NFC Institute Of Engineering & Fertilizer Research Faisalabad

Department Of Mechanical Engineering

Project Synopsis Project Title:Design and Installation of Hydro-oxy (hydrogen + oxygen) Gas Booster in Reciprocating IC Engine. Project Advisor:Professor Syed Amjad Ahmad Professor Dr. Ahmad Shafi

Members:Bilal Hassan Mubashar Javed Waheed Ahmed Sajid Irshad 2008-UET-IEFR-MECH-FD-52 2008-UET-IEFR-MECH-FD-53 2008-UET-IEFR-MECH-FD-35 2008-UET-IEFR-MECH-FD-17

Abstract IC engines the combustion of fuel is not complete or is partial in nature due to which efficiency as well as fuel economy suffers. New design a HHo gas producing device that will generate HHO gas by simple electrolysis of water. The current for electrolysis will be provided by vehicle alternator (generator).This gas will be introduce in combustion chamber through intake manifold in engine due to which it properly mixes with air eventually with air-fuel mixture .As hydrogen is highly combustible gas it burns 99% on spark which in result increase fuel combustion ,torque and decrease harmful carbon content. In this regard, hydroxy gas (HHO) was produced by the electrolysis process of different electrolytes (KOH(aq), NaOH(aq), NaCl(aq)) with various electrode designs in a leak proof plexiglass reactor (hydrogen generator). Hydroxy gas was used as a supplementary fuel in engine without any modification and without need for storage tanks. Its effect on exhaust emissions and engine performance characteristics were investigated. Key Points: Toque, Exhaust Emission, Fuel Economy, Introduction: Now a days IC engines are the main source of providing useful mechanical power .These engines has vast application in every field like transportation, energy production, heavy mechanical tools etc. although they are widely used around the world but they are not much efficient , petrol engine only 27-30% ,diesel 35%.the main reason behind there inefficiency is incomplete combustion of fuel in power stroke [1].The device we are designing will produce hydrogen and oxygen gas (HHO) by the simple electrolysis of water .This gas is then introduced in engine with air fuel mixture. As hydrogen is highly combustible gas so in power stroke when spark plug ignites the air fuel mixture hydrogen burns completely and increase the burning of fuel .As a result we get more power and break horse power with same amount of fuel .Our device works on the electrolysis

of water. Electrolysis means breaking of water molecules in to Hydrogen and oxygen gas by the passage of electricity through electrodes. There are so many designs of electrolysers (reactors) .which uses different shape, different materials as electrodes, different solutions as electrolytes, i.e. water with baking soda, NaOH, KOH etc .These solution provides ions for the passage of electricity. But the most efficient method is passage of current through plate with minimum gap between them, 3-8mm. There are two types of electrolysers. Wet cell: In these cell SS (stainless steel) two electrodes are completely dip in water and current is passed through it .it produces gas but very less efficient. Dry cell: In dry cell two metal plates usually SS plates are placed at distance of 38mm and sealed from the borders so it becomes a cell between them and 3mm gap is filled with water .When current is passed water is converted into gas .This type of cell is very efficient due to following factors:1-Controlled temperature of water (below boiling temperature of water), 2-maximum use of applied amperes, 3-No leakage of current from edges of plates.

There electrolyser efficiency depends upon these factors gap between the plates, ratio of electrolyte used to conduct current, amount of current applied.

Materials and Methods We will use following materials. Stainless Steel (SS-316) .8mm thick as the electrodes. Teflon .3mm is used as refractory material as gasket between the Cell. Industrial grade plastic sheet to hold the series cell assembly. PVC pipe for Bubbler. Industrial grade adhesives.

The rector will produce hydro-oxy gas due to passage of current which will be shifted to bubbler .From bubbler it is transferred to engine intake manifold .The

vacuum of engine sucks the HHo gas from bubbler so no need of any pump in the whole system. We are using Dry cell due to its high efficiency with following parameters It is design for small size motorcycle engine or electric generator. (50200cc) Uses 12 volts and 4-5 amperes of current

The system has following components Electrolyser (reactor) Bubbler Safety devices Moisture absorber

Electrolyser (reactor) is a 7 cell SS 316 electrolyser with target voltages of 12 volt 1.8 volts each cell draw 4-5 amps .It produces hydrogen and oxygen gas .The produced hydrogen and oxygen gasses are not separated to separate containers, but kept mixed. The produced oxyhydrogen gas is a stoichiometric mixture of hydrogen (2 parts vol.) and oxygen (1 part vol.) and can be combusted in vacuum. The combination of series-cell topology is very efficient, because it allows the cells to operate as close to their optimal cell voltage (1.47V) as possible. The electrolyzer runs fairly cool, at about 30-50 C depending on the current and electrolyte.Each plate has a hole at bottom to fill water in each cell and hole at top of plate to transfer HHO gas to the engine

Fig-1, Electrolyte in each compartment is practically isolated from other compartments, but there is 3mm diameter electrolyte level equalization holes drilled in the bottom corner of each plate.

Bubbler is simple water container .It is a safety device to prevent black flash, due to high flammability of hydrogen .Produced gas in introduce in bubbler which is filled with water 5-6 high .Gas is released at the bottom of bubbler in the form of bubble which gather at vacant space at the top of bubbler. Then with the help of pipe it is introduced in the intake manifold of engine. Pressures gauges are used to monitor the gas pressure in Bubbler. Electrical rely and fuses are installed for the safety of electrical parameters. Rely are used to monitor and control the amount of current for electrolyser and prevent over current. Moisture absorber is used to absorb the moisture from HHO gas before entering in the intake manifold. If these vapors are not stopped they are converted into steam by absorbing large amount of energy and decrease the efficiency.

Fig-2, Dry cell and bubbler assembly

OBJECTIVE Increase fuel economy of Engine. Increase in torque and power output Less emission of carbon content Draw minimum electric load from vehicle engine for electrolysis.

Fuel economy: As we know that hydrogen is highly flammable. It ignites 99% on combustion. When this gas is introduced in engine, it burns the air fuel mixture withdrawn from carburetor to a higher extent then simple spark ignition. As a result we obtain more power from the same amount of fuel. We will calculate this by calculating specific fuel consumption of engine. We will apply a constant load through dynamometer and will calculate the fuel consumption under same conditions with and without the introduction of HHO gas. Torque and Power Output: As the maximum combustion of fuel will take place with the introduction of HHO gas, the Brake Horsepower will improve. As the

fuel will burn properly resulting better explosion during power stroke resulting higher pressure built on the piston in power stroke. We will calculate this with Dynamometer by applying more loads on the same input of fuel (throttle). Less Emission Of Harmful Carbon Content: As HHO gas increase the fuel combustion due to which maximum amount of CO2 and H2O are produced and decrease the emission of Harmful CO (mono-oxide) which is produced by incomplete combustion of fuel. Draw Minimum Electric Load from Vehicle Engine For Electrolysis. Our objective is also to have minimum load on the engine due to the fact that electricity used for the production of HHO gas is produced itself by the engine. Minimum electrical load means more efficiency of the engine. Thats why we are using dry cell design for the electrolysis of water which is more efficient than the other conventional design due to following factor

LITERATURE REVIEW: Hydroxy gas (HHO) was produced by the electrolysis process of different electrolytes (KOH(aq), NaOH(aq), NaCl(aq)) with various electrode designs in a leak proof plexiglass reactor (hydrogen generator). Hydroxy gas was used as a supplementary fuel in a four cylinder, four stroke, compression ignition (CI) engine without any modification and without need for storage tanks. Its effects on exhaust emissions and engine performance characteristics were investigated. Experiments showed that constant HHO flow rate at low engine speeds (under the critical speed of 1750 rpm for this experimental study), turned advantages of HHO system into disadvantages for engine torque, carbon monoxide (CO), hydrocarbon (HC) emissions and specific fuel consumption (SFC). Investigations demonstrated that HHO flow rate had to be diminished in relation to engine speed below 1750 rpm due to the long opening time of intake manifolds at low speeds. This caused excessive volume occupation of hydroxy in cylinders which prevented correct air to be taken into the combustion chambers and consequently, decreased volumetric

efficiency was inevitable. Decreased volumetric efficiency influenced combustion efficiency which had negative effects on engine torque and exhaust emissions. Therefore, a hydroxy electronic control unit (HECU) was designed and manufactured to decrease HHO flow rate by decreasing voltage and current automatically by programming the data logger to compensate disadvantages of HHO gas on SFC, engine torque and exhaust emissions under engine speed of 1750 rpm. The flow rate of HHO gas was measured by using various amounts of KOH, NaOH, NaCl (catalysts). These catalysts were added into the water to diminish hydrogen and oxygen bonds and NaOH was specified as the most appropriate catalyst. It was observed that if the molality of NaOH in solution exceeded 1% by mass, electrical current supplied from the battery increased dramatically due to the too much reduction of electrical resistance. HHO system addition to the engine without any modification resulted in increasing engine torque output by an average of 19.1%, reducing CO emissions by an average of 13.5%, HC emissions by an average of 5% and SFC by an average of 14%.

Conclusions By these all modifications in the engine, following result are to be exacted. Approximately 20% Increased in torque Approximately 20% Better fuel economy Less Harmful carbon content emission

REFERENCES 1-www.michigan.gov/documents/cis_wsh_cet5011_115680_7.doc
2-http://tuning.mbs.id.au/Tuning/exhaust_analysers.htm 3-http://www.free-energy-info.com/chapter10 4-http://www.free-energy-devices.com 5-http://www.free-energy-info.co.uk/chapter10 6-http://peswiki.com/index.php/Directory:Brown%27s_Gas 7-http://www.tradekey.com/company/Ranko-Solutions-5235969.html