HHO Gas / Waterfuel -- Canadian
Patents
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CA2229694
ELECTROLYSIS APPARATUS FOR INTERNAL COMBUSTION ENGINE
ENHANCED FUEL EFFICIENCY
Efficiency of hydrocarbon fuel in an internal combustion engine
is obtained by supplying to the air intake of the engine oxygen,
hydrogen, steam and structured water from an electrolytic cell.
The chamber of the cell includes various means for eliminating
the risk of explosion including a plug releasable by internal
pressure, a burstable section on the housing, and a solenoid
valve actuated to vent any mixed materials generated while the
engine is not operating and a mixed materials
production/consumption feed back loop. The chamber is formed of
a ABS material which tends not to shatter.
This application is related to Canadian Application no. 2207116
filed 6t" June and is a continuation in part of US application
no. 08895817 filed July 16t" 1997.
Field of the Invention
The invention relates to method of enhancing fuel efficiency in
an internal combustion engine using a water electrolysis system.
Background of the Invention
An electrolysis chamber for generation of oxygen and hydrogen
gas for supply to the cylinder of an internal combustion engine
is taught in U.S. Patent 5,231,954 to Stowe. The chamber
includes a housing having a pair of electrodes therein at least
partially submerged in an electrolyte solution. The electrodes
are connected to a source of electrical potential to generate
oxygen and hydrogen from the electrolyte solution in the
chamber. The chamber is mounted in association with an engine
and oxygen and hydrogen generated are fed to the engine via a
line connected to the air intake manifold. In order to reduce
the risk of explosion, the chamber has a friction fitted top cap
which provides for pressure release under conditions where
oxygen and hydrogen gas builds up within the chamber. The top
cap has an end wall and a cylindrical side wall extending
therefrom. The side wall fits over and extends down the sides of
the chamber. To be removed, this top cap requires substantial
clearance above the chamber. Such clearance is often unavailable
in the engine area of most vehicles. In addition, should the top
cap described in the patent be released it is generally
incapable of reseating itself to seal the chamber. If the top
cap blows off, the vehicle operator can continue to operate the
vehicle for a period of time without noticing that the chamber
is open. This results in the potential for spillage of the
electrolyte solution and, most importantly, in the operation of
the vehicle without the benefits of the oxygen and hydrogen
supplementation of the fuel. Summary of the Invention It is one
object of the present invention to provide an improved method
for enhancing the fuel efficiency of internal combustion engine
using an electrolysis cell. According to a first aspect of the
invention there is provided a method for improving the
efficiency of combustion in an internal combustion engine
including at least one combustion chamber, and air intake for
supplying air to the chamber and a fuel supply system for
supplying a hydrocarbon fuel to the chamber such that the fuel
burns in the combustion chamber, the method comprising:
providing an electrolysis chamber sealed against the ingress of
air and the escape of liquid; providing an aqueous electrolyte
solution in the electrolysis chamber; providing in the
electrolysis chamber a pair of electrodes disposed therein in
contact with the electrolyte solution and connecting the
electrodes to a supply of direct current across the electrodes
so as to cause an electrolytic action therein; communicating
mixed materials from electrolytic action in a sealed duct from
the electrolysis chamber to the air intake; arranging the
electrolyte solution, the electrolysis chamber and the
electrodes such that the electrolytic action generates oxygen,
hydrogen, steam and structured water; and using combustion of
the oxygen and hydrogen in the combustion chamber with the
hydrocarbon fuel in conjunction with the steam and structured
water to effect cracking of unspent portions of the hydrocarbon
fuel. Preferably the electrolyte is KOH. Preferably there is
provided a replenishing supply of the KOH. Preferably the
combustion of the oxygen and hydrogen in the combustion chamber
with the hydrocarbon fuel in conjunction with the steam and
structured water effects cracking of long chain and aromatic
hydrocarbons to produce readily combustible shorter chain
hydrocarbons. Preferably the combustion of the oxygen and
hydrogen in the combustion chamber with the hydrocarbon fuel in
conjunction with the steam and structured water effects
combustion of pollutants generated by the combustion of the
hydrocarbon fuel products. Preferably the electrodes are mounted
and shaped in the electrolysis chamber to reduce spatter of the
electrolyte solution.
Preferably spatter of the electrolyte solution is reduced by
providing a cover plate inside the electrolysis chamber at the
top of the electrolyte solution through which the electrolyte
solution and mixed emitted materials can pass. Preferably the
electrolysis chamber includes a pressure releasable plug formed
to be inserted into an opening in a top wall of the electrolysis
chamber, the plug being formed with a bottom and side walls, the
side walls converging toward the bottom of the plug. Preferably
the electrolysis chamber is constructed at least in part of
acrylonitrile butadiene styrene resin. Preferably the
electrolysis chamber includes a pressure release device on the
housing burstable upon application of pressure thereon.
Preferably the method includes providing a valve in the duct,
the valve having a first outlet for diverting the mixed
materials to the air intake and a second outlet for diverting
mixed materials to a vent line for release to the atmosphere,
the valve being actuated to divert mixed materials to the first
outlet when the engine of the engine is operating and being
actuated to divert mixed materials to the second outlet when the
engine is not operating. Preferably the electrolysis chamber
includes a plurality of intermediate electrodes disposed in said
chamber between the electrodes, the intermediate electrodes
being arranged so as to define a plurality of individual
electrolysis cells and such that the voltage across each is less
than 2 volts.
Preferably the intermediate electrodes are arranged such that
the cells have equal potential differences. Preferably said
electrolysis chamber forms a cylinder and said first electrode
is a cylinder of a diameter equal to that of the electrolysis
chamber, said second electrode is a cylinder coaxial to said
first electrode and each said intermediate electrode Is a
cylinder disposed coaxially with said first and second
electrode. Preferably the number of intermediate electrodes is
selected to maintain an electrical potential between each said
electrode and the next adjacent electrode sufficient to
electrolyze any conductive solution in contact therewith.
Preferably the number of intermediate electrodes is selected to
maintain said electrical potential is in a range between about
1. 2 and 2 volts. Preferably said electrodes are constructed
from stainless steel. Preferably the method includes controlling
the supply of mixed materials obtained from the electrolysis
chamber by detecting a vacuum at the duct whereby operating
vacuum present in said duct exceeding the supply of
supplementary fuel mixed materials present in said supply line
causes a net differential vacuum to be supplied to produce a
control signal increasing the supply of mixed materials
available from said cell and, conversely, operating vacuum
present in said duct exceeded by the supply of supplementary
fuel mixed materials present in said supply line causes a net
differential pressure to produce a control signal decreasing the
supply of mixed materials available from said cell.
Preferably the method includes providing a filling opening and a
filling duct communicating with a filling opening, the duct
being sealed in the opening and providing a filling container
connected to the duct for supplying replacement electrolyte
solution, the chamber having a first contact for indicating a
minimum level of electrolyte solution and a second contact for
indicating a maximum of electrolyte solution and providing a
switch arranged to allow flow of electrolyte solution from the
container into the chamber in response to vacuum from the
engine. Preferably the switch is operated manually by visual
observing lights illuminated by engagement with the electrolyte
solution with the contact. Preferably the method includes
providing an automatic control unit responsive to engagement of
the electrolyte solution with the contacts for actuating the
switch. Preferably the method includes providing an automatic
control unit responsive to current in the electrolysis chamber
for indicating when the strength of the electrolyte solution
falls too low. Preferably the method includes providing an
automatic control unit responsive to the presence of current in
the electrolysis chamber when the engine is not operating for
indicating to an operator a fault in the chamber. According to a
second aspect of the invention there is provided an apparatus
for use in improving the efficiency of combustion in an internal
combustion engine including at least one combustion chamber, and
air intake for supplying air to the chamber and a fuel supply
system for supplying a hydrocarbon fuel to the chamber such that
the fuel burns in the combustion chamber, the apparatus
comprising: an electrolysis chamber sealed against the ingress
of air and the escape of liquid for receiving an aqueous
electrolyte solution in the electrolysis chamber; a pair of
electrodes disposed in the electrolysis chamber arranged to be
in contact with the electrolyte solution and means for
connecting the electrodes to a supply of direct current across
the electrodes so as to cause an electrolytic action therein; a
sealed duct for communicating mixed materials from electrolytic
action from the electrolysis chamber to the air intake; the
chamber comprising a base, an upstanding wall and a top cap
fixed to the wall at an upper end thereof, the top cap having an
opening therein and a plug with a frusto-conical side wall
inserted in the opening as a friction fit. Preferably there is
provided a pressure release portion in the top cap which is of
reduced thickness. Preferably the pressure release portion
comprises a weakened line of reduced thickness surrounding the
opening According to a third aspect of the invention there is
provided an apparatus for use in improving the efficiency of
combustion in an internal combustion engine including at least
one combustion chamber) and air intake for supplying air to the
chamber and a fuel supply system for supplying a hydrocarbon
fuel to the chamber such that the fuel burns in the combustion
chamber, the apparatus comprising: an electrolysis chamber
sealed against the ingress of air and the escape of liquid for
receiving an aqueous electrolyte solution in the electrolysis
chamber; a pair of electrodes disposed in the electrolysis
chamber arranged to be in contact with the electrolyte solution
and means for connecting the electrodes to a supply of direct
current across the electrodes so as to cause an electrolytic
action therein; a sealed duct for communicating mixed materials
from electrolytic action from the electrolysis chamber to the
air intake; and a plurality of intermediate electrodes arranged
between said pair of electrodes and a top support plate arranged
for engaging upper edges of the electrodes and for holding the
electrodes at a predetermined spaced position relative to each
other and relative to the pair of electrodes. Preferably the
electrodes are cylindrical and concentric around a center
electrode defining one of said pair. Preferably there is
provided means for connecting to the pair of electrodes, said
connecting means passing through the chamber at a position
thereon above the electrolyte solution. Preferably there is
provided a splash plate parallel to the top plate and above the
top plate.
Preferably the center electrode passes through the top plate and
through the splash plate and wherein there is provided a
conductor extending from the center electrode across the top of
the splash plate to connection means on the chamber. Preferably
there is provided a low level contact for engaging the
electrolyte solution mounted in the chamber at a position just
below the top plate and a high level contact above the top
plate. Water is a polar molecule) that is, one end of the
molecule has a slight positive charge while the other has a
slight negative charge. In structured water, the water molecules
form alternating negative and positive layers around a
positively charged ion. This gives the water a
pseudo-crystalline or solid structure, even at room temperature.
In the present invention, the potassium provides a positive ion
and causes the formation of structured water around the negative
electrode since the potassium ion is attracted to the electrode
and acts to align the polar water molecules around the ion.
Preferably the chamber is manufactured from ABS. Brief
Descriation of the Drawin4s A further, detailed, description of
the invention, briefly described above, will follow by reference
to the following drawings of specific embodiments of the
invention. These drawings depict only typical embodiments of the
invention and are therefore not to be considered limiting of its
scope.
In the drawings:
Figure 1 is a perspective view of a electrolytic chamber
according to the present invention;
Figure 2 is a sectional view along line 2-2 of Figure 1;
Figure 2A is an alternate embodiment of the explosion vent of
Figure 2;
Figure 3 is sectional view along line 3-3 of Figure 1; Figure 3A
is a sectional view of an alternative shape of the electrolysis
chamber; and
Figure 4 is a schematic view of an apparatus including an
electrolysis cell according to the present invention;
Figure 5 is a schematic view of the electrolysis cell of figure
2 including an automatic system for testing the electrolyte
solution strength and for replenishing solution;
Figure 6 is a schematic view of the electrolysis cell of figure
2 including a manual filling system.
Detailed Description of the Preferred Embodiments
Referring to Figures 1 and 2, an electrolytic chamber 2 is
shown. When in use) the chamber generates oxygen and hydrogen
gases together with steam or water vapour and structured water.
The various features of the invention for release of internal
pressure, for avoiding spillage and leakage of electrolytic
solution and for enhancing operation of the chamber, as will be
described, need not all be present in the same chamber or
electrolysis system, as the presence of one or more of the
features may not be required for the application to which the
chamber is to be put.
Alternately, the various aspects can all be present in the
chamber or the system at all times, but be only used as needed.
Chamber 2 includes a housing 4 formed to contain an electrolyte
solution 6, The chamber can be cylindrical as shown or any other
shape suitable for its intended use. To facilitate construction,
housing 4 preferably has a top 4a and a bottom 4b sealably
secured as by suitable adhesives to a cylindrical side wall 4c.
Housing 4 is formed from any chemically and electrically inert
material. Preferably, housing 4 is formed from the material
known as' acrylonitrile butadiene styrene resin (ABS) because of
its resistance to chemicals such as the electrolyte solution and
its ability to withstand large temperature fluctuations without
degradation. In addition, ABS plastic is not brittle and during
a chamber failure wherein there is a build up of internal
pressure, the chamber formed using ABS will tend to crack rather
than shatter. Housing 4 has a pressure release section 8 which
is burstable upon application of pressure, such as internal
pressure) thereon. Section 8 of the housing has a reduced
thickness T relative to the thickness of the balance of the
housing. This section can be formed during the molding or
extrusion process or can be milled out after formation of the
housing. Section 8 can be integral with the housing or,
alternately) be an inset piece of material, such as is shown by
way of example in Figure 2a. In the alternative configuration of
Figure 2A, a vent port 8a is covered by a displaceable cover 8b
which is urged into sealing contact with the top 4a by means of
a biasing element 8c such as a spring. In the preferred
embodiment of Figure 2, pressure release section 8 has a lower
strength than the material used in the formation of the
remainder of the housing. Section 8 is selected to burst when a
selected amount of pressure, such as caused by an explosion of
the combustible mixed materials within the chamber, is applied
thereto. To burst section 8, the amount of pressure is selected
to be greater than that pressure which is exerted toward the
inside of the chamber when the chamber is under vacuum during
use. Port 10 is formed through the housing at an upper portion
thereof for introduction of water, electrolytes and/or
electrolytic solution. Port 10 has removably inserted therein a
plug 12 for sealing the port. Preferably, plug 12 is only
fractionally engaged in the port and can be removed by
application of a force to pull or push the plug out of the port.
Preferably, plug 12 has side walls 12a which converge toward the
bottom 12b of the plug (i.e. the end which is inserted into the
port) and the port is preferably positioned on the top of the
housing, as determined by the intended mounting position of the
chamber. Such a plug and port arrangement facilitates the
release of internal pressure and greatly reduces the risk of
explosion which was encountered in previous systems since) it
will be appreciated, that due to the converging side walls any
movement of the plug out of the port will immediately break the
seal between the plug and the housing. In addition, the shape of
the plug permits it to easily resent itself should it be pushed
out of sealing position, but remain loosely, in the port. To
further facilitate resenting, the plug is preferably formed to
be generally conical in shape.
Preferably, side walls 12a of plug 12 are coated with a
resilient material, such as rubber, to facilitate sealing
against the edges of port 10. Alternately. plug 12 can be formed
at least in part of a resilient material. In a preferred
embodiment, plug 12 is formed from a rubber stopper. An opening
for passage of electrolysis mixed materials is provided by means
of delivery port 14 found at the upper portion of the chamber
and is present to provide an exit for the mixed materials
produced during the electrolysis process. In a preferred
embodiment, port 14 is formed through plug 12. As may be
understood, the port 14 can alternately be formed through any
suitable opening provided in housing 4. A connector 16 is
provided at port 14 for connection to a delivery line 18 at the
time of installation for use. Preferably, as shown, connector 16
is removable from the port for replacement or repair. Referring
also to Figure 3, electrodes 22, 23 and 28 are provided within
chamber 2. The electrode material is selected from any suitable
electric conductor which will not chemically react with the
electrolytic solution either when electrically energized or not.
A suitable material for construction of electrodes 22, 23) and
28 is stainless steel. While it will be understood that
electrode 28 may be configured as a cathode and electrode 22 as
an anode, or polarity of each may be reversed without changing
the principles of operation, for the purpose of illustration.
the central electrode 28 has been configured as an anode while
outer electrode 22 is configured as a cathode. Preferably
electrode 22 is positioned to rest against the interior surface
of housing 4 consequently making it cylindrical in shape to
correspond with the cross- sectional dimension of the chamber.
An extension 22a of the cathode extends up the inside of the
housing 4 for electrical connection to a power supply terminal
24, which is conveniently provided by a bolt. Bolt 24 passes
through an aperture in the housing and is electrically connected
to a wire 26 when installed for use. Wire 26 extends to a
negative ground pole of a battery or a ground) as will be
described in more detail with reference to Figure 4. Centrally
located in the electrolyte solution 6 is anode 28. Anode 28 may
be constructed from any suitable electrical conductor which does
not react with the electrolyte solution and is preferably a
cylinder and may conveniently be a rod formed of stainless steel
in common with cathode 22 and intermediate electrodes 23. Anode
28 is connected by a conductor bracket 30 to a power supply
terminal 32 which is a bolt extending through an aperture in the
housing. Bolt 32 is electrically connected at one end to bracket
30 and, when installed, to wire 34 at its opposite end when
installed for use. Wire 34 is ultimately in electrical contact
with the positive pole of a battery, as will be described in
more detail with reference to Figures 4 and 5. Anode 28 is
further maintained in position concentrically within cathode 22
by plates 36, 37. Plates 36) 37 are formed of a non-conductive
material such as, for example, an ultra high molecular weight
polyethylene (UHMW polymeric resin). Anode 28 is positioned in
centrally located apertures in the plates. A plurality of
apertures 41 are formed in plate 36 for passage of the
electrolysis generated mixed materials from area 40 to area 42
where the mixed materials will bubble up and flow toward
delivery port 14.
A plurality of intermediate electrodes 23 are disposed between
the powered cathode 22 and anode 28. The shape of these
electrodes conforms to the equipotential lines of the electric
field induced in electrolyte solution 6 when power is applied to
the cathode 22 and anode 28. As most clearly seen in Figure 3,
the intermediate electrodes 23 are formed into cylinders to
conform with the circular cross-sectional shape of the
electrolysis chamber 4 and are positioned between anode 28 and
cathode 22. Each electrode is constructed from suitable
chemically inert electrically conductive material, such as
stainless steel, which has been rolled and either welded along a
seam (not shown) or the edges left open. The number of
intermediate electrodes 23 is selected to provide approximately
2 volts across each cell formed by the gap in spacing between
each electrode. A 2 volt difference is preferable to reduce the
ohmic heating of the electrolyte solution bounded by adjacent
electrode by the current passing therethrough as the
electromotive force or voltage required for electrolysis of
water is approximately 1.5 volts. Thus for a 12 volt system, a
group of intermediate electrodes 23 may be provided. For other
operating voltages, a differing number of electrodes are
provided to achieve like effect. While the electrodes are
depicted in Figures 2 and 3 as being equidistantly spaced, it
will be understood that the actual physical placement or spacing
of the intermediate electrodes 23 will be such as to create
approximately a 2 volt differential between adjacent electrodes.
With concentric cylindrical electrodes, varying physical
spacings are required to maintain a uniform electromotive force
differential between adjacent electrodes increasing the
complexity of the electrolyte chamber in both construction and
operation. For cylindrical electrolysis chambers, each cell,
being the electrolyte solution and surrounding operative
electrode pair, has a unique electrolyte solution volume and
electrode surface area resulting in variations in production.
efficiencies and operating parameters. A uniform result for each
cell in the electrolysis chamber apparatus may be obtained by
employing a chamber in the shape of a box having a rectangular
cross-section as shown in Figure 3a. With such a chamber shape,
the equipotential surfaces induced in the electrolyte solution
when electrical potential is applied to the cathode 22 and anode
28 are flat surfaces enabling the intermediate electrodes 23 to
be flat and equidistantly spaced from one another resulting in
substantially uniform construction and operating parameters for
the electrolysis chamber 4. The spacing of the intermediate
electrodes 23 can be achieved in any suitable way, for example,
by plates 36, 37 which have formed therein a plurality of
grooves into which intermediate electrodes 23 are fitted as
shown most clearly in cross section in Figure 2. The grooves
maintain the positioning of the electrodes relative to each
other and to the anode and cathode. The intermediate electrodes
23 serve a number of useful purposes. First, the electrodes act
as baffles to substantially damp any wave action in the liquid
within the chamber. This reduces the likelihood that the
electrolyte solution 6 will splash around in the chamber. Where
the chamber is cylindrical in shape the damping action will be
effective regardless of the direction in which the chamber is
moved. Additionally, the intermediate electrodes increase the
electrode surface area for the generation of electrolysis mixed
materials, as well as reduce the electromotive force being
applied to the cell to a value most efficacious for water
electrolysis. This provides a more efficient chamber with higher
generation capabilities and lower operating temperatures than a
chamber of similar size having therein only the cathode and the
anode electrodes. Also each pair of plates creates its own
electrolytic cell. It will be noted that the terminals 24 and 32
are mounted in the wall of the chamber above the top plate 36.
This is arranged at a position which is above the intended
height of the electrolyte solution in its upper most filled
position. Thus in the wall just below the level of the
connectors is provided a high level indicator contact 90 which
is provided to contact the electrolyte solution in the highest
intended position to indicate through the light, as described in
more detail hereinafter that the container is filled.
A low level indicator 91 positioned on the waH of the chamber at
a height below the upper level indicator and at a position just
below the top plate 36. The central electrode 28 in the form of
the rod includes a washer 92 positioned directly above the plate
36 and locating the plate relative to the central rod. The plate
36 is thus clamped between the washer 92 which prevents the
plate from moving upwardly and the upper edges of the
cylindrical intermediate electrodes. The central rod is fastened
to the base plate 37. Above the top plate 36 is provided a
splash plate 93 supported on the central rod 28 by two spaced
washers 94 and 95. The splash plate 93 is a solid plate formed
of UHMW polyethylene extending outwardly to a position adjacent
but spaced inwardly from the inside surface of the cylindrical
container leaving an annular space for the passage of mixed
materials but preventing or reducing the possibility of
spattering of the electrolyte solution from its position
underneath the splash plate to the discharge outlet 14. Thus the
top plate, the splash plate and the cylindrical electrodes
cooperate in reducing movement of the electrolyte solution
during normal operation of the engine. Turning now to Figures 5
and 6 there is shown schematically the upper portion of the
electrolysis chamber and particularly the top cap. An additional
opening 96 is provided with a plug 97 similar to the plug 12.
The plug 97 receives a filler duct 98 connected with a supply
container 99 containing the electrolyte solution including
distilled water and a makeup quantity of KOH. A solenoid valve
100 is located in the duct 98 for controlling flow of liquid
through the duct. The solenoid valve is actuated by output 4 of
a micro-controller 101. The high level indicator 90 is connected
to input 2 of the micro- controller. Similarly the low level
contact 91 provides an input to terminal 3 of the
micro-controller when the electrolyte solution drops below the
contact 91 and therefore is no longer electrical communication
with that contact. An input terminal 1 of the micro-controller
receives an input from the contact 24 so that it is responsive
to operation of the electrolysis chamber. Thus when the chamber
is in operation and therefore vacuum is applied through the duct
to the opening 14, in the event that the level of electrolyte
solution falls below the level of the low contact 91, the
micro-controller 101 actuates the solenoid switch 100 to allow
liquid to be drawn from the container 99 into the chamber to
replenish the electrolyte solution. The automatic control system
of Figure 5 also has two further functions. Firstly the
measurement of the current through the electrolysis unit which
is provided to input 1 is used to determine when the strength of
the electrolyte in the solution falls below a predetermined
required level. This will occur when the current falls below a
predetermined minimum. In this situation the control unit is
arranged to illuminate light 90A to show to the operator that
additional electrolyte is required. Electrolyte is then added
through the top plug manually from a concentrated solution.
Secondly the input 3 of the controller detects the presence of
current in a situation where the ignition is turned off and
therefore the engine is not operating. In the presence of such
current, the controller is arranged to actuate light 91 A so
that the operator is apprised of a situation where current is
flowing when no current should be flowing thus indicating a
fault. In Figure 6 is shown a similar manual arrangement in
which a light 91 B at the dashboard of the vehicle, or at any
other suitable location where it can be viewed by the operator,
is illuminated when the electrolyte solution level falls to a
low position. The operator can therefore actuate a press button
switch 103 when the operator has noted that the electrolyte
solution level is too low and that the engine is applying vacuum
to the duct 18. The press button switch operates the valve 100
and this is maintained actuated until the electrolyte solution
level reaches the upper contact 90 and illuminates the visible
light 90B. Referring to Figure 4, electrolysis chamber 2
generates hydrogen and oxygen gases together with the steam and
structured water to supplement the fuel supply of a combustion
engine, such as a hydrocarbon fueled internal combustion engine
employed to supply motive power to an automobile. It will
however be appreciated that the present invention can be used
with other machines using an engine.. Common gasoline or diesel
engines have an air intake system supplying a mixture of fuel
and air to be combusted within the engine. The air intake system
is maintained under vacuum during operation of the engine. A
battery 60 has a positive pole 60a and a negative ground pole
60b. In accordance with the invention, a chamber 2 is mounted in
a suitable location at the engine when possible. Power supply
wire 26 from cathode 22 is grounded) for example by contact with
the frame. Power supply wire 34 runs from contact with anode 28
to a control power relay switch .62. From relay switch 62, power
wire 34 runs through an over-current protection device 66, such
as a circuit breaker, fusible link or fuse to positive pole 60a
of battery 60. Relay switch 62 controls the supply of electrical
energy to the electrolysis chamber 2. Over-current protector 66
prevents over-current damage to the components caused by a
malfunction, such as a short circuit. To control and prevent
unwanted generation of the mixed materials, the control relay
switch 62 is configured in such a manner as to ensure that no
electrical power will be supplied to electrolysis chamber 2
unless the engine is both switched on and running. This is
controlled in the following manner. Power relay control wire 68
controls the activation of power relay 62 depending on control
signaling received via vacuum switch 70. Vacuum switch 70 is a
normally open switch which is Gosed, making electrical contact
with ignition line 72, when vacuum is supplied to tubing 71.
Ignition line 72 is powered from the ignition key system 81,
becoming powered when the ignition switch is turned ON. A fuse
75 is provided for safety. The vacuum to operate the vacuum
switch 70 is obtained from the air intake system of the engine
communicated by intake supply line 73 to which tubing 71 is
connected via T-connector 80. As will be readily understood, the
engine will only generate a vacuum when it is running and the
presence of vacuum switch 70 ensures that production of the
mixed materials will only occur when the engine is running. Thus
when the engine has stalled or the ignition switch is, for any
reason) on but the engine is not running, no electrolysis will
occur. While it will be understood that tubing 71 can be
directly connected to the engine manifold to obtain a vacuum
supply directly from the engine, the preferred construction is
to employ a T-connector 80 which bridges engine intake supply
line 73 and the supply line 75. This provides added safety by
preventing the undesirable escape of the combustible mixed
materials into the engine compartment thereby avoiding potential
explosion risks. When the rate of production of electrolysis
mixed materials delivered by supply line 75 exceeds the rate of
consumption of those mixed materials through the engine vacuum
present in the engine intake supply line 73, the excess
production mixed materials will "flood" into the vacuum tubing
71 thereby causing vacuum switch 70 to open, thereby,
interrupting the power 75 supplied to the electrolysis chamber 2
halting further production. The electrolyte solution can be any
suitable solution of water and electrolytic agent permitting
current to move through the solution between the electrodes 22
and 28. An efficacious electrolytic agent will not react during
or be affected by the water electrolysis process to thereby
become expended, decomposed or depleted during the water
electrolysis process. The electrolytic agent must not be so
volatile as to be removed from solution along with the emitted
mixed materials; and, because hydrogen-ion concentrations are
being rapidly perturbed at the electrodes during the water
electrolysis process, the electrolytic agent should have a
strong resistance to pH changes. In one embodiment, the
electrolyte solution is made of distilled water and the
electrolytic agent is effective quantities of potassium
hydroxide (KOH), generally about 10 g KOH per 1.2L of water.
During operation, electrolytic agent concentrations in the water
will vary. The electrolyte solution is added through port 10 to
the chamber. Once it is added, it is only necessary to add
distilled make-up water on an occasional basis to maintain the
unit in operation. Adding make-up water may be accomplished by
removing plug 12 and pouring in the make-up water and thereafter
replacing plug 12. Make-up water should be distilled water to
avoid contamination of the electrolytic solution with the
dissolved salts and other minerals and. contaminants present in
water that is not distilled. Electrical current to the system is
actuated by turning the ignition switch key to start the engine.
The current flowing from anode 28 to cathode 22 causes the
electrolysis of the water in the electrolyte solution. The
operation of the engine causes a vacuum to be set up in the air
intake system of the engine. This vacuum draws the plug 12 down
into port 10 to seal the port. Any generated mixed materials
from the chamber are drawn through supply line 18, to air intake
manifold 113 wherein they are mixed with the air and burned with
the fuel.
Electrolysis occurs as long as the engine is running and vacuum
is applied to vacuum switch 70. When either the ignition key 81
is turned to the off position, or the supply of vacuum to vacuum
switch 70 falls below a preselected threshold amount (because
either the engine stalls or stops) or production of the mixed
materials delivered over line 75 exceeds engine vacuum) power to
the electrolysis chamber is cut off by power relay 62 in
response to interruption of the control signal provided to the
relay by wire 68 resulting in cessation of generation of mixed
materials. Electrolysis mixed materials produced within chamber
2 are carried along supply line 18 to flow control valve 78
which is a directional valve connecting supply line 18 to supply
line 75 when control wire 68 is energized (the ignition 81 is on
and vacuum switch 70 is receiving vacuum) allowing produced
mixed materials to be directed to engine supply line 73. Any
mixed materials which, through a system failure, are generated
while the engine is turned off or remain in electrolysis chamber
2 following engine shut off causes control line 68 to lose power
thereby causing solenoid valve 78 to couple supply line 18 to
the vent line 82 to expel the excess/surplus mixed materials
harmlessly into the ambient atmosphere. in the unlikely event
that solenoid valve 78 falls or ignition of the mixed materials
occurs within electrolysis chamber 2) any accumulated mixed
materials or excessive pressures will be released by pushing out
plug 12 or bursting area 8. The arrangement as previously
described herein of the electrolysis chamber, its arrangement of
the electrodes and the selection of the electrolyte using KOH
provides an arrangement in which the electrolytic action
generates not only oxygen and hydrogen but also steam and
structured water. The potassium in the KOH is particularly
important in this regard. All these elements are then
communicated from the chamber through the duct to the combustion
chamber 110. Thus the duct 73 is connected to the air intake 111
of the combustion chamber at a position downstream of the air
filter 112. A manifold 113 receives fuel through a pump 114 from
a fuel supply 115 from an injector 116. The manifold 113
supplies the fuel, air and the mixed materials from the
electrolysis chamber into the combustion chamber 110. The above
components from the electrolysis chamber cooperate with the
combustion of the hydro carbon fuels from the supply 115 so as
to effect cracking of the unspent fuel in the presence of oxygen
and hydrogen. The oxygen and hydrogen can increase the
temperature of the combustion and the presence of the steam and
structured water operates as an effective cracking agent.
The above components therefore in the combustion chamber crack
the normally unspent long chain and aromatic hydrocarbons
causing the production of shorter chain hydrocarbons which are
readily combustible thereby dramatically reducing emissions. The
long chain and aromatic hydrocarbons can make up 30 to 50% of
the total fuel so that it will be appreciated that a significant
increase in efficiency is obtained by cracking these
hydrocarbons and making them readily combustible. Yet further,
the addition of the above components from the chamber results in
a combustion in the combustion chamber which is sufficient to
effect combustion of the pollutants normally produced in
combustion of hydrocarbon fuels. It has been found, therefore,
that such pollutants in the air drawn into the air intake can be
burnt in the combustion chamber. In this way the pollutants
released from the combustion through the exhaust system can be
significantly reduced relative to the amount of pollutants drawn
in through the air intake. In this way instead of the combustion
chamber acting to generate additional pollutants which are
emitted into the atmosphere, the combustion chamber and its
combustion using the components set forth above can obtain a
situation where it acts to reduce the amount of pollutants in
the air surrounding the combustion chamber by drawing those
pollutants into the combustion chamber from the air intake. It
will be appreciated that this effect of cracking of the
hydrocarbons and of providing an increased combustion effect
thus burning the pollutants does not simply arise from the
submission of oxygen and hydrogen into the combustion system.
The amount of hydrogen generated in the electrolysis chamber is
relatively small and is certainly insufficient to generate the
improvements in energy from the hydrocarbon fuel which are
obtained using this arrangement. In practice it has been found
that increase in energy of 30 to 50% can be obtained utilizing
amounts of the mixed materials which cannot possibly themselves
provide this additional energy. It will be apparent that many
changes may be made to the illustrative embodiments, while
failing within the scope of the invention and it is intended
that all such changes be covered by the claims appended hereto.
CA2513539
ELECTROLYZER APPARATUS AND METHOD FOR HYDROGEN PRODUCTION
Also published as: WO2004076721 // US7510633 // JP2006518812
An electrolyzer cell (10) for the electrolysis of water
comprises a cathode (12) of generally tubular configuration
within which is disposed an anode (1 6) separated from the
cathode (12) by a separation membrane (14) of generally tubular
configuration which divides the electrolyte chamber (15) into an
ano de sub-chamber (15a) and a cathode sub-chamber (15b). An
electrolyzer apparatus (36) includes an array (38) of individual
cells (10) across each of which an electric potential is imposed
by a DC generator (40) via electrical leads (42a, 42b). Hydrogen
gas generated within cells (10) from electrolyte (18) i s
removed via hydrogen gas take-off lines (20) and hydrogen
manifold line (21) . By-product oxygen is removed from cells
(10) by oxygen gas take-off lines (2 2) and oxygen manifold line
(23). The electrolyzer apparatus (36) may be configured to
operate either batchwise or in a continuous electrolyterecycle
operation to produce high purity hydrogen at high pressure,
e.g., up to abou t 10,000 psig, without need for gas compressors
to compress product hydrogen.
The present invention concerns an electrolyzes apparatus and
method to produce high- pressure hydrogen at pressures up to
10,000 psig or higher, by means of electrolysis of water and
without necessity of separate compression equipment. Direct
electrolytic generation of such high-pressure hydrogen (and
by-product oxygen) is attainable by the practices of the present
invention. [0002] Electrolytic production of hydrogen is, of
course, well known, as illustrated by U.S. Patents 5,665,211 for
"Electrolysis Apparatus for Producing Hydrogen"; 6,033,549 for
"Method of Electrolysis"; 6,071,386 for "Electrolysis Apparatus;
and 6,153,083 for "Electrolyzes Isolated by Encapsulation with
Respect to Pressurized Water". [0003] Known electrolytic
equipment, sometimes herein referred to as "electrolyzers",
using liquid electrolyte to generate hydrogen, operates in the
following way. Two electrodes are placed in a bath of liquid
electrolyte, such as an aqueous solution of potassium hydroxide
(KOH). A broad range of potassium hydroxide concentration may be
used, but optimally, a concentration of about 25 to 28% by
weight KOH solution is used. The electrodes are separated from
each other by a separation membrane that selectively allows
passage of liquid but not gas through it. When a voltage is
impressed across the electrodes (about 2 volts), current flows
through the electrolyte between the electrodes. Hydrogen gas is
produced at the cathode and oxygen gas is produced at the anode.
The separation membrane keeps the hydrogen and oxygen gases
separated as the generated gas bubbles rise through the liquid
electrolyte. There is a disengagement space above the liquid
electrolyte comprised of two separate chambers or two sections
isolated from each other by being separated by a gas-tight
barner into two separate sections, one chamber or section to
receive the hydxogen gas and the other to receive the oxygen
gas. The two gases are separately removed from the respective
sections of the disengagement space for storage or venting.
SUMMARY OF THE INVENTION
Generally, in accordance with the present invention, there is
provided an electrolytic apparatus and a method of generating
pressurized hydrogen and by-product oxygen directly from the
apparatus, without necessity of a separate pressurization step.
The electrolytic apparatus, usually referred to as an
"electrolyzer", has a tubular cathode within which a rod-lilce
anode is disposed to define between the anode and cathode an
electrolyte chamber. A tubular separation membrane is disposed
between the anode and the cathode to divide the electrolyte
chamber into an anode sub-chamber and an electrolyte
sub-chamber. In a specific embodiment, the anode, separation
membrane and cathode have a coaxial configuration, so that the
anode sub-chamber and the cathode sub-chamber are of concentric,
annular configuration. The two electrolyte sub-chambers are
respectively connected in gas-flow communication to respective
gas/liquid separators to provide segregated hydrogen and oxygen
sections from which the two generated gases are separately
withdrawn. [0005] Specifically, in accordance with the present
invention there is provided an electrolyzer cell for the
electrolysis of water having first and second opposite ends and
comprising the following components. A cathode of tubular
configuration is connectable to a source of DC electricity, and
defines a cathode active inner surface and a cathode outer
surface. An anode is connectable to a source of DC electricity,
defines an anode active outer surface, and is disposed within
the cathode to define therewith an annular electrolyte chamber
disposed between the cathode inner surface and the anode outer
surface. A separation membrane of tubular configuration is
disposed within the electrolyte chamber between the cathode and
the anode to divide the electrolyte chamber into an anode
sub-chamber and a cathode sub- chamber. The separation membrane
serves to seal against the passage therethrough of gases. First
and second gas-tight seals are disposed at, respectively, the
first and second opposite ends of the cell. A gas tale-off
connection is in liquid- and gas-flow communication with the
electrolyte chamber for removing from the cell gases generated
in the electrolyte chamber. [0006] In accordance with another
aspect of the invention, the gas take-off connection is
dimensioned and configured to remove gas generated in the
cathode sub-chamber separately from gas generated in the anode
sub-chamber. [0007] In another aspect of the invention, the
cathode, separation membrane and anode are all disposed
coaxially relative to each other, and the cathode inner surface,
the anode outer surface and the separation membrane are each of
circular configuration in transverse cross section.
Other aspects of the present invention provide that the
electrolyzer cell may further comprise a pressure vessel
separate from and surrounding and contacting the outer surface
of the cathode or, alternatively, the cathode itself may
comprise a pressure vessel. In either case, one aspect of the
invention provides that the pressure vessel is capable of
containing gas at an elevated pressure, wluch elevated pressure
is at least about 10 psig. In some cases, the elevated pressure
is not greater than about 10,000 psig, e.g., is not greater than
about 5,000 psig. [0009] Yet ailother aspect of the present
invention provides that at least one of the gas-tight seals
comprises an anode-sealing collar affixed to the anode adjacent
one end thereof; an electrical isolation bushing, which may be
cup-shaped to define a recess in which the anode- receiving
collar is received, the bushing being affixed to the anode
between the anode-sealing collar and the one end of the anode,
the bushing engaging the anode-sealing collar; and an end
fitting engaging the bushing and providing a gas-tight seal of
the cathode at one end thereof. [0010] Another aspect of the
invention provides an electrolyzes comprising a plurality of
electrolyzes cells as described above, first gas-flow conduits
connected in liquid- and gas-flow communication between the
respective cathode sub-chambers of the plurality of cells and a
first gas collector; and second gas-flow conduits connected in
liquid- and gas-flow communication between the anode
sub-chambers of the plurality of cells and a second gas
collector. [0011] In accordance with a method aspect of the
present invention there is provided a method of electrolyzing
water to generate pressurized hydrogen and oxygen therefrom
utilizing an electrolyzes comprising one or more electrolyzes
cells. The cells individually comprise (i) a cathode of tubular
configuration within which a rod-shaped anode is disposed to
define an annular-shaped electrolyte chamber between the cathode
and the anode, (ii) a separation membrane of tubular
configuration disposed within the electrolyte chamber between
the cathode and the anode to divide the electrolyte chamber into
an anode sub- chamber and a cathode sub-chamber and seal the
sub-chambers against gas flow therebetween. The method comprises
the following steps: (a) introducing an aqueous solution of
electrolyte, e.g., an aqueous solution of potassium hydroxide,
into both sub-chambers of the electrolyte chamber; (b) applying
a DC voltage drop across the respective anodes and cathodes of
the cells to dissociate water into hydrogen at the cathode and
into oxygen at the anode; and (c) separately withdrawing
hydrogen and oxygen from the one or more electrolyzes cells.
[0012] In another method aspect of the present invention, the
cell further comprises a pressure vessel and the hydrogen and
oxygen are generated at an elevated pressure of at least about
10 psig, e.g., a pressure not greater than about 10,000 psig, or
not greater than about 5,000 psig.
Method aspects of the present invention include one or more of
the following, alone or in suitable combinations: the pressure
differential between the hydrogen and oxygen withdrawn from the
cells is maintained at not more than about 0.25 psig,
preferably, not more than about 0.2 psig, and more preferably
not more than about 0.17 psig. [0014] Electrolyte and product
hydrogen are flowed into a hydrogen separator, electrolyte and
by-product oxygen are flowed into an oxygen separator, the
respective electrolyte liquid levels in the hydxogen and oxygen
separators are sensed and controlled to maintain a pressure
differential between the hydrogen and oxygen withdrawn from the
cells of not more than about 0.2 psig. [0015] The electrolyte
may be, but need not be, recirculated through the electrolyzer
in a continuous operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Figure 1 is an elevation view of a gas-generation
cell in accordance with one embodiment of the present invention;
[0017] Figure lA is a perspective view, partly broken-away, of
the gas- generation cell of Figure 1;
[0018] Figure 1B is a transverse cross-sectional view, enlarged
relative to Figure l and taken along line I-I of Figure 1,
showing electrolyte contained within the cell, the body of
electrolyte being brolcen away for improved clarity of
illustration;
[0019] Figure 1 C is a view corresponding to that of Figure 1B,
except that a body of electrolyte corresponding to that shown in
Figure 1B is omitted, showing a gas generation cell in
accordance with a second embodiment of the present invention;
[0020] Figure 1D is a longitudinal cross-section view, enlarged
relative to Figure 1 and talcen along line II-II of Figure 1;
[0021] Figure 2 is a longitudinal cross-sectional view, enlarged
relative to Figure 1, of a seal member in accordance with an
embodiment of the present invention, and utilizable as a
component of the gas-generation cell of Figure l;
[0022] Figure 3 is a schematic flow diagram showing an
electrolyzer apparatus in accordance with one embodiment of the
present invention and including an array of a plurality of gas-
generation cells of the type illustrated in Figures 1 through
1B; and
[0023] Figure 4 is a schematic, cross-sectional view of a liquid
level sensor utilizable in one embodiment of the electrolyzer
apparatus of Figure 3.
DETAILED DESCRIPTION OF THE INVENTION AND SPECIFIC
EMBODIMENTS THEREOF
Referring to Figures 1, lA and 1B, there is shown a
gas-generation cell 10 comprising a cathode 12 which also serves
as an outer containment shell, a separation membrane 14 (Figure
1B) and an anode 16. Cathode 12 has an inner surface 12a and
anode 16 has an outer surface 16a. Surfaces 12a and 16a are
active electrode surfaces which are exposed to, and in contact
with, a liquid electrolyte 18 which is contained within
electrolyte chamber 15 of gas-generation cell 10. Electrolyte
chamber 15 is defined by the space between surfaces 12a and 16a.
As seen in Figure 1B, separation membrane 14 divides electrolyte
chamber 15 into an anode sub- chamber 15a containing an anode
portion 18a of electrolyte 18, and a cathode sub-chamber 15b,
containing a cathode portion 18b of electrolyte 18. It is seen
that the anode 16, cathode 12, and separation membrane 14 are
configured coaxially, with the tubular separation membrane 14
disposed coaxially within the tubular cathode 12 and the
rod-shaped anode 16 disposed coaxially within the separation
membrane 14. As shown in Figure 1B, cathode 12 and separation
membrane 14 are of annular shape in transverse cross section,
thereby imparting the same cross-sectional annular shape to the
anode and cathode sub-chambers 15a and 15b. Cathode 12 is
separated from the anode and sealed at one end against high
pressure by seal 13 (Figures 1 and lA). A gas-tight seal 12b
(Figure 1D) closes the other end of cell 10. Gas-tight seal 12b
is shown in simplified schematic form for simplicity of
illustration; its construction will be similar to that of
gas-tight seal 13 except that, as shown in Figure 1D, the anode
16 does not protrude through it, but stops short of it. A pair
of gas tale-off lines 20 and 22 protrude through gas-tight seal
12b to establish liquid- and gas-flow communication with the
interior of gas-generation cell 10, as described below. The
cathode 12 serves as the hydrogen-generating electrode and the
anode 16 serves as the oxygen-generating electrode. The
illustrated configuration of cell 10 separates the liquid
electrolyte 18 into an anode electrolyte portion 18a and a
cathode electrolyte portion 18b. The liquid electrolyte may be,
for example, a 25% to 28% by weight KOH aqueous solution
contained within electrolyte chamber 15, i.e., between the
electrodes 12, 16 on both sides of the separation membrane 14. A
plurality of individual gas-generation cells formed in this
manner may be assembled into an array for use in an
electrolyzer, as described below. [0025] Upon imposition of a
direct current ("DC") voltage drop, typically about from 1.5 to
3 volts, preferably about 2 volts, across cathode 12 and anode
16, hydrogen gas is generated at cathode 12 within cathode
sub-chamber 15b of electrolyte chamber 15, and oxygen gas is
generated at anode 16 within anode sub-chamber 15a of
electrolyte chamber 15.
[0026] The cathode component may, but need not necessarily, also
serve as the pressure boundary of the electrolysis cell. That
is, in some embodiments the cathode also serves as the
containment or pressure vessel, whereas in other embodiments the
co-axially disposed anode, separation membrane and cathode may
all be contained within a pressure vessel, enabling thin- wall
construction of the cathode as well as the anode. [0027] For
high pressure generation in cases where the cathode also serves
as the pressure vessel, the wall thiclcness T of cathode 12 arid
consequently the outside diameter D of the cell 10 is dictated
by the desired generation pressure, by material properties such
as yield strength and electrical conductivity of the metal from
which cathode 12 is made, and by practical considerations
limiting the wall thickness of cathode 12 which, as noted above,
also may serve as the containment vessel of cell 10. For
inexpensive steel or other suitable metal tube or pipe material,
consistent with hydrogen embrittlement constraints, there are
practical limits on the diameter D of individual cells for
generation at 10,000 prig. These practical limits are imposed by
practical limits on the wall thickness T of cathode 12 and
result in a range of diameter D of from about 2 to 3 % inches
(about 5.1 to 8.9 cm). Generally, the wall thiclcness T may vary
from about 1/4 to 5/8 inches (about 0.64 to 1.59 cm). The length
L of the individual cell 10 is determined by the desired
gas-generation rate, generation pressure, and annular flow gaps.
Typically, the length L of the cell 10 is from about 2 to 6 feet
(about 0.61 to 1.83 meters). The annular flow gaps are shown in
Figure 1B by the radial dimension lines g~ (cathode annular flow
gap) and ga (anode annular flow gap). Typical dimensions for the
cathode annular flow gap g~ are from about 3/16 to 3/8 inches
(about 0.48 to 0.96 cm), and for the anode annular flow gap ga
are from about 1/8 to 1/4 inches (about 0.32 to 0.64 cm). [0028]
A simple construction, shown in Figure 1D, is used to maintain
the balance of pressure across the separation membrane 14 within
the individual cells 10 to within 2 inches of water (less than
0.1 psig). Maintaining such pressure balance enables maintaining
product (hydrogen) purity because the separation membrane 14
cannot seal against gas leakage at pressure differentials
exceeding a few inches of water. Gas-tight seal 12b has a
circular flange 11 on the inside thereof in which is formed a
groove (unnumbered) within which the end of separation membrane
14 is received to provide a gas-tight seal between cathode
disengagement space 19a and anode disengagement space 19b. A
similar grooved-flange construction may or may not be supplied
at the inside of seal 13 (Figures 1 and lA) to seal the opposite
end of separation membrane 14. [0029] Gas off take line 20
transports hydrogen gas from cathode disengagement space 19a
(Figure 1D) within cell 10 above the level 1 of cathode
electrolyte portion 18b of liquid electrolyte 18. Gas tale-off
line 22 transports oxygen gas from anode disengagement space 19b
within cell 10 above the level 1' of anode electrolyte portion
18a of a liquid electrolyte 18. The respective hydrogen and
oxygen disengagement spaces are isolated from each other by a
gas- tight bullchead structure (not shown). [0030]' Figure 1C
shows a second embodiment of the invention, wherein parts
identical or similar to those of the embodiment of Figure 1B are
nmnbered 100 higher than the numbers used in Figure 1B. With the
single exception noted, the parts and their function of cell 110
of Figure 1C are identical to those of the corresponding parts
of the embodiment of Figure 1B, and therefore a description of
their structure and function is not repeated. In cell 110, anode
112 is not designed to resist the operating pressures of cell
110, and there is therefore provided a pressure vessel 113 which
is separate from, but surrounds and contacts, the outer surface
(unnumbered) of cathode 112. Pressure vessel 113 has end
portions (not shown) which encase the first and second ends of
cell 110 to provide an effective pressure vessel for cell 110.
[0031] The illustrated configuration of cell 10 enables
optimization of the electrode areas for the cathode and anode.
Because the gas-generation rate (of hydrogen) at the cathode is
twice the gas-generation rate (of oxygen) at the anode, the
respective surface areas of cathode inner surface 12a and anode
outer surface 16a ideally should have the same 2:1 ratio, or at
least an approximation thereof, to allow the maximum
gas-generation rate for a cell of given dimensions. The
gas-generation rate is normally determined by the surface area
12a of the cathode for a given material and surface conditions.
In prior art parallel plate electrode configurations, where the
anode and cathode are of equal surface area, there is a wasteful
excess of anode surface area. In contrast, in the coaxial
configuration of the present invention, the diameter of the
anode is smaller than the diameter of the cathode as measured at
its inner surface 12a. The anode (outer) surface area is
therefore smaller than the inner surface area of the cathode.
The anode (outer) surface and the cathode inner surface are the
surfaces in contact with the liquid electrolyte and therefore
constitute the active electrode surfaces. The respective
electrode diameters and annular flow gaps can be established to
create a cathode-to-anode active surface area ratio near or at
the optimum 2 to 1 value.
Usually, the separation membrane 14 of Figure 1B and the
separation membrane 114 of Figure 1C will be dimensioned and
configured so that the volume of sub- chambers 15b and 115b are
approximately twice the volume of their respective associated
sub- chambers 15a and 115a. The individual cells 10 are sealed
by providing a seal between the anode 16 and the containment
vessel provided by the cathode 12 at each end of the latter. The
seal must provide low voltage (~2 volts) electrical isolation
between the anode and cathode as well as sealing the cell 10
against liquid leakage with internal pressures in the cell of up
to about 10,000 psig or more. Figure 2 is an illustration of a
simple and effective seal design. [0033] The seal 13 is
comprised of four basic components. An anode-sealing collar 24
is made of metal and is welded to the a~iode 16 at an
appropriate location to align it with the lower end of cathode
12 (Figure 1). Collar 24 may alternately be made by machining
anode 16 from a larger-diameter rod so that collar 24 and anode
16 are of one-piece, unitary construction. An O- ring groove 24a
is machined into the bottom end surface (unnumbered) of sealing
collar 24 to receive an O-ring 24b. An electrical isolation
bushing 26 is of cup shape and is made of a dielectric material
to provide an electrical isolation piece through which the anode
16 passes. Bushing 26 is made from non-conducting material and
has an O-ring groove (unnumbered) formed about the periphery
thereof to receive an O-ring 26a. A high-pressure end fitting 28
is made of metal and provides an end piece through which the
anode passes a~.id which seals the lower end of the cathode 12
by means of either threading or welding. The outer diameter of
the end fitting 28 may be threaded to provide exterior threads
28a to mate with inner diameter threads (not shown) provided at
both ends of the inner surface 12a (Figure 1B) of the
containment vessel wall provided by cathode 12. The end fitting
may be welded to the lower end of the cathode. Either
arrangement forms a seal against the high gas pressure generated
within cathode 12. [0034] An electrical insulating sleeve 30 has
a sleeve bore 33 extending through it and is disposed within the
end-fitting bore (unnumbered) extending through high- pressure
end fitting 28. Anode 16 is received within the sleeve bore 33.
Electrical insulating sleeve 30 thus serves to maintain
electrical isolation between the anode 16 and cathode 12 outside
the pressurized area within cathode 12. Sleeve 30 also has an
end flange 30a that electrically isolates a nut 32 which is
threaded onto the anode 16, at threads 17 formed at or near the
end thereof, and is used to preload and hold the entire assembly
together. A washer 34 is interposed between nut 32 and end
flange 30a.
It will be appreciated that the various components, i.e.,
anode-sealing collar 24, electrical isolation bushing 26, and
end fitting 28 are so dimensioned and configured as to position
and maintain anode 16 at the center of the electrolyte chamber
15 (Figure 1B) defined between cathode 12 and anode 16.
Structure is similarly provided to position and hold separation
membraale 14 in place concentrically relative to anode 16 and
cathode 12. This may be accomplished by one or more suitable
positioning members which are dimensioned and configured to
position and maintain separation membrane 14 in place. [0036]
Referring now to Figure 3, an electrolyzer apparatus 36
comprises an array 38 of individual cells 10 across each of
which an electric potential is imposed by an electrical energy
source provided, in the illustrated embodiment, by a DC
generator 40. Electrical leads from generator 40 to cells 10 are
schematically illustrated by electrical leads 42a, 42b. A given
hydrogen production capacity for electrolyzer apparatus 36 is
attained by appropriately sizing individual cells 10 and
selecting an appropriate number of such cells for connection to
a common manifold system as described below. In use, a method
for producing hydrogen (with an oxygen by-product) is carried
out by utilizing an electrolytic apparatus as described above
~to produce hydrogen (and oxygen by-product) at an elevated
pressure of up to 10,000 pounds per square inch gauge ("psig"),
for example, a pressure range from about 0 to about 10,000 prig.
The upper end of this pressure range (from about 5,000 to about
10,000 psig) is uniquely well suited to directly provide
hydrogen fuel for storage in high-pressure storage vessels of
hydrogen-based fuel cell-powered automobiles or other self
propelled vehicles, or portable or stationary devices. Any
pressure ranges between about 0 to about 10,000 psig may of
course be used. Typical of such intermediate ranges are
pressures above about 3,000 prig, e.g., from above about 3,000
psig to about 10,000 psig; from about 3,500 psig to about 8,000
psig; and from about 3,500 psig to about 10,000 psig. Generation
of hydrogen at pressures above 10,000 psig may be feasible in
certain aspects of the invention, provided that it is
economically practical for the contemplated use to provide
pressure vessels and associated equipment capable of sustaining
such high pressures. [0037] An electrolyte reservoir 44 is
supplied by make-up water pump 48 with make-up water from water
treatment and storage zone 46 in order to replenish water which
was dissociated by electrolysis to provide product hydrogen and
oxygen. Electrolyte is taken from the electrolyte reservoir 44
and is fed by supply line 45 to electrolyte-replenishing pump 50
from which it is transported via electrolyte feed line 51 to an
electrolyte manifold 52 which supplies the electrolyte liquid to
individual cells 10 via electrolyte feed lines 54.
Hydrogen gas generated within cells 10 and some electrolyte 18
(Figure 1B) is removed via gas off take lines 20 and hydrogen
manifold line 21 to hydrogen separator 56, wherein liquid
electrolyte 18 (Figure 1B) is separated from the hydrogen gas.
Hydrogen product from hydrogen separator 56 is flowed via
hydrogen discharge line 60 and is free to flow through check
valve 62 and into hydrogen storage tanlc 63, or to use or
further treatment. Separated electrolyte provides a liquid seal
within hydrogen separator 56. Hydrogen pressure will continue to
rise as hydrogen is supplied to the fixed volume storage tank
63. Similarly, oxygen and liquid electrolyte 18 is removed from
cells 10 by gas off take lines 22, which supply oxygen manifold
line 23. The oxygen gas and liquid electrolyte 18 flow via line
23 to oxygen separator 64 in which liquid electrolyte is
separated from the oxygen. Separated oxygen flows via oxygen
discharge line 68 at a rate, which is controlled by oxygen
pressure regulator 70, to an oxygen storage tans (not shoml) or
to venting or to use or fixrther treatment. Separated
electrolyte provides a liquid seal within oxygen separator 64.
The oxygen flow rate is controlled to maintain the liquid level
in separator 64 to be equal to the liquid level in separator 56.
The same operational function could be performed by maintaining
the pressure in separator 64 to be equal to the pressure in
separator 56. This allows the individual cells 10 to be operated
in a flooded condition with the generated gas bubbles passing
through the gas off take lines 20, 22 leading from each cell to
the separators 56, 64 and the common reservoir 44. In such mode
of operation, the levels 1, f of electrolyte 18 shown in Figure
1D are maintained at a higher level within the apparatus
illustrated in Figure 3. The electrolyte 18, in such case,
floods the cells 10, gas take-off lines 20 and 22, hydrogen
manifold line 21 and oxygen manifold line 23, the electrolyte
surface level in such case being at level 1 of Figure 4. [0039]
The separators 56 and 64 are sized in cross-section so as to act
as a liquid trap preventing or greatly reducing electrolyte
carry over and loss of potassium hydroxide. Make-up potassium
hydroxide may be added to the system as needed, e.g., manually
during shut-downs for periodic maintenance. In addition, the
oxygen gas exiting the oxygen separator is connected to the gas
space over the liquid in the electrolyte reservoir to maintain
reservoir pressure at near cell pressure. This enables the
electrolyte supply pump to operate as a low differential
pressure circulator. Make-up water is only added to the
electrolyte reservoir when level sensors in the reservoir (not
shown) indicate the need to replenish the reservoir liquid.
[0040] Check valve 62 allows the hydrogen product gas to flow
through line 60 into a storage tanlc 63 or to fixrther
processing or use when the hydrogen gas pressure in cells 10
exceeds that in line 60, e.g., in the hydrogen storage tank 63.
A pressure sensor (not shown) acts to automatically shut off the
electrical current to the electrolyzer apparatus 36 when the
maximum design pressure in hydrogen storage tank 63 has bean
reached. [0041] The liquid level in the hydrogen separator 56 is
sensed by a simple level-sensing device, shown in Figure 4,
which is mounted on hydrogen separator 56. Level- sensing device
72 comprises a pair (or more) of electrically isolated probes
74, 76 that extend into the separator 56 at lengths that define
the maximum and minimum desired level 1 of liquid electrolyte 18
in the separator 56 at, respectively, probe tips 74a and 76a.
The electrically isolating seal is essentially the same design
as the cathode/anode seal 13 (Figures 1 and lA) described above.
A low-voltage source 78, typically, less than about 1.5 volts,
is connected by electrical leads 80, 82 to probes 74, 76 and is
grounded to separator 56 by electrical ground lead 84.
Electrical continuity is checlced between the probes 74, 76 and
the shell of separator 56. If the electrolyte level drops below
the lower level, i.e., no continuity is found in either probe,
the electrolyte supply pump 50 is actuated and electrolyte is
sent to the cells. When electrical continuity is sensed on both
probes 74 and 76, the electrolyte has reached the maximum level
and the electrolyte supply pmnp 50 is stopped, and no more
electrolyte is sent to the cells. If the conductive electrolyte
is between the two probe lengths, i.e., continuity is found on
one probe only, the make-up water pump 48 status is left
unchanged, whether on or off, until one of the two above
mentioned conditions is met. [0042] The flow of oxygen can be
easily controlled to minimize the pressure differential between
the separators (and therefore across the diaphragm) in either of
two ways: differential pressure sensing, or liquid-level
sensing. [0043] In the differential pressure-sensing technique,
the flow from the oxygen separator 64 is controlled by
pneumatically actuated pressure regulator valve 70. In this case
the actuator diaphragm (not shown) of valve 70 is connected by
lines (not shown) to sense the pressure differential between the
gas in the oxygen separator 64 and hydrogen separator 56, and
opens to vent the gas space of oxygen separator 64 to maintain a
set pressure differential. This pressure differential is set at
near zero, e.g., a pressure differential of about from 0.17 to
0.2 psig, so that the pressure balance inherently keeps the
liquid levels in the two separators 56, 64 stable and equal to
within the differential pressure setting. [0044] In the direct
liquid-level sensing technique, a liquid-level sensor identical
to liquid- level sensing of Figure 4 is installed on device 72
in the oxygen separator 64. In this case the valve 70 regulating
the flow of gas from the oxygen separator 64 cycles between high
and low (or on and off) settings. This simple level-control
scheme is satisfactory for operation of cells
10. The setting of valve 70 is determined by the liquid
electrolyte level in separator 64 as follows. When the valve 70
is at its high flow setting and the liquid level in the oxygen
separator 64 rises and reaches the high level contact (analogous
to probe tip 74a of Figure 4), the valve 70 is switched to its
low flow-rate position by a suitable electronic control device
(not shown). When the valve 70 is in the low flow setting and
the liquid level drops and reaches the low level contact
(analogous to probe tip 76a of Figure 4), the valve 70 is
switched to its high flow-rate position by the control device.
[0045] In a different embodiment of the present invention, the
electrolyte is circulated in a continuous recycle operation.
This continuous-operation embodiment enables the production of
high-pressure hydrogen with the potential to increase the
length, and therefore the production rate, for a given cell. In
the batch mode embodiment described thus far, the individual
cell length is limited by a combination of the cell dimension
(flow gap), gas volume generation rate, and bubble rise rate.
Circulating the electrolyte upward through the cell at
appropriate rates in a continuous recycle embodiment of the
invention will increase the bubble rise rate via entrainment and
allow longer cathode and electrode length for otherwise
similarly dimensioned cells. To implement this recycle approach
the separator reservoirs (items 56 and 64 in Figure 3) would be
altered by adding a return path for the electrolyte from
separators 56 and 64 back to the electrolyte reservoir (item 44
in Figure 3). The remainder of the apparatus schematically
show~l in Figure 3 and the basic control system as described
above for the batch mode embodiment stays largely unaltered for
the electrolyte-circulating continuous recycle embodiment.
[0046] The present invention provides at least the following
advantages over the prior art. [0047] 1. The coaxial
anode/cathode configuration allows very high-pressure hydrogen
generation with practical wall thicl~nesses of conventional
materials in the containment vessel provided by the cathode 12.
The value of this invention is further enhanced by the use of
advanced pressure-containment materials, such as composite
structures, which may make practical larger individual cell
sizes at elevated pressures. The co-axial configuration also
allows optimization of the surface areas of anode 16 and cathode
12, as described above. [0048] 2. Independent gas/liquid
separators (such as separators 56, 64) are used for each of the
hydrogen and oxygen production sides. This allows multiple
gas-generation cells 10 to be connected to common gas/liquid
separation vessels (e.g., 56, 64) and the utilization of a
liquid electrolyte level control system.
13. A novel, low-cost pressure seal design for entry of the
anode 16 into the gas- generation cell 10 enables satisfaction
of high-pressure and electrical isolation requirements at
reasonable cost. [0050] 4. The invention provides a simple,
inexpensive control strategy for untended operation during
hydrogen production, including automated control of the level of
liquid electrolyte 18, or the control of the differential
pressure between the separators (56 and 64) and release of
generated hydrogen and oxygen gases, such that high-purity gas
products are obtained. [0051] The ability of the apparatus and
method of the present invention to enable hydrogen (and oxygen)
production at pressures of up to or even exceeding 10,000 psig
exceeds the highest direct generation pressure of about 3,000
psig that has been previously reported as attainable from prior
known electrolyzers. The apparatus and method of the present
invention can produce such high-pressure hydrogen without need
for a separate compressor to pressurize the product hydrogen
gas. Producing 10,000 psig hydrogen is key to supplying
compressed hydrogen gas for fuel-cell-powered or internal
combustion engine-powered vehicles at acceptable
volume-to-weight ratios for onboard storage that yields a
single- tank driving range equivalent to gasoline powered
vehicles. The present invention allows high- pressure hydrogen
production to be performed in a unique way that reduces the
component cost and system complexity so that the equipment is
easily affordable by individuals for commuter vehicle home
fueling and for small fleet fueling applications. The invention
is scalable to any given production capacity and is also
practical for service-station type applications for dispensing
of hydrogen to fuel-cell-powered vehicles and equipment. [0052]
The apparatus and method of the present invention rnay be
utilized to generate pressurized hydrogen on site at locations
such as service stations for hydrogen fuel cell-powered
automobiles; service stations, hardware/home improvement stores,
and local energy distributors for retail sale of hydrogen fuel
via high-pressure canisters; and in residences, factories and
office buildings for on-site energy storage and/or use in fuel
cell or internal combustion engine- based portable power supply
or home, garden or other appliance applications.
CA2143448
ELECTROLYSIS APPARATUS FOR PRODUCING HYDROGEN
CA1215672
ELECTROLYTIC PRODUCTION OF HYDROGEN
CA1153333
METHOD FOR ELECTROLYTIC PRODUCTION OF HYDROGEN
CA1247038
PROCESS FOR OBTAINING HYDROGEN AND OXYGEN FROM WATER
CA2570922
HYDROGEN GAS ELECTROLYSIS AND SUPPLY APPARATUS
CA1137921
CATALYSING GASEOUS HYDROGEN EVOLUTION IN AQUEOUS ALKALINE
ELECTROLYSIS
CA2479427
HYDROGEN-ASSISTED ELECTROLYSIS PROCESSES
WATERFUEL: 40/08
CA2054493
MOTOR FUEL COMPOSITION HAVING ENHANCED WATER TOLERANCE
CA2509286
WATER BLENDED FUEL COMPOSITION
CA2204695
SELF EVACUATING WATER-SEPARATING FUEL FILTER
CA2344044
WATER FUEL EMULSIFIED COMPOSITIONS
CA1096621
VAPORIZATION OF ELECTRICALLY CONDUCTIVE WATER-HYDROCARBON
EMULSION
CA2315094
SUPERCRITICAL WATER FUEL COMPOSITION AND COMBUSTION
SYSTEM
CA2397623
FUEL-WATER EMULSIONS CONTAINING EMULSIFIERS
CA2341437
VAPORIZATION DEVICE FOR CONVERTING FUEL AND WATER INTO
HYDROGEN
CA1303192
ELIMINATING AIR AND WATER FROM FUEL
CA2380091
SUB-CRITICAL WATER-FUEL COMPOSITION AND COMBUSTION SYSTEM
CA2210256
PLATINUM METAL FUEL ADDITIVE FOR WATER-CONTAINING FUELS
CA2499064
CONVERTING MIXTURE OF WATER AND ETHANOL INTO FUEL
WATER INJECTION:
CA1213738
FUEL INJECTOR ASSEMBLY WITH WATER
CA2154452
DUAL FUEL INJECTION NOZZLE WITH WATER INJECTION
Related :
http://peswiki.com/index.php/Free_Energy_Blog:2014:11:18#Philippine_Police_Car_Powered_with_HHO
Free Energy Blog:2014:11:19
Philippine Police Car Powered with
HHO
Habibur Rahman posted this on my [ Sterling Allen ] Facebook
page.
The police force in the Philippines have started to use hho on
their vehicles this saves them 30% on fuel and reduces emissions
by 90% .
