is
the initial stack sequence, and four stacks are stacked vertically on top of each other.
The separator is next placed, followed by four more stacks stacked in the same order as
the separator
3. Finally, the other cover plate is installed, and the arrangement is completed by
tightening the 11 bolts and 22 nuts that hold all of the plates in place. Insulation tubes
are used to cover them. Bolts for the power supply are inserted in the two holes of
radius 2.25mm. They are connected to the power supply battery of 12volts and
12ampere.
4. A gasket is installed between each plate to prevent leakage.
5. The cover plates still have two holes in which the gas and water pipes will be
connected. The gas pipe will be linked to the upper hole, while the water pipe will be
attached to the bottom hole.
6. These lines are connected to two tanks that will hold gas and water.
7. For pipe connections, four pneumatic elbows and four connectors are employed.
8. A wooden base is constructed on which the assembly and containers are mounted.
9. The entire arrangement is depicted in the following figure no.
51
7.2.2. Assembly procedure for HHO generator (Series Connection):

1. The assembly operation begins after the components have been manufactured. Here the
sequence for plate arrangement is, first cover plate - one electrode- six neutral plates-
one electrode-second cover plate.
2. This arrangement of plates does not have a separator and it is joined by 11 bolts and 22
nuts to hold the plates together. Then 2 bolts of radius 2.25 mm are inserted through
which power will be supply to the electrodes. They are connected to the power supply
battery of 12 volts and 12 amperes.
3. A gasket is installed between each plate to prevent leakage between them.
4. The cover plates still have two holes in which the gas and water pipes will be
connected. The gas pipe will be linked to the upper hole, while the water pipe will be
attached to the bottom hole.
5. There is only one tank here in which gas is collected. Both outlet ports for gas are
joined together by a T-fitting and then it is collected to the one port of the container.
Same thing goes for the outlet ports of water. Total 4 elbows, 2 t-fits and 2
connectors are used pneumatic type fitting accessories in the assembly.
6. Wooden base is made on which the assembly and the container is placed upon.

7.3 Cost Estimation:

Cost estimation is the process of estimating all the costs associated with completing a project
within scope and according to its timeline. A thorough cost estimate should include both the direct
and indirect costs associated with bringing a project through to completion. Depending on the
specifics of the venture, this will likely include various overhead costs (utilities, labour, etc.),
labour costs (including both time and wages paid), materials and equipment costs, vendor fees (if
the project requires third-party workers, freelancers, or other contractors), and more.

52
7.3.1. Material Cost:

COMPONENT MATERIAL COST/ITEM NUMBER OF TOTAL COST

ITEMS OF
MATERIAL(RS)

Electrode plate SS316 60 10 600

Neutral plate SS316 60 6 360

Cover plate Acrylic 100 4 400

Separator Acrylic 30 1 30

Gas chamber plate Acrylic 70 6 420

Gasket Rubber 5 25 125

Bolt and Nuts M.S 5-bolts 22-bolts 198

(for holes of radius 2-nut 44-nuts

4mm)

Power supply bolt M.S 4-bolts 4-bolts 24

and nut (for holes of
2-nut 4-nuts
radius 2.25mm)

Gas pipe and water ABS 80 1.5 120

pipe

Gas and water tank Acrylic 150 3 450

Fitting accessories 20 10 200

Battery 1300 1 1300

Total cost: 4227

53
7.3.2. Manufacturing cost:

Component Material Manufacturing Manufacturing

process cost
Electrode plate SS316 Laser 1000
Neutral plate SS316 Laser 600
Cover plate Acrylic Laser 240
Separator Acrylic Laser 60
Gas chamber plate Acrylic Laser 360
Gasket Rubber Hand cut 125
Bolt and Nuts M.S NA 0
(for holes of radius
4mm)
Power supply bolt and M.S NA 0
nut (for holes of radius
2.25mm)
Gas pipe and water pipe ABS NA 0
Gas and water tank Acrylic NA 0
Fitting accessories NA 0
Battery NA 0
Total cost :2385

7.3.3 Total Cost :

Total cost (Rs) : Total material cost (Rs)+ Total manufacturing cost (Rs)
= 4227 + 2385
= Rs.6612/-

54
 CHAPTER 8

Experimentation & Data Analysis

8.1. Need of experimentation:

1. To obtain optimum mass flow rate of hydrogen and oxygen from the experimental prototype
of oxy-hydrogen generator. Hydrogen will further mix with fuel and burned during combustion
process, as a result increasing fuel efficiency. Hydrogen is nearly unavailable in its molecular form
on earth. A number of production methods including electrolysis, steam reformation of natural gas,
and coal gasification are the foci of widespread production research, but electrolysis currently
offers the greatest potential for a sustainable hydrogen economy.

When a HHO generator is added to a fuel-based engine , then the result will be obtained in the
form of improved the combustion efficiency which means that it can save fuel to produce the same
mechanical energy. This will also reduces overall capital cost of a system.

Following figure illustrates whole experimental setup :

Figure 8.1.1. Experimental setup

2. To analyse and study the behaviour and relevant properties of the HHO gas that will be released
after electrolysis process. In Dry cell HHO gas generator electrode is not fully dipped in electrolyte
liquid and electrolytes only used for filling the gaps present between the electrodes themselves. A
typical dry cell consists of a container, few plates (neutral, positive, negative, and end plates),

55
wires, pipes, DC power supply, bubbler, flashback arrester, rubber seals, fasteners, etc. The plates
are separated by rubber seals to avoid the leakage of water

3. To study the performance of oxy-hydrogen generator by varying the number of electrode plates
used in experimental prototype of oxy-hydrogen generator and varying the DC supply of 12 volts
and 12 amperes. Also, to check and determine which parameter affects or doesn't affect the output
of the experiment. These parameters are area, shape, electrolyte used, no of stacks, etc.

4. To have comparative study between oxy-hydrogen generator having Parallel and Series
connections. Because efficiency of dry cell can be improved by increasing number of plates
along with increasing number of stacks. But, in general if we kept number of plates constant and
increased number of stacks, then it has no effect on the output of dry cell HHO generator.

8.2. Specifications of experimental setup:

Supply Voltage: 12 Volts

Supply Amperes: 12 Amps

Type Of Battery Used: Lithium Ion Battery

Operating Temperature: 29º C

Standard Pressure: 1.01325 bar

Type Of Catalyst Used: Potassium Hydroxide (KOH)

56
8.3. Actual experimental Setup:

Figure 8.3. Actual experimental setup

8.4. Experimental procedure:

The procedure outlines the steps we take to properly complete the testing on the oxyhydrogen
generator and obtain reliable findings.

1. First, we fill the tank with water to see whether there is a leak, and if there is, we repair the
leak.
2. After repairing all leaks, we used a weight machine to weigh 30 grams of KOH.
3. The 30gm KOH is then dissolved in one liter of tap water/distilled water.
4. We receive the final solution after properly mixing the KOH.
5. Fill the generator with this solution by pouring it into tanks.
6. Finally, connect the generator bolts to the power supply.
7. After the electrolysis process is completed in the generator, oxygen and hydrogen are
separated and sent to parallel generators, while HHO gas is combined and sent to a series
generator.

57
8. The HHO generator was turned on for 10 minutes before we began observing and
recording the results.
9. The produced gas is determined using the gas over water method, which involves placing
a tube in the container inverted so that the gas collects and the water in the tube drains.
When the tube has emptied completely, the time is recorded.

Figure.8.4. Gas over water method

10. We used the stopwatch to determine how long it took to fill the 10ml tube with gas.
11. Reading is taken five times and then calculate the average time required for fill 10ml tube
with gas.
12. This procedure is carried out same for all the three tanks for calculating gas flow.

58
8.5. Results Obtained:

8.5.1. Electrolyte used: tap water with KOH

8.5.1.1. For parallel connection oxyhydrogen generator (tap water with KOH):

TYPE OF TIME REQUIRED FOR FILL AVERAGE GAS FLOW

GAS THE 10 ML TUBE WITH TIME RATE
PRODUCED GAS(SECONDS) REQUIRED (ML/MIN)
(SECONDS)
READINGS 1 2 3 4 5

HYDROGEN 24 28 27 29 24 26.4 22.72

(H2)
OXYGEN 27 26 22 25 23 24.6 24.39
(O2)
TOTAL HHO HYDROGEN + OXYGEN 22.72+24.39
GAS (ML/MIN) (ML/MIN) = 47.11
Table 8.5.1.1. Result for parallel connection oxyhydrogen generator (tap water with Koh)

Note: Gas flow rate is calculated by converting the average time required to fill the 10ML tube
with gas into volume of gas flow rate i.e. (ml/min)

X = 10*60/26.4
X = 22.72 (ml/min)
where, X = Gas flow rate (ml/min) of hydrogen
Y = 10*60/24.6
Y = 24.39 (ml/min)
where, Y = Gas flow rate (ml/min) of oxygen

59
8.5.1.2. FOR SERIES CONNECTION OXYHYDROGEN GENERATOR (Tap water
with KOH):
TYPE OF TIME REQUIRED FOR FILL THE 10 ML AVERAGE GAS
GAS TUBE WITH GAS(SECONDS) TIME FLOW
PRODUCED REQUIRED RATE
(SECONDS) (ML/MIN)
Readings 1 2 3 4 5

HHO Gas 11 10 9 13 11 10.8 55.55

Table 8.5.1.2. Result for series connection oxyhydrogen generator (tap water with KOH)

Note: Gas flow rate is calculated by converting the average time required to fill the 10ML tube
with gas into volume of gas flow rate i.e. (ml/min)

X = 10*60/10.8
X = 55.55 (ml/min)
where, x = Gas flow rate (ml/min) of HHO gas.

60
 8.5.2. Electrolyte used: Distilled water with KOH

8.5.2.1. For parallel connection oxyhydrogen generator (distilled water with

KOH):

TYPE OF TIME REQUIRED FOR FILL THE 10 ML TUBE AVERAGE TIME GAS
GAS WITH GAS(SECONDS) REQUIRED FLOW
PRODUCED (SECONDS) RATE
(ML/MIN)
READINGS 1 2 3 4 5

HYDROGEN 19 20 21 18 22 20 30
H2
OXYGEN 22 24 26 25 23 24 25
O2
TOTAL HYDROGEN + OXYGEN 30+25=55
HHO GAS (ML/MIN) (ML/MIN)

Table 8.5.2.1. Result for parallel connection oxyhydrogen generator (distilled water with KOH)

Note: Gas flow rate is calculated by converting the average time required to fill the 10ML tube
with gas into volume of gas flow rate i.e. (ml/min)

X = 10*60/20
X = 30 (ml/min)
where, X = Gas flow rate (ml/min) of hydrogen
Y = 10*60/24
Y = 25 (ml/min)
where, Y = Gas flow rate (ml/min) of oxygen

61
8.5.2.2. For series connection oxyhydrogen generator (Distilled water with
KOH):

TYPE OF TIME REQUIRED FOR FILL AVERAGE TIME GAS FLOW

GAS THE 10 ML TUBE WITH REQUIRED RATE
PRODUCED GAS(SECONDS) (SECONDS) (ML/MIN)

READINGS 1 2 3 4 5

HHO GAS 8 10 12 8 8 9.2 65.21

Table 8.5.2.2. Result for series connection oxyhydrogen generator (distilled water with KOH)

Note: Gas flow rate is calculated by converting the average time required to fill the 10ML tube
with gas into volume of gas flow rate i.e. (ml/min)

X = 10*60/9.2
X = 65.21 (ml/min)
where, x = Gas flow rate (ml/min) of HHO gas.

8.6. Health & Safety Considerations:

Hydrogen is the most abundant element in the universe, the first element in the periodic table, and
one of the most promising new alternative fuels of the future. The 21st century will be the time of
change, end of the widespread use of fossil fuels that have been harming our environment. Fossil
fuels, such as coal and petroleum, are the remains of prehistoric organisms buried beneath the
earth's surface millions of years ago and they're in limited supply. The reserves of these fuels will
eventually vanish by the rate that we are abusing them. Preferably long before we extinguish them,
we must find alternatives. It is important that we find new ways to power our technology. Vehicles
that currently use internal combustion engines to burn diesel or gasoline fuel will need to run off
new fuels that are less scarce and burn cleaner, reducing or even eliminating the possibility of
pollution and keeping away harmful gasses that can affect consumers’ health.

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8.6.1. Environment:

Since the industrial revolution started, the environment has experienced some changes which are
irreversible. All the exhaust gasses emitted by factories, coal power plants, airplanes, vehicles, etc.
are heating up the planet and are causing the polar caps to melt. Such phenomenon is changing the
global temperature of the planet. Scientists predict that by the end of the 21st century the sea level
will rise to 6ft. This will affect about 100 million people that live in cities like Miami. CO2
emissions are accountable for such drastic effects. Another way machinery is affecting the
environment is with the uses of substances that contribute to ozone depletion. These usually have
high concentrations of chlorine or bromine. Some of these include chlorofluorocarbons, or CFCs,
halons, methyl bromide, carbon tetrachloride and methyl chloroform; most of these are used as
refrigerants for HVAC systems. It is also aimed to show people an example that young engineers
such as we do care for the well-being of earth and humanity in general. The Implementation of one
single HHO generator will not help the environment much. However, we are hopeful that devices
such as this one will become a trend. Not only they will save people money, but they will help the
environment by consuming less gasoline and they will also emit less harmful gasses.

8.6.2. Vehicle impact:

Vehicles consume a lot of energy and use many different fluids including battery acid, motor oil,
antifreeze, gasoline, air-conditioning refrigerants, and brake, transmission, hydraulic and
windshield-wiper fluids. In most cases, these toxins are harmful to humans and animals, and can
pollute waterways if they leak from the vehicle or are disposed incorrectly. Many vehicle fluids
are exposed to heat and oxygen while an engine is running and undergo chemical changes. These
fluids also pick up heavy metals from engine wear and tear, making them even more toxic to the
environment. There is no question about the damaging environmental effects that are involved with
automobiles, and it is our duty as engineers to address these issues

8.6.3. Health Considerations:

Using hydrogen as a fuel supplement for transportation applications such as combustion engines
in cars introduces certain potential safety hazards for the public and consumers. Hydrogen is an
odourless, tasteless, colourless, and highly flammable gas. In comparison with gasoline, hydrogen
has higher flammability. Storage of hydrogen gas under high pressure introduces hazards to nearby

63
personnel in the event of a loss of containment from material failure, so therefore choosing the
correct materials is the key to properly maintain the tolerance required. The released hydrogen
poses a combustion hazard because hydrogen burns with an invisible flame and has a very wide
flammability range as mentioned.

Hydrogen generators can provide a cost-effective method of supplying high purity hydrogen. Since
it is three times more potent than gasoline, hydrogen generators generally keep the hydrogen at low
pressures (40-60 psi), diminishing the chances of any sudden releases of high pressurized H2 gas.
Periodic maintenance is recommended to ensure no parts have been worn off. Since these systems
are relatively simple, most maintenance can be done in a house garage in a timely manner. It is
important to install a hydrogen generator with care. Although the hydrogen generators may require
the user to add a caustic solution to produce hydrogen gas, most generators for car applications
need only distilled or de-ionized water. Generators that use only water are more desirable as they
eliminate the hazards associated with handling additional chemicals. While only small quantities
of hydrogen are stored in the vessel, as well as the HHO gas being sent to the engine almost
immediately, hydrogen is a flammable substance that requires care and should be handled with
care. In the case of the prototype manufactured for this senior thesis, all team members will follow
a series of precautions when handling the generator. First, the generator will be equipped with a
pressure gage to ensure that the pressure contained will never exceed 60 psi. Even though, the
vessel selected for the prototype is a GE Whole House Filter, which, as specified by the
manufacturer, can hold up to 100 psi, we won’t allow for a pressure build up to reach more than
60 psi since we are dealing with hydrogen. Furthermore, tests and installation of the generator will
be conducted in a safe place with no flames or flammable materials around. Additionally, team
members working on the generator will always wear protective gear. This includes goggles, gloves,
etc. The prototype will be seal proved to ensure no hydrogen gas will leak; there will be sealant
paste applied to the top cap of the vessel as well as at every hose or pipe connection. When dealing
with flammable materials it is important to have a set of safety regulations to abide by. Following
all these safety precautions will greatly reduce the chances of a mishap.

64
 CHAPTER 9:
Conclusion

There is a lot of scepticism about oxyhydrogen generators for vehicles found online. It was
determined that to supplement fuel consumption with hydrogen gas completely, many
modifications need to be made to the fuel system of the car, that were out of our reach. The
generator produced oxygen and hydrogen from water through electrolysis. Minimization the cost
was done by using wildly available materials. From the results of the experiment, it can be
concluded that having an HHO generator such as this one, will improve gas mileage. Since
implementing the hydrogen generator will produce less carbon dioxide to the atmosphere, as well
as less consumption in gas. Therefor it will reduce greenhouse gasses. Hence, less effect on global
warming on the long run. Addition to it will provide more fuel efficiency, it will save money for
people who will use our product.

1. Oxyhydrogen generator can be fabricated in two configurations series and parallel respectively.

2. Series Configuration is economical, compact, and easy to fabricate.

3. Efficiency and production of gas increases with the use of distilled water as it increases the
conductivity.

4. KOH is found to be the best electrolyte as it yields 95-100 % pure hydrogen production along
with the right generator design.

5. From the experiments conducted, it is established that series configuration is more efficient as it
yields maximum mass flow rate of hydrogen as compared to parallel configuration.

65
 CHAPTER 10

Future Scopes

1. Integration of Oxyhydrogen Generator with automobile engines.

2. Finding out various other parameters affecting mass flow rate and efficiency of the
generator.

3. Optimization in the design of Oxyhydrogen Generator.

4. Exploring applications of hydrogen in various fields of engineering other than automobile.

5. Considering thermal losses while designing the Oxyhydrogen Generator.

66
 REFERENCES

[1] Arinola B. Ajayi and Olayiwola O. Akerele , Development Of Hydrogen Generator For
Hydrogen Gas Production, Lagos , Nigeria | The International Journal Of Engineering
And Science (IJES) , Volume 2 Issue , 7 Pages 126-130 , ISSN(e): 2319 – 1813 ISSN(p):
2319
– 1805 | Published :2013 Available At : https://www.theijes.com/papers/v2-
i7/Part.6/Q027601260130.pdf

[2] Yadav Milind S , Sawant S. M. , Anavkar Jayesh A and Chavan Hemant V ,

Investigations on generation methods for oxy-hydrogen gas, its blending with
conventional fuels and effect on the performance of internal combustion engineer ,
Ratnagiri , Maharashtra , India
| Journal of Mechanical Engineering Research Vol. 3(9), pp. 325-332 , ISSN 2141 -
2383 | Published : 21 September, 2011 Available At :
https://doi.org/10.5897/JMER.9000031

[3] Mohammad M. El – Kassaby , Yehia A. Eldrainy , Mohammed E. Khidr , Effect of

hydroxy (HHO) gas addition on gasoline engine performance and emissions | Alexandira
University , Egypt , Alexandra Engineering Journal , (2016) 55 , 243 – 251 | Published :
21 November 2015 Available At : https://doi.org/10.1016/j.aej.2015.10.016

[4] T. S. De Silva , L Senevirathne and TD Warnasooriya , HHO Generator : An Approach

To Increase Fuel efficiency In Spark Ignition Engines , Malabe , Sri Lanka | European
Journal Of Advances In Engineering And Technology , 2015 ,2(4) : 1-7 , ISSN 2394 –
658X | Published : 2015 Available At : https://ejaet.com/PDF/2- 4/EJAET-2-4-1-7.pdf

[5] Senthil Kumar , Manoj Mohan Prasanth , Krishnaraj S , Balakrishnan S , Kathirvel R ,

Design And Fabrication Of Hydrogen Generator , Pollachi , India | International Journal
Of Progressive Research In Science And Engineering , Volume 1,Issue
Available At :
https://www.researchgate.net/publication/326060285_DESIGN_AND_FABRICATION
_OF_HYDROGEN_ GENERATOR

[6] Bambung Sudarmanta , Sudjud Darsopupito , Application Of Dry cell HHO Gas
Generator With Pulse Width Modulation on Sinjai Spark Ignition Engine Performance
, Surbaya ,
 Indonesia | International Journal of Research in Engineering and Technology eISSN:
2319-1163 , ISSN: 2321-7308 | Published : Feb 2016 Available At
https://ijret.org/volumes/2016v05/i02/IJRET20160502019.pdf

[7] Jeremiah R , Vigneshwaran B, Design , Fabrication And Analysis Of HHO Generator

For Two Wheelers , Chennai, India | International Journal Of Advance Research Trends
In Engineering And Technology, Volume 4 , Special issue 19 | Published : 19 April 2017
Available At : https://ijartet.com/2631/v4s19march2017kingscse/conference

[8] Kolbe Joy , Jithin Raj , Ijas K , Adarsh Babu , Rajamani B , Design and Fabrication Of
Hydro Tech Tool Saver Kit , Tamil Nadu , India | SSRG International Journal
OfMechanical Engineering | Published : March 2019 Available At :
https://www.internationaljournalssrg.org/uploads/specialissuepdf/ICRTETM-
2019/2019/ME/PSN1045.pdf

[9] Tamer Nabil , Efficient Use Of Oxy – Hydrogen Gas in Vehicle Engines , Ismailia , Egypt
| Journal Europeen Des Systemes Autoatises , Volume 52 , pp 87 -96 Suez Canal
University , Egypt | Published : 7 January 2019 Available At :
https://doi.org/10.18280/jesa.520112
 SVKM’S INSTITUTE OF TECHNOLOGY, DHULE, MAHARASHTRA, INDIA
International Conference On Futuristic Developments in Mechanical Sciences and Technology
(ICFDMST - 2021)

DESIGN AND ANALYSIS OF OXYHYDROGEN GENERATOR – A REVIEW

1 2 3
KAUSTUBH DHANU NIMISH R. DICHWALKAR SAHIL S. NARKAR
4 5
ANIKET S. NAVALE PRATHAMESH CHOUGHULE
1, 2 ,3 ,4 5
U. G. STUDENTS ASSISTANT PROFESSOR
1
Mechanical Engineering Department
1
New Horizon Institute of Technology And Management, Ghodbunder Road , Thane , India

ABSTRACT :
Greenhouse gases are the major cause behind the present global climate change and heating issue. The
transportation sector generates the most important share of the greenhouse emission. To solve this issue,
an alternate renewable fuel used for internal combustion engine is one of the best ways through which
we can get solution about fuel shortage and carbon emission of the engine. The unique combustion
characteristics of hydrogen helps to scale back the carbon emission of the engine. The oxy-hydrogen
generator has been used to increase the fuel efficiency without major changes within the existing internal
combustion engine. The production rate of HHO gas depend upon the various elements, i.e., input voltage,
quality of water, temperature of water. An efficient HHO generator is meant to supply an outsized
amount of HHO gas by employing a less amount of power. This HHO gas can be use as a secondary fuel
on demand, in internal combustion engine (petrol and diesel) with no need of storage. Characteristics of
HHO gas helps to enhance the combustion which ultimately reduces the engine emission. In this paper,
we have study and reviewed some research done by people over a recent time on the use of HHO gas and
its generation for IC engines to increase the efficiency and reduce the overall use of conventional fuels.

Keywords: Greenhouse gas , HHO Generator, Electrolysis process, Enhanced Combustion, Efficient
HHO Generator etc.

I. INTRODUCTION
Air pollution causing due the vehicle emissions is a major factor of concern and are also responsible for affecting air
quality index in some urban areas over a decade. Over a decade passenger vehicle which are using petrol and diesel
as a fuel are one of major a cause concern for pollution contributor , producing significant amount of Carbon Dioxides,
Nitrogen Oxides , and other pollutant gases into the atmosphere , that promotes global warming which is major
cause of concern in current situation. Increasing world’s population and excessive increased use of fossil fuels leads
to the dominant increased in need of fossil fuels as compared last few years. Below data shows World Energy
Consumption by Fuel. The use of fossil fuels such as petrol , diesel and other non-renewable sources of energy is
increasing day by day. Due to which the companies which takes production steels and chemicals in industries is now
considered as emissions-heavy sectors. But hydrogen powered technique is slowly changing things. The
petrochemical as well as chemicals sector, which produces up to 1.25 to 1.50 gross tonnage of carbon emissions
from 2010 to 2017, is turning to electrolytic hydrogen as a substitute for fossil fuels.

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 Fig. 1.1 World Energy Consumption by Fuel

Since HHO generator is considered as a one of best energy alternative according to a global demand. HHO
generator is a device that can convert water into hydrogen gas and oxygen by using electrolysis process. HHO
generator uses phenomenon of electrolysis to separate and extract both hydrogen and oxygen out of water and supply it to
combustion chamber. Hydrogen gas which will be produced from the electrolysis process will result in zero
greenhouse gas [3]. When a HHO generator is added to a fuel-based engine, then there is result will be obtained in
the form of improved the combustion efficiency which means that it can save fuel to produce the same mechanical
energy. HHO generator increases fuel efficiency in such a way that when it is added to an air intake engine manifold
of a system and injection into the cylinders of a system where HHO is going to mix with fuel, there is an increase in
mileage of engine performance will be observed. To increase the fuel efficiency in a combustion engine by
increasing the energy produced per mole of fuel, HHO generator is used [4]. The need of using hydrogen generator
is, it provides supplemental fuel (gas) to conventional fuel to achieve efficient combustion of conventional fuels,
decrease in amount of unburnt charge, increase in thermal efficiency, initially designed, and used for welding and
gas cutting operations.

Hydrogen is considered as a one of best energy alternative according to a global demand. Electrolysis of water is the
beneficial method which is used to produce high quality hydrogen gas. The equipment used is called as oxy
hydrogen generator. In the water electrolysis process, water is split up into hydrogen and oxygen by means of
electric current, this process is also described as a hydrogen generation. This Process consist of three main
components two conducting electrodes, container having suitable electrolyte and power source. The electrolyte used
a type of chemical substance containing free ions which carries electric current. The main element of the oxy
hydrogen generator is the electrolysis cell where the electrolysis reaction takes place. The electrolysis cell consists
of two electrodes one is cathode and other is anode.

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 Fig. 1.1 electrolysis process

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When a continuous current is applied to the electrodes on the electrolysis cell, the following reactions takes place.
anode is the positively charged electrode, the water molecules lose two electrons, forming an oxygen molecule and
four hydrogen ions.

Anode (Oxidation)
2H2O - 4e = O2 + 4 H+

The oxygen is produced in this half of the reaction is vented to atmosphere from the back of the oxy hydrogen
generator. The four hydrogen ions that have been produced then attracted by the negatively charged cathode and
collect four electrons reducing them to two hydrogen molecules.

Cathode (Reduction)
4H+ + 4e = 2H2

HHO generator uses phenomenon of electrolysis to separate and extract both hydrogen and oxygen out of water and
supply it to combustion chamber. Hydrogen gas which will be produced from the electrolysis process will result in
zero greenhouse gas. When a HHO generator is added to a fuel-based engine, then there is result will be obtained in
the form of improved the combustion efficiency which means that it can save fuel to produce the same amount of
energy. HHO generator increases fuel efficiency in such a way that when it is added to an air intake engine manifold
of a system and injection into the cylinders of a system where HHO is going to mix with fuel, there is an increase in
mileage of engine performance will be observed. To increase the fuel efficiency in a combustion engine by
increasing the energy produced per mole of fuel, HHO generator is used. The need of using hydrogen generator is, it
provides supplemental fuel (gas) to conventional fuel to achieve efficient combustion of conventional fuels,
decrease in
amount of unburnt charge, increase in thermal efficiency, initially designed, and used for welding and gas cutting
operations. HHO gas is not a replacement or alternative for conventional fuel but can be blend with other fuels for
efficiency improvement.

II. OBJECTIVES
1. To analyze the behavior and characteristics of the HHO gas.
2. To analyze the best approach for production and extraction of HHO gas.
3. To analyze the capacity of the HHO gas in various industries such as manufacturing, medical etc.
4. To cut down the dependency on the expensive fossil fuel.
5. To develop a cost-effective renewable energy-based system such as Oxyhydrogen generator.
6. To make HHO gas as user friendly as the conventional fuels such as gasoline, diesel etc.
7. To develop innovative approach for integrating the oxyhydrogen generator with existing system without
much complexity.

III. LITERATURE REVIEWS

The main purpose of literature of review is to give an overview on HHO generator (Oxy – Hydrogen Generator), Its
importance, Process of production of hydrogen i.e., Electrolysis process carried out in HHO generator and its
fabrication etc.
Ajayi et al. (2013) [1], researchers have successfully fabricated HHO generator which includes a closed container
containing six electrode rods and an aqueous electrolyte with electrodes being connected to two terminals of the
battery. The generator housing is fabricated with low density plastic with Perspex for rigid support. The current
supplied to the generator is 60 amps for 30 mins and volume of HHO gas produced during electrolysis is calculated
using Faradays Law. It was found that 27.379 liters of HHO gas was produced in during the above-mentioned run
time. One main advantage of hydrogen is the ease of storing, shipping, and using. This means that other foreign
countries having little space for solar and wind equipment will still be able to take advantage from carbon free
energy. Yadav et al. (2011) [2], researchers describe the two different methods of oxyhydrogen gas generation and
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 their Implementation on the engine. The resonance is produced inside water molecules between the electrodes by DC
pulses

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(typically square wave output). This causes enormous electrical force to break the bond between the hydrogen and
the oxygen and they freed as gas molecules which are magnetically coupled to each other. In this study instead of
using plastic container a 304 stainless steel container of same capacity is used which itself acts as cathode during the
process of electrolysis. It was observed that presence of water in the combustion chamber decreases the temperature
of combustion chamber, reduces detonation, and does not allow deposition of carbon on the cylinder wall.
Electrolysis of water is the beneficial method which is used to produce high quality hydrogen gas. In the water
electrolysis process water is split up into hydrogen and oxygen by means of electric current, this process is also
described as a hydrogen generation. This Process consist of three main components Two conducting electrodes,
Container having suitable electrolyte and Power source. The electrolyte used a type of chemical substance
containing free ions which carries electric current. In an electrolyser, an electrolyser separates into cathode and
anode. Due to the various types of ionic species and electrolyte material they conduct, different electrolysers work in
different ways. In recent research which is done on hydrogen and wind systems based on the electrolysis of water
with energy generated using wind is used to generate the electricity required by this method which uses a renewable
source of energy in the form of wind energy. In this regard, sources which includes energy generated using wind are
used as a renewable energy option. Using this technique, renewable energy-based electricity can be converted to
hydrogen, which is also considered as environment friendly method.
De silva et al. (2015) [3], author describes the research done on the production of HHO gas using dry cell HHO
generator. The electrolyte-catalyst combination used is distilled water and potassium hydroxide (KOH). Two
separate implementations were carried out using two and three electrodes respectively to evaluate the effect of distance
between the plates as well as the number of electrodes used. It has been concluded that the most convenient and
efficient design methodology for optimal generator is three electrodes with minimum plate distance.
Kassaby et al. (2015) [4], author describes the experiments conducted on Skoda Felicia 1.3 GLXi gasoline engine
with and without HHO generator at engine speeds 1500rpm, 200rpm and 2500rpm. In addition, the emissions were
measured using TECHNO TEST exhaust gas analyzer TE488. The optimized parameters were number of plates,
distance between the plates and type and quantity of the electrolytes. It was found that 6 g/L of KOH as catalyst
gives highest efficiency at different motor speeds compared to 4 g/L of NaOH. HHO gas to the fuel/air mixture has
positive impact on octane rating of gasoline fuel. Therefore, the engine compression ratio can be raised and more
gain in the thermal efficiency can be obtained. The results shows that engine thermal efficiency was improved by
10%, reducing the fuel consumption up to 34%. The concentrations of NOx, CO and HC gases has been reduced to
almost 15%, 18% and 14% respectively.
Kumar et al. (2019) [5], author describes about fabrication of the optimal hydrogen generator using stainless
teel 216K electrodes, low density polyethylene (LDPE) container, SMPs and sodium hydroxide as electrolyte. The
different materials for successful fabrication were considered during the design and their favorable properties were
stated.
Sudarmanta et al. (2016) [6], Dry cell HHO gas generator performance optimization was done by varying the
duty cycle of pulse width modulation, PWM on the Sinjai spark ignition engine port injection, 2-cylinder 650 cc
with gas inlet mechanism using a venturi. Variations performed on HHO gas generator is the duty cycle of PWM,
i.e.,20%, 40%, 60%, 80% and 100% (or the same as non PWM). Sinjai engine performance optimization done on setting
ignition timing for minimum advance for best torque, MBT mechanism. The results show that optimum performance
of HHO gas generator is generated by PWM system with 40% duty cycle with parameters such as specific energy
input of 33,121 MJ/kg, generator efficiency of 20,064% and generator temperature can be maintained below 60 0C.
Application of HHO gas generator in point above on standard ignition timing Sinjai engine produce in an increase of
performance such as torque, power, BMEP and thermal efficiency respectively of 2.27%, 2.76% and 3.05% and a
decrease of bsfc 7.76 %. Retarded ignition timing is adjusted to MBT can increase performance such as torque, power,
thermal efficiency, respectively 6.55%, 7,65%, 15,50% and a decrease of bsfc 22,06 %.
Jeremiah et al. (2017) [7], hydroxy gas was produced by the electrolysis process using different electrolytes
such as KOH. NaOH, and NaCl with various electrode design in a leak proof plexiglass reactor. The testing was
carried out 0n TVS Sper XL, air cooled 69.9 cc gasoline engine. Results showed that constant flow rate at low
engine speeds (critical speed 2800rpm) has adverse effects on engine parameters. The solution to this was found by
designing a Hydroxy Electronic Control Unit (HECU) which decrease the flow rate of the HHO gas by decreasing
voltage and current automatically. Increase in engine torque by an average of 19% and reduction in CO and HC
gases were recorded as 13.5% and 5% respectively. For 100ml gasoline consumption without HHO vehicle covered
4.8Km while with HHO gas the distance covered was 7.2 km. Figure showing Experimental Setup of Dry Cell HHO
Generator is as follows,
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 Fig 2.2 Experimental Setup of Dry Cell HHO Generator

Joy et al. (2019) [8], author describes the two different approaches to feed the HHO gas into the engine produced
by the wet cell HHO generator. The wet cell design is more complicated, expensive, and complicated to fabricate.
But since effectiveness and rate of HHO gas produced is higher the design was selected to further optimization.
Miles per gallons (MPG) comparison with and without HHO was tabulated which shows 25% decrease in fuel
consumption. The physical parameters which are consider for production of HHO gas using wet cell type are
Material of the electrodes, Number of electrodes, Spacing between the electrodes, Type of electrolyte, Amount of
electrolyte, Quality of the electrical wiring, etc.
Nabil et al. (2019) [9], author investigated the engine performance and gas emission for two different engines:
150CC old engine with carburetor and 1300CC new engine with Electronic Control Unit (ECU). According to the
required amount of HHO gas and available electric power source the number of cells and stacks are determined;
also, the effective area of the plates is calculated. In this study, different generators are designed, fabricated, and
tested; 5, 7, 9 plates single stack generators, 13 plates two stacks (2 negative and 1 positive plates) generator and 19
plates 3 stacks (2 negative and 2 positives plates) also 7 plates single stack generator was tested with different
electrolyte concentrations (sodium hydroxide, NaOH). It is observed that, a directly proportion relationship between
the electrolyte temperature and the cell amperage, which is considered generator obstacle. The increased current
through the cell causes the generator to become hotter which is a closed loop results in bad efficiency. The generator
with 5 plates has abnormal behavior due to the cell voltage has 3V which is very large value compared to the
standard cell voltage that results in high temperature and amperage. It is suggested that the face area of the plates
between 2 to 4 in2 per ampere of current. Results showed reduction 14.8 % and 16.3 % in fuel consumption, 33 %
and 24.5 % reduction in CO, 27.4 % and 21 % reduction in HC and obvious reduction in the exhaust gases
temperature for 150CC and 1300CC engines respectively. Also, 17.9 % and 22.4 % increase in brake power and
15.7 % and 22.4 % increase in thermal efficiency were recorded for 150CC and 1300CC respectively. Heavily
dependent on fossil fuels for energy, the transportation sector contributes to a staggering 20 percent of carbon dioxide
emissions globally. Hydrogen- powered vehicles could be the answer to this problem, as fuel cell vehicles, which
use hydrogen gas to power an electric motor, emit only heat and water as by-products.

IV. PERFORMANCE BASED COMPARATIVE STUDY

1. The most convenient way of building up efficient HHO generator and is built by conceding distance
between plates, materials used, catalyst used, also number of electrodes used during the process of
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 electrolysis. The

8
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 idea which proposed is that, when the amount of current will flow through the generator with increase in
temperature of generator will make battery drain in less amount of time. Considering this situation, future
research will mainly focus on limiting the amount of current flow through the generator in order to obtain
maximum amount of HHO production and next step will take into consideration is to connect the HHO
generator which will be proposed is used along with an IC engine i.e. a spark ignition engine and will measure
the efficiency of fuel in vehicle and reduction in emission of air pollutants such as carbon dioxide and
carbon monoxide [3].
2. HHO gas consists of nature of implosion due to the atomic structure, when a gas burnt continuously the
vacuum is created suddenly which is responsible for this implosion. Flame temperatures of HHO gases are
varied according to receipting materials. HHO gas flame is awfully directional and having properties like
odorless, colorless, and lighter than air. HHO gas does not need oxygen externally during combustion as it
already contains oxygen internally. Due to this reason and wide range of flammability, high burning
velocity (100 time greater than petrol vapor), the HHO gas used for lean air fuel mixture with considerable
emissions and combustion efficiency [9].
3. Quality of air and fuel mixture influences thermal efficiency of system. By adding HHO gas into the
system, there will be an increase in magnitude of thermal efficiency. The engine thermal efficiency has been
increased up to 10% when HHO gas has been introduced into the air/fuel mixture, consequently reducing
fuel consumption up to 34%. This obtained results indicates that HHO gas which added on engine is
consists of dual function, i.e., hydrogen gas has higher calorific value. Due to the presence of oxygen
process of mixing and oxidation becomes easier. Since we can conclude Hydrogen gas which is used in
HHO generator will easily replace gasoline in small the concentration of NOx, CO and HC gases has been
reduced to almost 15%, 18% and 14% respectively on average. Therefore, HHO generator can be
integrated easily with existing engine systems [4].
4. When HHO is introduced into the system. electric power generators especially in India, where demand for
utility of power is more. This HHO generator which makes use of hydrogen gas will easily replicated.
Since, making use of renewable energy will become far easier [8].

V. CONCLUSION
From the above studies, research and experiments which are done on HHO generator following conclusions can be
made,
1. H. H. O. generator can increase the fuel efficiency in a combustion engine by increasing the energy
produced per mole of fuel during the ignition process and thus increase in the fuel efficiency can be
observed.
2. In Europe, USA, and Australia the HHO generator gas conversion kits are being offered to actual use. But
in India there is a need of detail study in making this kit to use in normal vehicle, since only overview study
has been done.
3. Due to increase in demand of electricity, HHO can be used in combination with coal or oil to increase the
electricity generation and to meet the requirement of energy production increasing efficiency of energy
production system.
4. HHO with coal can reduce coal consumption. Due to the addition of HHO up to 1 kg will lead to the saving
of 7.3 to 7.9 kg for Indian lignite and 5.1 to 5.4 kg for sub bituminous. These advantageous things mainly
come from the high GCV of HHO which enables the system for more efficient combustion in the boiler.
5. Research has been done on the use of HHO gas in IC engine to reduce carbon emissions and increase fuel
economy and efficiency by studying various parameters (e.g., loading conditions use of electrolytes,
number of plates, electronic materials etc. But there is the scope of research on some other factors such as
compression ratio, effect of using different ignition systems [9].

VI. REFERENCES
[1] Arinola B. Ajayi and Olayiwola O. Akerele, Development of Hydrogen Generator for Hydrogen Gas
Production, Lagos, Nigeria | The International Journal of Engineering And Science (IJES), Volume 2 Issue 7,
pp. 126-130, ISSN(e): 2319 – 1813 ISSN(p): 2319 – 1805 | Published :2013.
9
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 Available at https://www.theijes.com/papers/v2-i7/Part.6/Q027601260130.pdf

1
ICFDMST - 2021 0
 [2] Yadav Milind S, Sawant S. M., Anavkar Jayesh A and Chavan Hemant V, Investigations on generation
methods for oxy-hydrogen gas, its blending with conventional fuels and effect on the performance of internal
combustion engineer, Ratnagiri, Maharashtra, India | Journal of Mechanical Engineering Research Vol. 3(9), pp.
325-332, ISSN 2141 - 2383 | Published: 21 September 2011.
https://doi.org/10.5897/JMER.9000031

[3] Mohammad M. El – Kassaby, Yehia A. Eldrainy, Mohammed E. Khidr, Effect of hydroxy (HHO) gas
addition on gasoline engine performance and emissions | Alexandira University, Egypt, Alexandra
Engineering Journal, (2016) 55, pp. 243 – 251 | Published: 21 November 2015.
https://doi.org/10.1016/j.aej.2015.10.016

[4] T. S. De Silva, L Senevirathne and TD Warnasooriya, HHO Generator: An Approach to Increase Fuel
efficiency In Spark Ignition Engines, Malabe, Sri Lanka | European Journal of Advances in Engineering
And Technology, 2015 ,2(4): pp. 1-7, ISSN 2394 – 658X | Published: 2015.
Available at: https://ejaet.com/PDF/2-4/EJAET-2-4-1-7.pdf

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1
ICFDMST - 2021 1
Kaustubh Vineet

International Conference On
Futuristic Developments
In
Mechanical Sciences And Technology (ICFDMST

2021)
Certificate of Participation
This is to certify that Kaustubh Vineet Dhanu has participated and presented a pa per entitled
“DESIGN AND ANALYSIS OF OXYHYDROGEN GENERATOR – A REVIEW” in ICFDMST – 2021,
organized by the Department of Mechanical Engineering, Shri Vile Parle Kelavani Mandal’s Institute
of Technology (SVKM’s IOT), Dhule.

Dr. Hitesh Thakare Dr. Nilesh Salunke

Convener Organizing Chair
Reference Number: ICFDMST2021_1
Nimish Dichwalkar

International Conference On
Futuristic Developments
In
Mechanical Sciences And Technology (ICFDMST

2021)
Certificate of Participation
This is to certify that Nimish Dichwalfiar has participated and presented a pa per entitled
“DESIGN AND ANALYSIS OF OXYHYDROGEN GENERATOR – A REVIEW” in ICFDMST – 2021,
organized by the Department of Mechanical Engineering, Shri Vile Parle Kelavani Mandal’s Institute
of Technology (SVKM’s IOT), Dhule.

Dr. Hitesh Thakare Dr. Nilesh Salunke

Convener Organizing Chair
Reference Number: ICFDMST2021_2
Sahil Narkar

International Conference On
Futuristic Developments
In
Mechanical Sciences And Technology (ICFDMST

2021)
Certificate of Participation
This is to certify that Sahil Narfiar has participated and presented a paper entitl ed “DESIGN
AND ANALYSIS OF OXYHYDROGEN GENERATOR – A REVIEW” in ICFDMST – 2021, organized by
the Department of Mechanical Engineering, Shri Vile Parle Kelavani Mandal’s Institute of
Technology (SVKM’s IOT), Dhule.

Dr. Hitesh Thakare Dr. Nilesh Salunke

Convener Organizing Chair
Reference Number: ICFDMST2021_3
Aniket Navale

International Conference On
Futuristic Developments
In
Mechanical Sciences And Technology (ICFDMST

2021)
Certificate of Participation
This is to certify that Anifiet Navale has participated and presented a paper entitl ed “DESIGN
AND ANALYSIS OF OXYHYDROGEN GENERATOR – A REVIEW” in ICFDMST – 2021, organized by
the Department of Mechanical Engineering, Shri Vile Parle Kelavani Mandal’s Institute of
Technology (SVKM’s IOT), Dhule.

Dr. Hitesh Thakare Dr. Nilesh Salunke

Convener Organizing Chair
Reference Number: ICFDMST2021_4
Prathamesh Choughule

International Conference On
Futuristic Developments
In
Mechanical Sciences And Technology (ICFDMST

2021)
Certificate of Participation
This is to certify that Prathamesh Choughule has participated and presented a pa per entitled
“DESIGN AND ANALYSIS OF OXYHYDROGEN GENERATOR – A REVIEW” in ICFDMST – 2021,
organized by the Department of Mechanical Engineering, Shri Vile Parle Kelavani Mandal’s Institute
of Technology (SVKM’s IOT), Dhule.

Dr. Hitesh Thakare Dr. Nilesh Salunke

Convener Organizing Chair
Reference Number: ICFDMST2021_5