FABRICATION OF WATER FUELLED VEHICLE 5

A PROJECT REPORT ON

FABRICATION OF WATER FUELLED VEHICLE

Submitted in partial fulfillment of the requirements for

the award of degree of

BACHELOR OF ENGINEERING
In
MECHANICAL ENGINEERING
By

K.JAGADISH Reg. no: 311136020046

Under the esteemed guidance of

Mr. P.Srinivasa Rao, M.Tech
Associate Professor
DEPARTMENT OF MECHANICAL ENGINEERING

RAGHU INSTITUTE OF TECHNOLOGY

(Affiliated to ANDHRA UNIVERSITY)
Dakamarri, Bheemunipatnam Mandal,
VISAKHAPATNAM-531162
2011-2015

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RAGHU INSTITUTE OF TECHNOLOGY

(Approved by AICTE, New Delhi & Affiliated to ANDHRA UNIVERSITY.)
Dakamarri (Post), Bheemunipatnam (Mandal), Visakhapatnam-531162.

CERTIFICATE

This is to certify that a project report entitled ―FABRICATION OF WATER

FUELLED VEHICLE‖ has been submitted by K.JAGADISH (311136020046) of
Mechanical Engineering Department, during the period 2011-2015 in the partial
fulfillment of the requirement for the award of Bachelor Degree of Engineering in
Mechanical Engineering under our guidance.

PROJECT GUIDE HEAD OF THE DEPARTMENT

Mr.P.Srinivasa Rao , M.Tech Mr.P.Vijaya Kumar, M.E. (Ph.D.)
Department of Mechanical Engineering Department Of Mechanical Engineering
Raghu Institute of Technology Raghu Institute of Technology
Visakhapatnam Visakhapatnam

Signature of the External Examiner Signature of the Internal Examiner

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ACKNOWLEDGEMENT

We wish to express deep sense of gratitude to our project guide Sri.P.Srinivasa Rao, of
Mechanical Engineering department for his unique way of guidance and training throughout our
project. We hope to retain the systematic training that he has imparted to us through this project
as a means. We feel greatly indebted to him, for imparting the many principles involved behind
doing project work. His association and guidance throughout our project work beginning from
the selection of problem to up to the completion of thesis writing will remain as a memorable
event in our heart.

We also express our sincere gratitude to Sri P. Vijaya Kumar, Head of the Department of
Mechanical Engineering and Dr. Ch.Prabhakar Rao, Prinicipal for their innovative teaching
and guiding us throughout our stay in the college and shaping us to be responsible engineers for
the welfare of the country.

We sincerely thank all our faculty members of Mechanical Engineering Department for
their sustained help in our pursuits.

We also thank all those who have contributed directly or indirectly in successfully carrying
out this work.

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CONTENTS

TOPICS PAGE NO

1. ABSTRACT.……………………………………………………………………………....8

2. INTRODUCTION………………………………………………………………………..10

3. LITERATURE REVIEW…………………………………………………………….…11

4. PARTS NEED FOR HYDROGEN GENERATOR……………...……………….…..16

5. PROPERTIES OF HYDROGEN………………………………….………………...….18

5.1 ATOMIC STRUCTURE…………………………………………...…………………………...….…...18

5.2 PHYSICAL PROPERTIES……………………………………………………………..……..……......22

5.2.1 STATE…………………………………………………………………………………………..............22

5.2.2 ODOUR, COLOR AND TASTE……………………………………………………………………….24

5.2.3 TOXICITY………………………………………………………………………………………….......24

5.2.4 DENSITY AND RELATED MEASURES …………………………………….....................................25

5.2.5 LEAKAGE………………………………………………………………………………………….......27

5.3 CHEMICAL PROPERTIES ……………………………………………………………………………29

5.3.1 REACTIVITY……………………………………………………………………………….………..…29

5.3.2 ENERGY………………………………………………………………………………………….…..…30

5.3.3 FLAMMABILITY………………………………………………………………………………………32

5.3.4 HYDROGEN EMBRITTLEMENT……………………………………………………………..….…..33

5.4 OXYHYDROGEN GAS…………………………………………………………………………………34

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6. DESCRIPTION OF DIFFERENT PARTS………………………………………...…36

6.1. CONTACT BREAKERS…………………………………………………………………………....36

6.2. LED………………………………………………………………………………………………...…37

6.3. BUBBLER……………………………………………………………………………………………38

7. BRIEF DESCRIPTION ON PARTS NEED FOR MAKING GENERATOR…….39

7.1 CONSTRUCTION OF THE HYDROGEN GENERATOR AND DIFFERENT TYPES OF

ACTIVITIES CARRIED ON IT………….................……………………………………………..42

7.2 CONSTUCTION OF BUBBLER ……………………….…………………………………………..58

8. WORKING PROCUDRE AND TESTING OF HYDROGEN GENERATOR…....60

8.1 HOW THE GENERATOR IS CONNECTED TO THE ENGINE…………..………………….…60

8.2 HOW TO POWER THE HYDROGEN GENERATOR …………………………………………...61

8.3 SETTING UP THE WATER IN THE GENERATOR…………………………………………..….62

8.4 INSTALLING THE GENERATOR………………………………………….……………………....63

8.5 OUTPUT HOSE AND BUBBLER………………………………………….…………………….….64

8.6 ADDITIONAL STUFF……………………………………………………………………………..…64

8.7 THE COMPLETE INSTALLATION PICTURE………………………………………………......70

9. SCOPE FOR FUTURE WORK…………………………………………………….....73

10. CONCLUSION..…………………………………………….……………………...….74

11. REFERENCE……………………………………………………………………...…..76

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LIST OF FIGURES

FIG.NO DESCRIPTION PAGE NO

1 OUTLINE OF HYDROGEN GENERATOR BOOSTER…………………………….…..9

5.1 ATOMIC STRUCTURE OF A HYDROGEN MOLECLULE………………………...19

5.2 CHEMICAL STRUCTURE OF A COMMON FUELS………………………….……..21

6.1 BLOCK DIAGRAM OF HYDROGEN GENERATOR………………….………..…...36

6.2 GENERATOR BODY & PLATE ASSEMBLY ………………………………………..37

7.1 PVC PIPES…………………………………………………………………………..……..40

7.2 ELECTRICAL COVER PLATES…………………………………………………...…..41

7.3 CUTTING OF STEEL PLATES………………………………………………………....42

7.4 IDENTATIONS MADE ON STEEL PLATES………………………………………....43

7.5 DRILLING & GRINDING PROCESS OF STAINLESS STEEL PLATES…………43

7.6 DRILLING THE STAINLESS STEEL PLATES BY USING THE DRILLING

MACHINE……………………………………………………………………………..………44

7.7 GRINDING THE STEEL STRAPS………………………………………..…………....45

7.8 INCREASING SURFACE AREA BY USING 36/100 GRIT SAND PAPER…….….46

7.9 MAKING THE ELECTROLYTE ……………………………………………….……...46

7.10 DIFFERENT TYPES OF COMPONENTS USED IN HYDROGEN GENERATORS

ARE……………………………………………………………………………………....…..…47

7.11 CROSS-SECTION THROUGH CAP…………………………………………….…….48

7.12 TOP CAP OF BOOSTER WITH PRESSURE GUAGE………………………...……48

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7.13 COMPLETE FIG.OF GENERATOR BOOSTER ………………………………..….49

7.14 STRAP FORMATION BY PLATES……………………………………………….....51

7.15 STEEL PLATE ASSEMBLY…………………………………………………………..52

7.16 PLATES ARE BEING DIPPED IN THE ELECTROLYTIC SOLUTION……..…53

7.17 BOOSTER BEING MADE FOR ELECTROLYSIS PROCESS…………………....54

7.18 SIDE VIEW OF PLATE ARRAY………………….……………………………...…..55

7.19 COMPLETE ASSEMBLY OF PLATES………………………………………..….....56

7.20 INSULATION…………………….………………………………………………....…..57

7.21 BUBBLER CONSTRUCTION .…………………………………………………….....58

7.22 THE COMPLETE BOOSTER………………………………….…………………...…59

8.1 CURRENT PASSING THROUGH PLATES……………………………………….….65

8.2 THE PLATES ARE CONNECTED……………………………………………...……..66

8.3 UNWANTED CURRENT PASSING THROUGH ELECTROLYSIS………….........67

8.4 VOLTAGE DROP FOR A 12 VOLT SUPPLY……………………………...……..…..69

8.5 THE COMPLETE INSTALLATION PICTURE…………………………………...…70

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CHAPTER - 1

1.ABSTRACT

Nowadays we are using fossils fuels for running an I.C engine to produce electric energy.

This fossil fuel produces harmful byproducts and costly. So here we are using water as a fuel.

When we introducing anode and cathode into the water the positive charged hydrogen are

attracted by cathode and negative charged oxygen is attracted by anode. Here the hydrogen and

oxygen are disassociated to form HHO. We can directly feed this HHO into IC engines for

running.

The H2O molecule is electrically neutral, but the positive and negative charges are not

distributed uniformly. The electronic (negative) charge is concentrated at the oxygen end of the

molecule, owing partly to the nonbonding electrons, and to oxygen's high nuclear charge which

exerts stronger attractions on the electrons. This charge displacement constitutes an electric

dipole, represented by the arrow at the bottom; you can think of this dipole as the electrical

"image" of a water molecule.

As we all learned, opposite charges attract, so the partially-positive hydrogen atom on water

molecule is electro-statically attracted to the partially negative oxygen on a neighboring

molecule. This process is called hydrogen bonding.

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Notice that the hydrogen is somewhat longer than the covalent O—H bond. This means that it is

considerably weaker; it is so weak, in fact, that a given hydrogen bond cannot survive for more

than a tiny fraction of a second.

Finally the HHO gas generated from hydrogen Generator is fed directly into the Air intake valve

or carburetor of the I.C Engine.

FIG.1 OUTLINE OF HYDROGEN GENERATOR BOOSTER

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CHAPTER - 2

2. HYDROGEN GENERATOR BOOSTER

INTRODUCTION

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

can increase the mpg performance of a car or motorcycle, or truck and reduces the harmful
emissions dramatically.
It does this by using some current from the cars battery and alternator to fracture

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

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

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

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

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

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

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

exhaust.

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

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

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

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CHAPTER - 3

3.LITERATURE REVIEW

We need to stop burning fossil fuels. If we do so, it leaves us with two

problems, namely, a way to generate power to run our electrical equipment and heat or cool our

homes, and a way to power our vehicles. In this document, we will consider the

question of powering vehicles.

There are two main options:

The first is to achieve a reduction in the amount of fossil fuel burnt. The second

is to eliminate the use of fossil fuel altogether. Both have been achieved. As an example of the

first option, consider a car powered by a petrol (gasoline) engine. In the average car, only 35%

or so of the fuel is burnt in the cylinders of the engine, the remaining 65% burns in the catalytic

converter or is pushed, unburnt, out of the exhaust pipe as major pollution.

Reducing the fuel used:

It is possible to reduce the amount of fuel used, by utilising any or all of the following:

1. Improving the quality of the burn.

2. Reducing the amount of fuel in the cylinder.

3. Introducing water vapour into the cylinder.

4. Improving the quality of the spark.

5. Improving the streamlining of the vehicle.

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1). The burn quality can be improved dramatically by replacing some or all of the air drawn

into the engine, by a mixture of hydrogen and oxygen. This can be done by sacrificing

a small amount of engine power to drive an electrolyser to split water into the hydrogen/oxygen

mix needed, passing it through a safety ―bubbler‖ and feeding the gas into the air intake of the

engine. This causes a dramatic improvement to the burn, increases the power of the engine,

reduces the pollution and improves the miles per gallon achieved.

2). The fuel mix can be made leaner. If more air is used, the engine will run hotter. If

a hydrogen/oxygen (―hydroxy‖) mix is used, then there is a general improvement all round. If the

vehicle has computer control of the fuel/air mix, it is necessary to add an extra circuit to prevent

the computer injecting more fuel to offset the leaner mix required.

3). Adding water vapour to the air intake can give a 25% improvement in the miles per

gallon.

4). If the power of the spark is increased by adding extra circuitry to the electrical system, the

fuel burn is improved. However, this tends to lead to greater plug wear. ‖The Firestorm‖

plug gives a major improvement in burn quality .

5) the car, and/or other passive devices can give a major improvement in fuel consumption

through reduced the car, and/or other passive devices can give a major improvement in fuel

consumption through reduced wind pressure.

If using hydroxy gas to improve the burn quality and improve the mpg of a vehicle, no

timing adjustments are normally necessary. However, all recent cars in the USA are fitted with

an Electronic Control Unit and if nothing is done about that, a decrease in mpg may

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actually occur as the Controller may start pumping more fuel into the engine when it sees a

change in the quality of the exhaust.

Stanley Meyer.

On 17th December 1995, the Channel 4 television series ―Equinox‖ ran a programme

which included an interview with Stanley Meyer of Ohio, USA. I watched Stan demonstrate

a new method of separating water into its components of hydrogen and oxygen. His method

is some 17 times more efficient than conventional electrolysis. With conventional

electrolysis, the temperature of the water (plus additives to help the process) rises

substantially during the process. With Stan‗s method, the water temperature does not rise at

all and no additives are needed. This strongly suggests that his method utilises zero-

point energy to provide the extra power needed to break down the water. Zero-point energy

shows a temperature drop as the current increases.

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

4,936,961; 4,826,581; 4,798,661 and 4,613,304. His first patent was very difficult to obtain

as the US Patent Office said it was impossible to do and demanded to see a working model.

Stan gave them a demonstration but even then, they took a further three years of

Stalling before they issued the patent.

Henry Puharich.

Henry also used a pulsed signal to split water molecules in an efficient manner. His

technique is rather different in that he starts with a modulated audio sine-wave signal and uses

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half-wave rectification to cut off the negative voltage components.

Paulo Mateiro.

It is reported that water has been efficiently split by Paulo Mateiro, using the most

simple electrodes possible, with only 4.8 Volts from a 555 timer circuit. Different

frequencies from 200Hz to 1,100Hz have been used and for the cell in the test, the optimum

was 923Hz. The current was 300mA and the hydrogen production was so great that the

bubbles were almost tossing the water out of the top of the HHO Generator.

Kiyoshi Inoue (Tokyo).

Kiyoshi has been granted US Patent 4,184,931 for an efficient pulsed electrolysis

system. His recommendation is for a pulse waveform which has an ―on‖ period of from 5

to 50 microseconds (500 microseconds at a push) and an ―off‖ time of 2 to 30 times the ―on‖

time. His circuit provides independent adjustment of both the ―on‖ and ―off‖ times (a

simple circuit to do this is in the electronics tutorial section of this set of documents).

Rothman Technologies.

Since 2003 Rothman Technologies of Canada have been running a 12HP petrol motor

on hydrogen produced by a chemical process. This is a cheap process in which metal is

consumed and so, although of great interest, this is not a ‗free-energy‗ engine. A recent

patent application by William Brinkley proposes a system where aluminium pipes are

consumed by a 25% solution of Potassium Hydroxide heated to 180 degrees Fahrenheit.

William remarks on the non-polluting nature of the system, but this is not really so in that a

very large amount of energy has to be put into producing the aluminium metal in the

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smelting and refining process, and the pollution is just moved from the end user to the

industrial plant.

Francis Cornish of the UK has a system where electrolysis of water is combined with a

chemical process consuming aluminium wire. The system works well, but I have

reservations about using consumables which tie you to industrial manufacturing, also

concerns about the reliability of mechanical feed systems when they are being used by non-

technical people (most car drivers). There is also the issue of removing and recycling the

chemical residue generated by the process.

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CHAPTER - 4

4. PARTS NEED FOR HYDROGEN GENERATOR

Part, Quantity, Comment:

 4-inch diameter PVC pipe, 12-inches long 1, this Forms the body of the generator.

 4-inch diameter PVC pipe end-cap 1, this Closes the bottom of the generator.

 4-inch diameter PVC pipe screw cap 1, this makes the top of the generator.

 90-degree Quick Connect Outlet fitting 1 3/8" O.D. Tube x 14" NPT (from Hardware
store).

 Level indicator Nylon barbed tube fitting 2 1/4" Tube x 1/8" NPT (from your local
hardware store Lowes or home depot.

 Quarter-inch I.D. Poly sight tube 8‖ Water-level indicator tubing (from Hardware store).

 Stainless steel switch covers 16 these make plate assembly components or stainless steel
sheet metal flat pieces from steel yard.

 Stainless steel straps 12-inches long 2 The electrical connections to the plates or stainless

steel utensils like spoons or forks from cooking supply stores or dept. stores will work.

 3/4" Inside Diameter Clear poly tube 12-inch From local hardware store.

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

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

 5/16‖ diameter nylon threaded rod 8‖ minimum.

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

 5/16‖ inch nylon washers 1.6 mm thick 1-pack Nylon 6/6 Flat Washer 5/16", pack of
100.

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

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

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

 PVC glue 1 tube Same colour as the PVC pipe if possible.

 5/16" Neoprene sealing washer 2 needed from the local Hardware store.

 Tool dip – tool coating, it‗s a liquid plastic used to dip tool handles in, sold at all
hardware stores.

 Optional: Light Emitting Diode 1 10 mm diameter, red, with panel mounting clip.

 Quarter-watt resistor : 1470 ohm (code bands: Yellow, Purple, Brown)

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CHAPTER - 5

5. PROPERTIES OF HYDROGEN

5.1 ATOMIC STRUCTURE:

Hydrogen is by far the most plentiful element in the universe, making up 75% of the mass

of all visible matter in stars and galaxies. Hydrogen is the simplest of all elements. We can

visualize a hydrogen atom as a dense central nucleus with a single orbiting electron,

much like a single planet in orbit around the sun. Scientists prefer to describe the

electron as occupying a ―probability cloud‖ that surrounds the nucleus some-what like a fuzzy

spherical shell. In most hydrogen atoms, the nucleus consists of a single proton, although a rare

form (or ―isotope‖) of hydrogen contains both a proton and a neutron. This form of

hydrogen is called deuterium or heavy hydrogen. Other isotopes of hydrogen also exist,

such as tritium with two neutrons and one proton, but these isotopes are unstable and decay

radioactively.

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HYDROGEN MOLECULE (H2)

Electron Probability Cloud

Nuclei

FIG.5.1 ATOMIC STRUCTURE OF A HYDROGEN MOLECULE

A proton has a positive electrical charge, and an electron has a negative electrical

charge. Neutrons do not carry a charge. Together, the charges associated with the proton and

electron of each hydrogen atom cancels each other out, so that individual hydrogen atoms are

electrically neutral as shown in figure 5.1.

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

reactive. For this reason, hydro-gen atoms naturally combine into molecular pairs (H2 in-stead

of H). To further complicate things, each proton in a hydrogen pair has a field associated with

it that can be visualized and described mathematically as a ―spin‖. Molecules in which both

protons have the same spin are known as ―ortho-hydrogen‖. Molecules in which the protons have

opposite spins are known as ―Para hydrogen‖. Over 75% of normal hydrogen at room

temperature is ortho-hydrogen.

This difference becomes important at very low temperatures since orthohydrogen

becomes unstable and changes to the more stable Para hydrogen arrangement, releasing heat

in the process. This heat can complicate low temperature hydrogen processes, particularly

liquefaction.

COMPOSITION OF OTHER FUELS:

It is natural for us to compare hydrogen to other hydrocarbon fuels with which we are more

familiar. All hydrocarbon fuels are molecular combinations of carbon and hydrogen atoms.

There are thousands of types of hydrocarbon com-pounds, each with a specific

combination of carbon and hydrogen atoms in a unique geometry as shown in figure 5.2.

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FIG.5.2 CHEMICAL STRUCTURE OF COMMON FUELS

The simplest of all hydrocarbons is methane, which is the principal constituent of natural

gas. (Other components of natural gas include ethane, propane, butane and pentane as well as

impurities.) Methane has the chemical formula CH4, which means that each molecule has four

hydrogen atoms and one carbon atom.

Other common hydrocarbons are ethane (C2H6), propane (C3H8) and butane (C4H10). These are

all considered light hydrocarbons since they contain less than five carbon atoms per molecule

and therefore have low molecular weight (a carbon atom is almost 12 times as heavy as a

hydrogen atom).

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

Is heptane (C7H16). Gasoline, diesel, kerosene, and compound found in asphalt, heavy oils and

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waxes, are considered heavy hydrocarbons as they contain many carbon atoms per molecule, and

therefore have high molecular weight.

The lightest hydrocarbons are gases at normal atmospheric pressure and temperature.

Heavier hydrocarbons, with 5 to 18 carbon atoms per compound, are liquid at ambient

conditions and have increasing viscosity with molecular weight. Other chemical fuels include

alcohols whose molecules com-bine an oxygen/hydrogen atom pair (OH) with one or more

hydrocarbon groups. Common alcohol fuels are methanol (CH3OH) and ethanol (C2H5OH).

5.2 PHYSICAL PROPERTIES:

5.2.1 STATE:
All substances exist on earth as either a gas, liquid or solid. Most substances

will change from one of these states to another depending on the temperature and pressure of

their surroundings. In general, a gas can be changed into a liquid by reducing its temperature,

and a liquid to a solid by reducing its temperature further. To some extent, an increase in

pressure will cause a substance to liquefy and solidify at higher temperature than would

otherwise be required.

The transition from liquid to gas is known as boiling and the transition from liquid to

solid as freezing. Accordingly, each substance has a characteristic boiling temperature and

freezing temperature (at a given pressure). The opposite transitions, from gas to liquid

and solid to liquid, are known as Condensation and Melting respectively.

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The condensation temperature is the same as the boiling temperature and the melting

temperature is the same as the freezing temperature. The process of condensation is also

known as liquefaction and the process of freezing is also known as solidification.

Boiling and freezing temperatures are most meaningfully compared relative to

―absolute zero‖. Absolute zero (0 ºR; 0 K; –459.69 ºF; –273.15 ºC) is the lowest temperature

in the universe at which all molecular motion stops.

Hydrogen has the second lowest boiling point and melting points of all substances,

second only to helium. Hydrogen is a liquid below its boiling point of 20 K (–423 ºF; –253 ºC)

and a solid below its melting point of 14 K (–434 ºF; –259 ºC) and atmospheric pressure.

Obviously, these temperatures are extremely low. Temperatures below –100 ºF (200 K; –73 ºC)

are collectively known as cryogenic temperatures, and liquids at these temperatures are

known as cryogenic liquids.

The boiling point of a fuel is a critical parameter since it defines the temperature

to which it must be cooled in order to store and use it as a liquid. Liquid fuels take up

less storage space than gaseous fuels, and are generally easier to transport and handle.

For this reason, fuels that are liquid at atmospheric conditions (such as gasoline, diesel,

methanol and ethanol) are particularly convenient.

The boiling point of a pure substance increases with applied pressure—up to a point.

Propane, with a boiling point of –44 ºF (–42 ºC), can be stored as a liquid under moderate

pressure, although it is a gas at atmospheric pressure. (At temperatures of 70 ºF (21 ºC)

a minimum pressure of 111 psig (7.7 bar) is required for liquefaction). Unfortunately,

hydrogen‗s boiling point can only be increased to a maximum of -400 ºF (–240 ºC)

through the application of approximately 195 psig (13 bar), beyond which additional

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pressure has no beneficial effect.

5.2.2 Odour, Colour and Taste:

Pure hydrogen is odourless, colourless and tasteless. A stream of hydrogen from a

leak is almost invisible in daylight. Com-pounds such as mercaptans and theophany‗s that are

used to scent natural gas may not be added to hydrogen for fuel cell use as they contain

sulphur that would poison the fuel cells.

Hydrogen that derives from reforming other fossil fuels is typically accompanied by

nitrogen, carbon dioxide, carbon monoxide and other trace gases. In general, all of these gases

are also odourless, colourless and tasteless.

5.2.3 Toxicity:

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

Asphyxiation:

Oxygen levels below 19.5% are biologically inactive for humans. Effects of

oxygen deficiency may include rapid breathing, diminished mental alertness, impaired

muscular coordination, faulty judgement, depression of all sensations, emotional instability and

fatigue.

As asphyxiation progresses, dizziness, nausea, vomiting, prostration and loss of

consciousness may result, eventually leading to convulsions, coma and death. At

concentrations below 12%, immediate unconsciousness may occur with no prior warning

symptoms.

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In an enclosed area, small leaks pose little danger of asphyxiation whereas large leaks

can be a serious problem since the hydrogen diffuses quickly to fill the volume. The potential

for asphyxiation in unconfined areas is almost negligible due to the high buoyancy and

diffusivity of hydrogen.

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

Inhaling hydrogen can lead to unconsciousness and asphyxiation”.

5.2.4 Density and Related Measures:

Hydrogen has lowest atomic weight of any substance and therefore has very low density

both as a gas and a liquid.

Density:

Density is measured as the amount of mass contained per unit volume. Density

values only have meaning at a specified temperature and pressure since both of these

parameters affect the compactness of the molecular arrangement, especially in a gas. The density

of a gas is called its vapour density, and the density of a liquid is called its liquid density.

Substance Vapour Density (at 68 Liquid Density (at

ºF; 20 ºC, 1 atm) normal boiling point, 1
atm
Hydrogen 0.005229lb/ft3 (0.08376kg/m3) 4.432 lb/ft3 (70.8 kg/m3)

Methane 0.0406 lb/ft3 (0.65 kg/m3) 26.4 lb/ft3 (422.8 kg/m3)

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Gasoline 0.275 lb/ft3 (4.4 kg/m3) 43.7 lb/ft3 (700 kg/m3)

Table 1- VAPOUR AND LIQUID DENSITIES OF COMPARATIVE SUBSTANCES

Specific Volume:

Specific volume is the inverse of density and expresses the amount of volume per unit mass.

Thus, the specific volume of hydrogen gas is 191.3 ft3/lb (11.9 m3/kg) at 68 ºF (20 ºC) and 1 atm,

and the specific volume of liquid hydrogen is 0.226 ft3/lb (0.014 m3/kg) at –423 ºF(–253 ºC) and

1 atm.

Specific Gravity:

A common way of expressing relative density is as specific gravity. Specific gravity is

the ratio of the density of one substance to that of a reference substance, both at the

same temperature and pressure.

For vapours, air (with a density of 0.0751 lb/ft3; 1.203 kg/m3) is used as the reference substance

and therefore has a specific gravity of 1.0 relative to itself. The density of other vapours

are then expressed as a number greater or less than 1.0 in proportion to its density relative to air.

Gases with a specific gravity greater than 1.0 are heavier than air; those with a specific gravity

less than 1.0 are lighter than air.

Gaseous hydrogen, with a density of 0.00523 lb/ft3, has a specific gravity of 0.0696 and

is thus approximately 7% the density of air.

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For liquids, water (with a density of 62.4 lb/ft3; 1000 kg/m3) is used as the

reference substance, so has a specific gravity of 1.0 relative to itself. As with gases,

liquids with a specific gravity greater than 1.0 are heavier than water; those with a specific

gravity less than 1.0 are lighter than water.

Liquid hydrogen, with a density of 4.432 lb/ft3, has a specific gravity of 0.0708 and is

thus approximately (and coincidentally) 7% the density of water.

Hydrogen Content:

Even as a liquid, hydrogen is not very dense. Ironically, every cubic meter of water

(made up of hydrogen and oxy-gen) contains 111 kg of hydrogen whereas a cubic meter of

liquid hydrogen contains only 71 kg of hydrogen. Thus, water packs more mass of hydrogen

per unit volume, be-cause of its tight molecular structure, than hydrogen itself. This is true of

most other liquid hydrogen-containing com-pounds as well; a cubic meter of methanol

contains 100 kg of hydrogen and a cubic meter of heptane contains 113 kg. Hydrocarbons are

compact hydrogen carriers with the added advantage of having higher energy density

than pure hydrogen.

When used as vehicle fuel, the low density of hydrogen necessitates that a large volume of

hydrogen be carried to provide an adequate driving ranges.

5.2.5 Leakage:

The molecules of hydrogen gas are smaller than all other gases, it can diffuse

through many materials considered airtight or impermeable to other gases. This property

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makes hydrogen more difficult to contain than other gases. Leaks of liquid hydrogen

evaporate very quickly since the boiling point of liquid hydrogen is so extremely low.

Hydrogen leaks are dangerous in that they pose a risk of fire where they mix with air

. However, the small molecule size that increases the likelihood of a leak also results in very

high buoyancy and diffusivity, so leaked hydrogen rises and becomes diluted quickly,

especially out-doors. This results in a very localized region of flammability that disperses

quickly. As the hydrogen dilutes with distance from the leakage site, the buoyancy declines

and the tendency for the hydrogen to continue to rise decreases. Very cold hydrogen,

resulting from a liquid hydrogen leak, be-comes buoyant soon after is evaporates.

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

resulting in a widespread, lingering fire hazard. Propane gas is denser than air so it

accumulates in low spots and disperses slowly, resulting in a protracted fire or explosion

hazard. Heavy vapours can also form vapour clouds or plumes that travel as they are pushed

by breezes. Methane gas is lighter than air, but not nearly as buoyant as hydrogen, so it

disperses rapidly, but not as rapidly as hydrogen. For small hydrogen leaks, buoyancy

and diffusion effects in air are often overshadowed by the presence of air currents from a slight

ambient wind, very slow vehicle motion or the radiator fan. In general, these currents serve to

disperse leaked hydrogen even more quickly with a further reduction of any associated fire

hazard.

When used as vehicle fuel, the propensity for hydrogen to leak necessitates special care

in the design of the fuel system to ensure that any leaks can disperse with minimum

hindrance, and the use of dedicated leak detection equipment on the vehicle and within

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the maintenance facility.

5.3 Chemical Properties:

5.3.1 Reactivity:

High reactivity is characteristic of all chemical fuels. In each case, a chemical reaction

occurs when the fuel molecules form bonds with oxygen (from air) so that the final, reacted

molecules are at a lower energy state than the initial, unreacted molecules.

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

corresponding release of energy that we can exploit to do useful work. This is true in both a

combustive reaction (as in an internal combustion engine where the energy is released

explosively as heat) or in an electrochemical reaction (as in a battery or fuel cell where the

energy is released as an electrical potential and heat).

This chemical energy release is analogous to that which occurs when water flows from

a high level to a low level. The water at the high level has potential energy that is released as

it falls to the low level. This energy can be harnessed to do useful work, such as turning a

turbine.

Once at the low level, the energy is spent and it cannot do further work at that level. In

order to do further work, it must either fall to an even lower level, or be raised back to the

high level through some external agency that inputs energy.

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5.3.2 Energy:

Energy Content:

Every fuel can liberate a fixed amount of energy when it reacts completely with oxygen

to form water. This energy fuel‗s higher heating value (HHV) and lower heating value

(LHV). The difference between the HHV and the LHV is the ―heat of vaporization‖ and

represents the amount of energy required to vaporize a liquid fuel into a gaseous fuel, as well

as the energy used to convert water to steam.

Fuel Higher Heating Value Lower Heating Value (at 25

(at 25 ºCand 1 atm) ºC
and 1 atm)

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

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

Propane 21,650 Btu/lb (50.36 kJ/g) 19,600 Btu/lb (45.6 kJ/g)

Gasoline 20,360 Btu/lb (47.5 kJ/g) 19,000 Btu/lb (44.5 kJ/g)

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

Table 2- HEATING VALUES OF COMPARATIVE FUELS

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The higher and lower heating values of comparative fuels are indicated in Table 1-3.

Although the terms HHV and LHV do not apply to batteries, the energy density of a lead acid

battery is approximately 46 Btu/lb (0.108 kJ/g).

Gaseous fuels are already vaporized so no energy is required to convert them to a gas.

The water that results from both a combustive reaction and the electrochemical reaction

within a fuel cell occurs as steam; therefore the lower heating value represents the amount of

energy available to do external work.

Both the higher and lower heating values denote the amount of energy (in Btu‗s

or Joules) for a given weight of fuel (in pounds or kilograms). Hydrogen has the highest energy-

-weight ratio of any fuel since hydrogen is the lightest element and has no heavy carbon

atoms. It is for this reason that hydrogen has been used extensively in the space program

where weight is crucial.

Energy Density:

Whereas the energy content denotes the amount of energy for a given weight of fuel,

the energy density denotes the amount of energy (in Btu‗s or Joules) for a given volume (in

ft3or m3) of fuel. Thus, energy density is the product of the energy content (LHV in our case)

and the density of a given fuel.

The energy density is really a measure of how compactly hydrogen atoms are packed

in a fuel. It follows that hydro-carbons of increasing complexity (with more and more

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hydrogen atoms per molecule) have increasing energy density. At the same time,

hydrocarbons of increasing complexity have more and more carbon atoms in each molecule

so that these fuels are heavier and heavier in absolute terms.

On this basis, hydrogen‗s energy density is poor (since it has such low density)

although its energy to weight ratio is the best of all fuels (because it is so light). The energy

density of comparative fuels, based on the LHV, is indicated in Table 1-4. The energy density

of a lead acid battery is approximately 8700 Btu/ft3 (324,000 kJ/m3).

5.3.3 Flammability:

Three things are needed for a fire or explosion to occur: a fuel, oxygen (mixed with the

fuel in appropriate quantities) and a source of ignition. Hydrogen, as a flammable fuel, mixes

with oxygen whenever air is allowed to enter a hydro-gen vessel, or when hydrogen

leaks from any vessel into the air. Ignition sources take the form of sparks, flames, or high heat.

Flashpoint:

All fuels burn only in a gaseous or vapour state. Fuels like hydrogen and methane are

already gases at atmospheric conditions, whereas other fuels like gasoline or diesel that are

liquids must convert to a vapour before they will burn. The characteristic that describes how

easily these fuels can be converted to a vapour is the flashpoint. The flashpoint is defined as

the temperature at which the fuel produces enough vapours to form an ignitable mixture with

air at its surface.

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If the temperature of the fuel is below its flashpoint, it can-not produce enough vapours

to burn since its evaporation rate is too slow. Whenever a fuel is at or above its flashpoint,

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

that is the auto ignition temperature.

The flashpoint is always lower than the boiling point. For fuels that are gases at

atmospheric conditions (like hydro-gen, methane and propane), the flashpoint is far below

ambient temperature and has little relevance since the fuel is already fully vaporized. For

fuels that are liquids at atmospheric conditions (such as gasoline or methanol), the flash-point

acts as a lower flammability temperature limit.

5.3.4 Hydrogen Embrittlement:

Constant exposure to hydrogen causes a phenomenon known as hydrogen

embrittlement in many materials. Hydrogen embrittlement can lead to leakage or catastrophic

failures in metal and non-metallic components.

The mechanisms that cause hydrogen embrittlement effects are not well defined.

Factors known to influence the rate and severity of hydrogen embrittlement include hydrogen

n-centration, hydrogen pressure, temperature, hydrogen purity, type of impurity, stress

level, stress rate, metal composition, metal tensile strength, grain size, microstructure and

heat treatment history. Moisture content in the hydrogen gas may lead to metal embrittlement

through the acceleration of the formation of fatigue cracks.

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5.4 OXYHYROGEN GAS or HHO GAS or BROWN’S GAS :

Oxyhydrogen is a mixture of hydrogen (H2) and oxygen (O2) gases. This gaseous mixture is used

for torches to process refractory materials and was the first gaseous mixture used for welding.

Theoretically, a ratio of 2:1 hydrogen:oxygen is enough to achieve maximum efficiency; in

practice a ratio 4:1 or 5:1 is needed to avoid an oxidizing flame.

This mixture may also be referred to as knallgas (Swedish; "bang-gas"), although some authors

define knallgas to be a generic term for the mixture of fuel with the precise amount of oxygen

required for complete combustion, thus 2:1 oxyhydrogen would be called "hydrogen-knallgas".

Brown's gas and HHO are fringe science terms for a 2:1 mixture of oxyhydrogen; its proponents

claim that it has special properties

Properties:

Oxyhydrogen will combust when brought to its autoignition temperature. For

the stoichiometric mixture, 2:1 hydrogen:oxygen, at normal atmospheric pressure, autoignition

occurs at about 570 °C (1065 °F). The minimum energy required to ignite such a mixture with a

spark is about 20 microjoules. At standard temperature and pressure, oxyhydrogen can burn

when it is between about 4% and 95% hydrogen by volume.

When ignited, the gas mixture converts to water vapor and releases energy, which sustains the

reaction: 241.8 kJ of energy (LHV) for every mole of H2 burned. The amount of heat energy

released is independent of the mode of combustion, but the temperature of the flame varies. The

maximum temperature of about 2,800 °C (5,070 °F) is achieved with an exact stoichiometric

mixture, about 700 °C (1,292 °F) hotter than a hydrogen flame in air. When either of the gases

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are mixed in excess of this ratio, or when mixed with an inert gas like nitrogen, the heat most

spread throughout a greater quantity of matter and the temperature will be lower

Production:

A pure stoichiometric mixture may be obtained by water electrolysis, which uses an electric

current to dissociate the water molecules

electrolysis: 2 H2O → 2 H2 + O2

combustion: 2 H2 + O2 → 2 H2O

William Nicholson was the first to decompose water in this manner in 1800. The energy required

to generate the oxyhydrogen always exceeds the energy released by combusting it, even at

maximum efficiency, the input energy of a closed system will always equal the output energy, as

the first law of thermodynamics state.

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CHAPTER – 6

6.DESCRIPTION OF DIFFERENT PARTS :

FIG.6.1 BLOCK DIAGRAM OF A HYDROGEN GENERATOR

As shown in the figure 6.1 the hydrogen generator contains a number of metal plates

and the electricity passing through the water inside the generator between the plates, causes

the water to fracture into HHO GAS.

 CONTACT BREAKER:

We can choose to use a contact-breaker, and a light-emitting diode (―LED‖) with

a current limiting resistor of 1k ohms in series with it, this can then be wired directly across the

contacts of the circuit breaker.

 LED :

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The LED can then be mounted inside the car within view of the driver. As the

contacts are normally closed, they short-circuit the LED and so no light shows. If the circuit-

breaker is tripped, the LED will light up to show that the circuit-breaker is working.

The current through the LED is so low that the hydrogen generator is switched off when

the contact breaker opens.

FIG.6.2 GENERATOR BODY AND PLATE ASSEMBLY

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 BUBBLER:

A very important safety item is the bubbler; the bubbler has a container with

some water in it. The bubbler has the HHO gas coming in at the bottom and bubbling

up through the water.

A bubbler is a very simple, very cheap and very easy and should be installed. It also

removes electrolyte fumes from the gas before it is passes into the engine.

The HHO gas collects above the water surface and is then drawn into the engine through an

outlet pipe above the water surface. To prevent water being drawn into the hydrogen

generator when the hydrogen generator is off and cools down, a one-way valve is placed in the

pipe between the booster and the bubbler.

If the engine happens to produce a backfire, then the bubbler stops the flame fire

from going back through the tubing hose and igniting the gas being produced in the

generator. If the generator is made with a tightly-fitting lid rather than a screw-on lid, then if

the gas in the bubbler catches fire and burns back thru, it will just blow the lid off the bubbler

and Stop the flame.

We can notice that the wires going to the plates inside the electrolyser are both

connected well below the water line inside the generator.

This is to stop the possibility of a connection working loose while driving

and causing a spark in the HHO gas filled region above the surface of the water, and this volume

is kept as low as possible to aid in this cause.

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CHAPTER – 7

7. A BRIEF DESCRIPTION ON PARTS NEED

FOR MAKING GENERATOR

The hydrogen generator is made from a length of 4-inch diameter PVC pipe shown in fig.7.1

caps, several metal plates, a couple of metal straps and some other various parts. Assembly is

fairly straight forward, and this hydrogen generator can be built by anybody.

There is a plastic tube added to the outside of the hydrogen generator, to show the

level of the water inside the generator, so you don‗t have to unscrew the cap.

Another nice thing is the compact see thru bubbler which is connected to the

generator side and shows the gas flow coming from the generator. The main PVC pipe length

can be adjusted to fit the space you have next to the engine.

The generator uses cheap, standard electrical stainless steel wall switch plate covers

from lowest or home depot or any hardware store and stainless steel straps, now you can cut

stainless strips from sheet metal 304 or 316L works well, or you can cut from the

handles stainless steel forks or spoons, buy them from any super market or kitchen supply store.

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FIG.7.1 PVC PIPES

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FIG.7.2 ELECTRICAL COVER PLATES

The electrical cover plates are bolted together in a group of eight closely-spaced pairs as

shown in fig.7.2. That need to drill the holes out to a larger size to fit the nylon bolts, the next

step is optional, it‗s a lot of extra work for just a little more hydrogen, but we can chose to do

it if we wish. Just hold the plates down dent them using a centre-punch and hammer.

These indentations bring up the gas output from 1.5 lpm to 1.7 lpm

as the both increase the surface area of the cover plate and provide spots where from which the

gas bubbles can leave the cover more easily. The more dents the better.

The active surfaces of the plates - that is, the surfaces which are 1.6 mm apart from

each other, need to be Prepared with sand paper. To do this, these surfaces are scored in

an X-pattern using 36-grade coarse sandpaper.

When we done this, it creates small sharp-edged bumps covering the

entire side of each of these plates. This type of surface helps the HHO hydrogen
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bubbles leave the surface as soon as they are formed.

It also increases the usable surface area of the plate by about 40%.

Now we have found fingerprints on the plates of any generator plates seriously slows down

the gas production this happens because we reduce the working area of the plate quite allot.

We need to avoid all fingerprints (by wearing clean rubber gloves) or clean the plates of all

grease and dirt, use a good solvent and then, wash that off afterwards with distilled

water.

Wearing rubber gloves is the better choice; cleaning chemicals are not a good thing to

Be applying to these stainless steel surfaces.

7.1 CONSTRUCTION OF THE HYDROGEN GENERATOR AND DIFFERENT TYPES

OF ACTIVITIES CARRIED ON IT :
CUTTING OF STEEL PLATES :

FIG. 7.3 CUTTING OF STEEL PLATES

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FIG.7.4 INDENTATIONS MADE ON STEEL PLATES

FIG. 7.5 DRILLING AND GRINDING PROCESS ON STAINLESS STEEL PLATES

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FIG 7.6 DRILLING THE STAINLESS STEEL PLATES BY USING DRILLING MACHINE

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FIG. 7.7 GRINDING THE STEEL STRAPS

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FIG.7.8 INCREASING SURFACE AREA BY USING 36/100 GRIT SAND PAPER

FIG. 7.9 MAKING THE ELECTROLYTE

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DIFFERENT TYPES OF COMPONENTS USED IN HYDROGEN GENERATOT ARE :

FIG. 7.10

As shown in the fig.7.4 are the hand tools used to make the indentations on

the stainless plates. The active plate surfaces that is, the plate surfaces that are 1.6 mm apart –

are indented and then sanded.

The stack of the prepared stainless plates is hung inside a Tube cut from a 4-

inch (100 mm) diameter PVC pipe. The pipe is changed to a suitable container by using PVC

glue to secure an end-cap on one end of the pvc pipe and a screw-cap fitting glued onto the

other end.

The container then has the gas-supply pipe fitting elbow fitted to the cap top,

which is drilled with a pair holes to allow the connecting straps for the stainless steel plate

assembly to be bolted to the cap, as shown here.

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FIG. 7.11 CROSS-SECTION THROUGH CAP

FIG.7.12 TOP CAP OF BOOSTER WITH PRESSURE GUAGE

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we need to make sure the stainless straps are tightly connected to the electric

wiring, the stainless cap bolts are both located in the stronger thicker portion on the

horizontal part of the cap, and bolted securely on both sides as shown in fig. 7.12.

A gasket from a piece of rubber or some silicone sealant is a good choice to

seal the outside of the cap. If available, a steel washer with built in rubber face will

also work.

FIG. 7.13 COMPLETE FIG. OF GENERATOR BOOSTER

As the stainless steel strap which connects the hydrogen generator plates to the

negative terminal of the power supply connects to the center section of the stainless plate

assembly, it is necessary to bend it inwards slightly. The angle used for this is in not

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important, but the strap should be vertical when it reaches the stainless electrical plates.

The picture above shows the stainless wall plates and how the bubbler is attached to the side

of the generator with super-glue or GOOP. It also shows the different pipe connections.

The stainless steel switch-cover plates are 2.75 inch x 4.5 inch (70 mm x 115

mm) in size and their two mounting holes need to be drilled out to 5/16 inch (8 mm) diameter

in order to take the plastic bolts used to hold the plates together to make as an assembly.

After a year of constant usage, these plates are shiny and not corroded thanks

to proper use of stainless parts two stainless steel straps that were made are used to attach the

plate assembly to the screw cap of the booster.

These straps are taken from the handles of cooking utensils or stainless strap

steel that you cut, and they connect to three of the plates as the outside strap travels across the

bottom of the plate assembly, clear of the plates, and connects to both outside plates as can be

seen in both the above photographs and the diagram below.

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FIG. 7.14 STRAP FORMATION BY PLATES

The plates are bolted in position by two plastic bolts which run through the

mounting holes in the stainless plates.

The arrangement is to have a small 1.6 mm gap between each of eight pairs of

plates. These gaps are created by putting plastic washers on the plastic bolts between

each pair of plates as shown in fig.7.15

The spacing is important is must be the 1.6 mm gap between the plates as this

spacing has been found to be the best at the electrolysis hydrogen production. The way that

the battery is connected is unusual in that it leaves most of the plate unconnected.

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FIG.7.15 STEEL PLATE ASSEMBLY

These plate pairs are called neutral plates and they do produce gas despite looking as if they

are not electrically connected. Stainless steel nuts are used between each pair of plates and

these form an electrical connection between Side by side plates.

The plate assembly made in this way is cheap, easy to construct and both

compact and robust. We can also constructs a plate assembly out of stainless steel

flat pieces, such as stainless sheet metal, or corrugated stainless metal and we can bought these

plates at steel trading shops.

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FIG.7.16 PLATES ARE BEING DEEPED IN THE ELECTROLYTIC SOLUTION

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FIG.7.17 BOOSTER BEING MADE FOR ELECTROLYSIS PROCESS

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FIG.7.18 SIDE VIEW OF PLATE ASSEMBLY

The electrical straps are bolted to the screw cap at the top of the generator and this

both positions the plate assembly securely and provides electrical connection to the bolts on

the outside of the cap while maintaining an airtight seal for the holes in the top screw on cap.

Another thing is that the stainless steel straps coming from the screw cap to the plate

assembly, they need to be insulated so that electrical current does not leak between them

through the electrolyte water.

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FIG.7.19 COMLETE ASSEMBLY OF PLATES

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

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

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

by wapping the straps in electrical tape as shown in fig.7.19 and fig.7.20.

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

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

insulated before the array is assembled.

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FIG.7.20 INSULTATION OF STEEL PLATES

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

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

water inside can be checked without removing the screw cap.

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

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

combined generator/bubbler.

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

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

attachment a little easier to view.

7.2 CONSTUCTION OF BUBBLER:

The half-inch diameter 90 degree elbows at the ends of the one inch diameter

bubbler tube have their threads coated with silicone before being pushed into position as shown

in figure 7.21. This allows both of them to serve as pressure-relief pop-out fittings in the seldom

seen event of the gas being ignited.

FIG.7.21 BUBBLER CONSTRUCTION

This is an added safety feature of the generator. This generator is operated

th a mix of Potassium Hydroxide also called KOH or Caustic Potash. We can also use

baking soda if we prefer, most people have baking soda around the house, KOH will last

longer and produce less brown water.

To get the right amount in the generator, fill the generator to its normal liquid

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level with distilled water and add the Hydroxide or baking soda a little at a time, until

the current through the booster is about 4 amps below the working current of 20 amps.

This allows for the generator heating up when it is working and pulling more amps

because the electrolyte water is hot. The amount of KOH is typically 2 teaspoonful‗s.

It is very important to use distilled water as tap water has impurities in it

which make a mess which will clog up the generator. Also, be very careful handling

potassium hydroxide as it is highly caustic. If any gets on you, wash it off immediately with

amounts of water, and if necessary, use some vinegar which is acidic and will offset the caustic

splashes. Baking soda does not have this problem.

THE COMPLETE ASSEMBLY OF HYDROGEN BOOSTER:

FIG. 7.22 THE COMPLETE ASSEMBLY OF HYDROGEN BOOSTER

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CHAPTER – 8

WORKING PROCEDURE AND TESTING OF

HYDROGEN GENERATOR

8.1 HOW THE GENERATOR IS CONNECTED TO THE ENGINE:

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

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

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

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

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

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

We can drill and tap a 1/4" (6 mm) NPT fitting into the plastic inlet tubing with a barbed

end for connecting the 1/4" (6 mm) hose.

The shorter the length of tubing to the air intake of the engine, the better it is. Again, for

safety concerns, we want to limit the amount of unprotected HHO hydrogen gas.

If a long run of 3 feet (1 meter) or more must be used due to space limits, then it

would be a good idea to add a second bubbler at the end of the tube, for additional fire safety.

If we do this, then it is better to use a larger diameter outlet hose, chose 3/8"or 5/16‖ (10 mm

or 8mm).

The normal mounting for the generator is close to the carb or throttle body so that

a short section of tubing can be used to connect the generator to the intake of the

vehicle engine. We can choose to connect to the air box where the air filter is, or into

the intake tubing.

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

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

We can drill and tap a 1/4" (6 mm) NPT fitting into the plastic inlet tubing with a

barbed end for connecting the 1/4" (6 mm) hose. The shorter the length of tubing to the air

intake of the engine, the better it is. Again, for safety concerns, we want to limit the amount

of unprotected HHO gas.

If a long run of 3 feet (1 metre) or more must be used due to space limits, then it

would be a good idea to add a second bubbler at the end of the tube, for additional fire safety.

If you do this, then it is better to use a larger diameter outlet hose, chose 3/8"or 5/16‖ (10 mm

or 8mm).

8.2 HOW TO POWER THE HYDROGEN GENERATOR:

 Use wire and electrical hardware capable of handling 20 amps DC, no less. Overkill is

better in this case, It is recommended to use parts that can handle 30 amps.

 Run the power through the ignition circuit, so that it only powers up when the

Engine is on.

 A 30 amp relay should be used to prevent damaging the ignition circuit and or
switch, the switch is not designed for an extra 20 amp load.

 Make sure to use a properly rated fuse, 30 amps is best.

 Use a toggle switch for further operational control. Also can add this safety

feature, run an oil pressure switch to the relay as well, so the unit operates only

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when the engine is actually started and running.

 It is very important that everything is tight, solder is better than, crimping.

 Any loose connections can cause heat and this could lead to a fire, so make sure
that connections are of good quality , and be sure to check them every so often to make sure

they have not worked loose.

8.3 SETTING UP THE WATER IN THE GENERATOR:

 Fill the generator with distilled water and baking soda or KOH.

 Clean it more often using baking soda First.

 Fill the generator with distilled water about 2" from the top.

 Add a teaspoon of KOH or NaOH, or baking soda to the water and then slip the top into
place.

 Do not tighten it up for now, leave the top loose and resting in place.

 Connect 12V power supply to the connectors and monitor the amp draw of the generator.

 Striving for 16 amps flowing when the generator is cold. As the water heats up over time, the

 amp load draw will increase by about 4 amps until it reaches around 20 amps, and this is why
we are trying for 16 amps when the generator is cold.
 If the amp draw is too high, pour out some of the water inside and add just a little
more distilled water.

 If the current is too low, add a small amount of baking soda or koh until the 16 amps is
reached.

 Overfilling the generator will cause some of the electrolyte water solution to be

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forced up the output tube, so a water level tube was added to the outside of the
generator to allow us to see the electrolyte water solution level inside of the
generator.

 The generator usually needs to be topped off once a week, depending on how often u have it
turned on. Add distilled water, then check the current amp draw again.

 Notice that a drop in amps over the course of a several water refills, and this is
normally what happens.

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

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

being operated.

8.4 INSTALLING THE GENERATOR:

 Select a ventilated area in the engine compartment or around the front bumper in front of the
radiator to install the generator every car or truck is different so look it over well, we need to

choose the best place to mount it.

 It must be mounted with the top pointing upwards. Large hose clamps work very good for

this, but do not over tighten them or the PVC may lose shape or possibly crack.

 Hold the weight of the generator from the bottom with a bracket made from strap metal, then

use two hose clamps to hold the generator in place, one close bto the top and one close to

the bottom. We can‗t install the Generator inside of the car or truck for safety reasons.

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8.5 OUTPUT HOSE AND BUBBLER:

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

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

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

when it cools and the gases inside contract.

Make sure the bubbler water level is always correct. Failure to do so could result

in a backfire event. That water inside the bubbler is water shield between the stored HHO gas

in the generator and the intake of your engine.

Install the output hose from the bubbler as close to the carburettor/throttle body.

by making a connection point into the intake tube/air cleaner. make the use as short as

possible to reduce the amount of HHO gas that it contains. I recommend using the same type

of 1/4" poly hose that is used on the unit. .

8.6 ADDITIONAL STUFF:

some people find the plate cell layout of the hydrogen Booster, rather difficult to

understand, so this additional section is just to try to explain the how it work, The hydrogen

generator plate arrangement is laid out in this way for a good reason.

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This is mainly because the sets are squeezed inside in this manner to create more

hydrogen two identical sets of plates into one pvc generator as shown here:

FIG.8.1 CURRENT PASSING THROUGH THE PALTES

This arrangement is two identical sets of plates positioned back to-back. Let‗s just take a

look at just one of the two sets of stainless steel plates as shown in fig.8.1. Here, we have just

the electrical Positive linked to the electrical negative by a set of four pairs of stainless plates in

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a daisy chain (the technical term is: connected "in series" or " series connected").

Easily the most electrically efficient way for doing this is to exclude all possible

current flow paths through the electrolyte water by sealing off around the edges of all

the stainless plates and forcing the current to flow through the plates and only through the

plates. So we use a equal spacing of the stainless plates as shown in fig.8.2.

FIG.8.2 THE PICTURE SHOWS HOW THE PLATES ARE CONNECTED

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FIG. 8.3 UNWANTED CURRENT FLOW THROUGH ELECTROLYTE

The red lines show paths of unwanted current flow which produce almost no HHO gas .

This lost current flow is opposed by the useful current flow across gap "A" in the fig.8.3.

To assist the flow across the 1.6 mm gap "A", the waste flows as long as possible.

This is done by the gap "B" being made as large as possible.

The voltage applied to the cell (13.8 volts when the engine is running) divides

equally across the four plate pairs, so there will be 1/4 of that voltage (3.45 volts) across each

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stainless plate pair.

If we look again at the original diagram, we will see that there are two of these

sets of four plate pairs, positioned back-to-back in the generator. Each of these acts

separately, except for the fact that there are additional electrical current leakage paths

through the electrolyte water between the stainless plates of one set and the plates of the

second set.

There is a steady voltage drop across the assembly of plates, that they are connected in

pairs in the middle due to the metal-to-metal connection created by the steel nuts between the

plates: It is often difficult for some to understand of how the voltage drops across a chain of

resistors (or matrix of plates).

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FIG. 8.4 VOLTAGE DROPS FOR A 12 VOLTS SUPPLY

The voltages are relative to each other, so each plate pair thinks that it has a negative

electrical connection on one plate and a positive connection on the other plate as shown in the

fig.8.4.

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8.7 THE COMPLETE INSTALLATION PICTURE:

FIG.8.5 THE COMPLETE INSTALLATION PICTURE

ADVANTAGES :

1) They improve gas mileage.

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

3) The added hydrogen/oxygen produced acts like a catalysis to your fuel, a more complete burn

and slightly cooler. The cell creates a clear clean more combustion able air, right into your air

stream, so it is the safest addition of any added voltage gas to a car or truck, on the planet.

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

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5) The ortho hydrogen and ortho oxygen created breaks apart the hydro-carbon chain of

molecules, leaving a much cleaner emission.

6) Increases horsepower.

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

DISADVANTAGES :

1) Hydrogen is a dangerous substance to handle. It‗s molecules are small enough to permeate

through materials generally thought to be suitable for containing gases.

2) It can make metals brittle.

3) It is considered a green fuel because when it is burnt with oxygen, it does not produce

carbon dioxide. While this is true, it is not the whole picture.

4) Hydrogen burnt with oxygen produces a flame inconveniently hot and in mobile

applications, we have to carry the oxygen around as well as the hydrogen. Unfortunately, the

flame temperature can be lowered conveniently by burning the hydrogen in air, which also

dispenses with the need to carry the oxygen around.

5) Burning hydrogen in air or an oxygen/air mixture produces nitrous oxide which is a major

pollutant - and if you do that, it is no longer a ―green fuel‖ (although it produces less pollution

than petrol & diesel).

SAFETY PRECAUTION :

Before getting into the details of how to construct the booster, you must be aware

of what needs to be done when using a hydrogen generator of any design. Firstly, hydroxyl HHO

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Gas is highly explosive.

If it wasn‗t, it would not be able to do its job of improving the gas mileage your

vehicle is getting; hydroxy gas needs to be treated with care and caution. It is important to

make sure that it goes into the engine as designed and nowhere else. It is also important

that it gets ignited inside the engine and nowhere else.

To make this happen, a number of common-sense steps need to be taken.

Firstly, the hydrogen generator must not make hydrogen gas when the engine is not running.

The best way to arrange this is to switch off the electricity going to the booster.

It is not enough to just have a manually-operated dashboard On/Off switch as it

is almost certain to be forgotten one day. And the generator will be left on making gas while

the engine is off Instead, the electrical supply to the booster is sent through the ignition

switch of the car. That way, when the engine is turned off, we can be sure that the hydrogen

generator is turned off.

So as not to put too much amp load through the ignition switch, and to allow for

the possibility of the ignition switch being on when the engine is not running, instead of

wiring the hydrogen generator directly to the switch, it is recommended that you wire a

standard automotive relay across the oil pressure sending unit and then the relay carry

the amp load electricity. The fuel pump is powered down automatically when the key is off, and

so this will also shut off the hydrogen generator.

An extra safety feature is to allow for the (very unlikely) possibility of an electrical

short-circuit occurring in the Hydrogen generator or its wiring. This is done by putting a fuse

or contact-breaker between the battery and the new wiring you are installing as shown in sketch.

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CHAPTER - 9

9. SCOPE FOR FUTURE WORK :

Hydrogen is the most abundant element in the universe, so there‘s no chance of human

consumers depleting the supply. There are certainly enough oil resources to meet global demand

now, but many energy experts predict that the world‘s supply of oil will be depleted within 60

years, according to a report from Ars Technica. Exhausting the world‘s supply of oil or even

approaching the inevitable shortfalls that come with a growing population — the planet now

hosts 7 billion people as of the end of October — and economic growth will not only create a

major energy crunch necessitating the rapid introduction of alternative energy sources; burning

that much fuel also means an enormous burden on the atmosphere in the process. And that

doesn‘t even account for the potential environmental consequences of extracting crude oil from

the Earth.

Hydrogen, by contrast, is clean-burning. The only byproduct of hydrogen power is water and

heat, both of which can by recycled. This essentially means turning an energy consuming process

into an energy producing one.

Hydrogen, however, is not a ready source of energy like oil and natural gas. Rather, it is a means

of storing energy since pure hydrogen isn‘t available on Earth in quantities necessary to fuel an

entire energy economy. To get hydrogen in the form of a usable fuel requires energy. Hydrogen

can be produced either by separating it from oxygen molecules in water through the process of

electrolysis, or by splitting it off hydrocarbon chains in fossil fuels, a process that itself creates

greenhouse gas emissions.

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CHAPTER - 10
10. CONCLUSION:

The new generation of hydrogen generators comes with extremely high purity devices,

that are safe and that present no danger to the environment. They are the best alternative to gas

cylinders, and they are simple to use anywhere. The hydrogen generator just needs to be plugged

in the electrical supply and It is ready to go.

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

models, to produce hydrogen, because it separates the hydrogen from the oxygen in the water,

thus producing highly pure hydrogen for weeks.

These hydrogen generators can generate hydrogen that is 99.99..% pure, giving over 1000

cc/min, and they do not require changing their cylinders. The safety of the hydrogen generators

has been certified.

How the hydrogen generator works may vary from manufacturer to manufacturer, for

example some models use a solid polymer electrolyte to separate oxygen from hydrogen, which

makes them more safe than other models that use a caustic liquid electrolyte. After the hydrogen

is generated it passes through a palladium membrane that lets only 99.99% pure hydrogen pass

through, thus insuring the gas purity.

Hydrogen Fuel cell vehicles are currently being researched for their feasibility of widespread

usage in automobiles and other forms of transportation. Hydrogen fuel does not occur naturally

on Earth and thus is not an energy source, but is an energy carrier. Currently it is most frequently

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made from methane or other fossil fuels . However, it can be produced from a wide range of

sources (such as wind, solar, or nuclear) that are intermittent, too diffuse or too cumbersome to

directly propel vehicles. Integrated wind-to-hydrogen plants, using electrolysis of water , are

exploring technologies to deliver costs low enough, and quantities great enough, to compete with

traditional energy sources.

Many companies are working to develop technologies that might efficiently exploit the potential

of hydrogen energy for mobile uses. The attraction of using hydrogen as an energy currency is

that, if hydrogen is prepared without using fossil fuel inputs, vehicle propulsion would not

contribute to carbon dioxide emissions.

In conclusion, the latest generation of hydrogen generators brings some series of

improvements that makes it extra reliable, with almost no need of maintenance or downtime.

The best way of increasing the safety and lowering the costs in the laboratory is to

acquire a hydrogen generator, and we can be sure that the investment is worth it, because we will

no longer have to buy hydrogen cylinders, so the hydrogen generator will pay for itself in a year
or two.

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CHAPTER - 11

11. REFERENCES:

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

2) http://www.answers.com

3) http://www.Automobile engineering.com

4) http://www.fuel from water.com

5) http://www.watercar.com

6) Heywood HB (1998). ―Internal combustion engine fundamentals‖. Tata McGraw Hill

Publishing Company Limited. McGraw Hill Company Limited, New York.

7) Brown Y (1978). Brown‘s Gas, United States Patent, Us patent 4014, 777; March 28, 1978.

8) www.OxyhydrogenProperties.com

9) www.PropertesofBrownsGas.com

10) www.OxyhydrogenEncyclopedia.com

11) www.hydrogenFirstAid.com

12) http://academiau.com

13) Smack booster.blog

14) RunYourCarWithwater.blogspot.in

15) www.FuelCellToday.com

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