INVESTIGATION OF PRODUCTION OF HYDROXY GAS USING

ADVANCED ELECTROLYZER

By

MOHAMAD ALIFF BIN MOHD SAHIMI (7697)

FINAL YEAR PROJECT PROGRESS REPORT

Submitted to the Electrical & Electronics Engineering Programme

In Partial Fulfillment of the Requirements
For the Degree
Bachelor of Engineering (Hons)
(Electrical & Electronics Engineering)

UniversitiTeknologiPETRONAS
Bandar Seri Iskandar
31750 Tronoh
Perak DarulRidzuan

Copyright 2010
By

Mohamad Aliff bin Mohd Sahimi, 2010

2
 CERTIFICATION OF APPROVAL

INVESTIGATION OF PRODUCTION OF HYDROXY GAS USING

ADVANCED ELECTROLYZER

by

Mohamad Aliff bin Mohd Sahimi

A project dissertation submitted to the

Electrical & Electronics Engineering Programme
UniversitiTeknologi PETRONAS
in partial fulfillment of the requirement for the
Bachelor of Engineering (Hons)
(Electrical & Electronics Engineering)

Approved:

__________________________
Mr. SaifulAzrin bin Mohd Zulkifli
Project Supervisor

UNIVERSITI TEKNOLOGI PETRONAS

TRONOH, PERAK

Jun 2010

2
 CERTIFICATION OF ORIGINALITY

This is to certify that I am responsible for the work submitted in this project, that the

original work is my own except as specified in the references and acknowledgements,

and that the original work contained herein have not been undertaken or done by

unspecified sources or persons.

__________________________
Mohamad Aliff bin Mohd Sahimi

2
 ABSTRACT

Soaring fuel prices have made us find alternatives which are cheaper and more
reliable. Hydroxy is aproduct of the electrolyzer, which consists of combination of
hydrogen and oxygen. Hydrogen is part of the alternative fuel in development to
replace gasoline as main fuel source. This document presents the study of hydrogen
fuel system that is applied on vehicles and the design of device to produce this gas on
demand without the risk of storing a high pressure tank of compressed hydrogen in
vehicles. The internal combustion of an engine and the study of itis also
presented.This document is divided into 5chapters: Chapter 1 describes the objective,
problem statement, scope of study, methodology, findings and background study,
meant to give the basic idea of this project. Chapter 2 describesliterature review &
theory required for the project to be done successfully. Chapter 3 and 4 discuss the
methodology and conclusion for the end product of the investigation. The
investigation will covers properties, technical details of the equipment, all the
required materials and steps taken for this project to be executeduntilthe prototype
level.

4
 TABLE OF CONTENTS
Abstract………………………………………………………………..………v
List of Figures…………………………………………………………..…...viii
List of Tables…………………………………………...……………….…….ix
List of Abbreviations………………………………………………….……....x

CHAPTER 1 : INTRODUCTION.....................………………….……..…1
1.1 Background Study…………………………………………………1
1.2 Problem Statement…………………………...……………………2
1.2.1 Problem Identification……………………………......…2
1.2.2 Significance of the Project………………………………2
1.3 Objectives and Scope of Study………………………………....…3
1.3.1 Relevancy of Project………………………………….…………3
1.3.2 Feasibility ofProject within Scope and Time Frame……3
1.3.3 Investigation………………………………………..……3

CHAPTER 2 :LITERATURE REVIEW & THEORY…………….....…4

2.1 Theory………………..…..…………………………..................…4
2.2 Mechanism of Combustion……………………………………..…5
2.3 Advanced Electrolyzer System……………………………………6
2.3.1 Building the Case…………………………………..……8
2.3.2 Preparing the Plates………………………………….…11
2.3.3 Electrolyzer Preparation Steps…………………………12

CHAPTER 3 :METHODOLOGY………………………………..………14
3.1 Procedure Identification…………………………………………14
3.2 Project Workflow………………………………………….......…15
3.3 Tools & Equipment.…………………………………….…….…16
3.3.1 Components ………………………………......…..……16
3.3.2 Equipment ………………………………..….…..……16
3.3.3 Tools………………………………………….……..…16

4
CHAPTER 4:RESULTS AND DISCUSSION……………….……....…17
4.1 Data Gathering & Analysis............................................................17
4.1.1 Normal Electrolysis Experiment.....................................17
4.1.1.1 Equipment Setup for Electrolysis.....................18
4.1.1.2 Data Collection ...............................................18
4.1.2 Advanced Electrolyzer Experiment................................19
4.1.2.1 Waveform Setup..............................................20
4.1.2.2 Fabrication Work.............................................20
4.2 Discussion………………………………………………..………20
4.2.1 Limitation............................................................21

CHAPTER5:CONCLUSIONANDRECOMMENDATION……..…..21
5.1 Conclusion……………………………………………………..…22
5.2 Recommendation…………………………………………………22

REFERENCES…………………………………….………….…………….23

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 LIST OF FIGURES

Figure 1 : Combustion Work in Gasoline Engine.....................................................................7

Figure 2 : Milled Body Case for Electrolyzer...........................................................................9
Figure 3 : Reinforced Acrylic Iron to Corners.........................................................................10
Figure 4 : Milled Plate Position in the Electrolyzer Housing..................................................11
Figure 5 : Sanded Electrolyzer Plate.......................................................................................13
Figure 6 : Plate Preparation for Electrolyzer...........................................................................13
Figure 7 : Electrolyzer Preparation..........................................................................................13
Figure 8 : Installation Layout for Electrolyzer in Vehicles System........................................14
Figure 9 : Sensors Circuit for Water Level Detection in Tank................................................14
Figure 10 : Water Supply to the Electrolyzer System.............................................................14
Figure 11..................................................................................................................................16
Figure 12 : Workflow of The Project......................................................................................16
Figure 13 : Normal Electrolysis Setup.....................................................................................18
Figure 14 : Oxygen & Hydrogen Gas Generation...................................................................19
Figure 15 : Data Analysis of Test 1 of Benchmarking............................................................20
Figure 16 : Data Analysis of Test 2 with Electrolyte..............................................................21
Figure 19 : Setup of Benchmark Test 1...................................................................................27
Figure 20 : Setup of Test 2 with Electrolyte............................................................................27
Figure 18 : Setup of Test 2 with Electrolyte

3
 LIST OF TABLES

Table 1 :Oxygen & Hydrogen Production..............................................................................19

Table 2 : Waveform Setup for Electrolyser Input....................................................................20

4
 LIST OF ABBREVIATION

1. D.C. - Direct current

2. A.C. - Alternating current
3. F.Y.P. - Final Year Project.

5
 CHAPTER 1
INTRODUCTION

1.1 Background Study

Traditional electrolysis is known for hundreds of years since it was first

introduced by Michael Faraday. The structures of the one done by Faraday uses two
carbon electrodes and water with the presence of an electrolyte such as Sodium
Hydroxide ,(NaOH) or Potassium Hydroxide,(KOH) to produce hydrogen,(H2) and
oxygen,(O2) gas. The process involves applying DC potential difference between the
two anode &cathode electrodes and delivering minimum energy required to break the
H-H-O bonds (68.3 kcal per mole at STP). The gases that are produced from the
normal electrolysis is by 1:2 ratio of hydrogen to oxygen from the cathode (-) and
anode (+) respectively. On a macro scale, the amount of gas produced depends upon a
number of variables, including the type and concentration of electrolyte solution used,
the anode and cathode electrode pair surface area, the electrolytic resistance (ionic
conductivity, the temperature and pressure) and the amount of supplied current and
voltage. The amount of supplied energy must be sufficient to produce oxygen and
hydrogen, avoiding corrosion or reduction of the electrodes inside the traditional
electrolysis system.

Hydrogen fuel car is state of the art technology that immensely developed by
giant automotive manufacturers like Mercedes, Toyota, Honda and BMW. This
technology enables consumers to have environment friendly cars with 0% emission
and become as an alternative to petrol as fuel. This investigation for production of
hydrogen,(H2) & oxygen,(O2) using electrolyzer will enable user to use water to

1
supply the required gas for combustion instead of carrying high pressure tank of
hydrogen in cars.

The advanced electrolyzer is a unique method of electrolysis. It contains up to

100 plates of stainless steel plate which act as electrodes. The required voltage supply
is more than 110 V. By using normal 12V accumulator or wet battery that easily
available and an inverter of 160V, we can produce the required energy in no time. The
structure of electrolyzer needs the electrodes to be arranged in certain way so that
optimum production of gas is obtained. Electrolyte to enhance the electrolysis is not
necessary -- normal tap water is the only required substance. Specially designed
circuit comes with the electrolyzer to help enhance the production ofgas by supplying
special square pulse train to the device. The system layout for installation also
described.

1.2 Problem Statement

1.2.1 Problem Identification

The traditional technique of electrolysis has insufficient production to make

good use of hydroxy gas. Using normal DC, the acceptable amount of power supply
for production of gas is too low [2]. The optimum voltage for electrolysis is only at
1.48Volt which means any extra voltage supplied is unnecessary because it will only
use up to 1.48Volt for the process. The quantity of gas produced is too small and
taking a long time to be accumulated to certain volume before it can be used. The
anode/cathode electrodes tend to corrode after being used for a long time and the
produced gas often leaks from the container. With the advancedelectrolyzer, not just
the weaknesses areeliminated; we can implement the device to a good use from
kitchen usage to the transportation accessories. The produced gas also abundant and
the quantity required can be produced on demand.

1.2.2 Significant of the Project

2
 The advanced electrolyzer is a ground breaking and feasible technology. The
required components for the project can be found in most electronic and hardware
shops. The investigation of production of Hydroxy (Hydrogen + Oxygen) gas is
important due to its concept of using the abundant material on earth: water, as its
source of energy and its application and usability in numerous engineering fields.

1.3 Objectives and Scope of Study

1.3.1 Relevancy of Project

Many research and investigation done by inventors from many parts of the
world to produce a well-functioninghydrogen + oxygen production devices. All the
way, many patents have been recorded in describing techniques of producing this gas.
This project is aimed mainly to test and investigate the workability of the electrolyzer
to produce required product. With respect to Final Year Project course outline, the
end product will be relevant to a few engineering programs and totally under the
scope of undergraduates studies. In environment and society wise, this investigation if
important as it will give alternative solution to the current situation of hiking fuel
price and global warming.

1.3.2 Feasibility of Project within Scope and Time Frame

The given time length is 12 month for this project to come to completion. It is
considered more than enough for the execution of the proposed F.Y.P title. With the
first semester will be the research and findings period and the second semester as the
construction period of prototype, the student will have enough time to do all kind of
tests and experiments required so that they can come out with the final product.

1.3.3 Investigation

2
 The investigation includes the study of the U.S patent documents and literature
study on the technical specifications on the constructed prototype. The design of the
circuit to produce proper waveform to be supplied to the prototype is the main aspect
of the project as it will affect the produce product and the optimality of the prototype.
For the study of internal combustion of Hydrogen gas and its properties, I refer most
of the sources from the Academic findings and journal.

3
 CHAPTER 2
LITERATURE REVIEW & THEORY

2.1 Theory

To decompose water electrically, it is necessary topass direct current between

a pair of electrodes whichare immersed in a suitable electrolyte. It is normal insuch
electrolysis to place some form of gas barrier betweenthe two electrodes in order to
prevent the gasesevolved during the electrolysis from forming an explosive mixture.
However provided suitable precautionsare taken it has been found that the gases can
be allowed to mix and can be fed into a storage tank for subsequentuse. Because the
gases when mixed form an explosivemixture, it is possible for the mixture to be
utilized for good use like stove kitchen and combustion engine. For that purpose, it is
necessary to control the explosiveness of the gasses when ignite by adding air mixture
to it. One of the difficulties encountered with electrolysisis that bubbles of gas are
liable to remain on the electrodesduring the electrolysis thus effectively limitingthe
area of electrode which is in contact with the electrolyteand preventing optimum
current flow between the electrodes. Because in accordance with the present
technique, it is desirable that the gases evolved duringthe electrolysis be mixed with
air, then it is possible forair to be passed through the cell while the electrolysis isin
progress. The passage of air through the cell can be directed past the electrodes so as
to entrain in the passageof air any bubbles of gas remaining on the electrodes.

Accordingly the prototype comprises an electrolyticcell including a gas tight

casing, a combination of electrodes usedis supported on a central post within the
cellin a spaced apart relationship and insulated from each other, each alternative
electrodebeing adapted to be connected to a positive direct currentsource or a negative
direct current source respectively and wherein the central post is in the form of atube,
one end of which is extended out of the cell and isadapted to be connected to a source
of air under pressure, with the other end of the central post terminatingin an air outlet
below the said electrodes, the said cell including a gas outlet to exhaust air forced into
the cellthrough the central post and to exhaust the electrolyticallyproduced gases
1
mixed with the said . The electrolysis will produce H2 & O2 and the act of combustion
will reproduce water in form of H2O [3].

2H2O→O2+2H2

Electrolysis Product: Produce 2 mole of hydrogen and 1 mole of oxygen with every 2
mole of water.

2H2+O2→2H2O

Combustion Product: For a perfect combustion of 2 mole of hydrogen with 1 mole of

oxygen will produce back 2 mole of water.

2.2 Mechanism of Combustion

[4]

“Details of the mechanics of combustion depend to a great extent on the fuel

and thenature of the combustion system. They are sometimes not well understood.
There are, however, certain fundamentals thatare useful in dealing with combustion
systems. The chemical reaction equations presented here do not portray the
actualmechanism of combustion; they merely indicate the initial and final
chemicalcompositions of a reaction. In most cases the reactions involve a sequence of
steps,leading from the reactants to the products, the nature of which depends on
thetemperature, pressure, and other conditions of combustion. Fuel molecules,
forinstance, may undergo thermal cracking, producing more numerous and smaller
fuelmolecules and perhaps breaking the molecules down completely into carbon and
hydrogen atoms before oxidation are completed.
In the case of solid fuels, combustion may be governed by the rate at
whichoxidizer diffuses from the surrounding gases to the surface and by the release
ofcombustible gases near the surface. Combustion of solids may be enhanced by
increasing the fuel surface area exposed to the oxidizer by reducing fuel particle size.
We have seen that, for combustion to occur, molecules of oxidizer must mixwith fuel
molecules, an action enhanced by the three T.s of combustion: turbulence, time, and
temperature. Chemical reactions take place more rapidly at high temperaturesbut
nevertheless require finite time for completion. It is therefore important that burnersbe
long enough to retain the fuel-air mixture for a sufficiently long time so that
combustion is completed before the mixture leaves. Turbulence, or mixing,
2
enhancesthe opportunities for contact of oxidizer and fuel molecules and removal of
products ofcombustion.
A flame propagates at a given speed through a flammable mixture. It
willpropagate upstream in a flow of a combustible mixture if its flame speed exceeds
theflow velocity. If a fixed flame front is to exist at a fixed location in a duct flow in
whichthe velocity of the combustion gas stream exceeds the propagation speed, some
form offlame stabilization is required. Otherwise the flame front is swept downstream
andflameout occurs. Stabilization may be achieved by using fixed flame
holders(partialflow obstructions that create local regions of separated flow in their
bases where theflame speed is greater than the local flow velocity) or by directing a
portion of the flowupstream to provide a low-speed region where stable combustion
may occur.Each combination of oxidizer and fuel has been seen to have a
particularstoichiometric oxidizer-fuel ratio for which the fuel is completely burned
with aminimum of oxidizer [6]. It has also been pointed out that it is usually desirable
to operateburners at greater than the theoretical air-fuel ratio to assure complete
combustion ofthe fuel and that this is sometimes referred to as a lean mixture.
Occasionally it may bedesirable to have incomplete combustion, perhaps to produce a
stream of products inwhich carbon monoxide exists or to assure that all the oxidizer in
the mixture isconsumed. In that case a burner is operated at less than the
stoichiometric air-fuel ratiowith what is called a rich mixture.There are limits to the
range of air-fuel ratios for which combustion will occurcalled limits of flammability.
Here the density of the mixture is important. The limits offlammability around the
stoichiometric A/F are reduced at low densities. If combustionis to occur reliably in
mixtures at low densities, it is necessary to closely control theair-fuel ratio.”

Figure 1 : Combustion Work in Gasoline Engine

2
2.3 Advanced Electrolyzer System

[4]
This is a “Hydroxy-On-Demand” (“HOD”) system. It is very difficult indeed
to generate hydroxy gas fast enough to power an internal combustion engine vehicle
under all road conditions. Moving from standstill to rapid acceleration causes such a
massive sudden requirement for additional volumes of hydroxy gas, that it is difficult
to provide that volume instantly.

A better solution is to use an electric engine for the vehicle. This can be an
electric vehicle which was designed from scratch as such, or it can be a standard
vehicle which has been adapted for electric engine use [2]. These electric vehicles
are usually limited in how far they can travel, but a good solution to this is to use an
electrical generator to charge the batteries, both when the vehicle is in use and when
it is parked. This electrolyzer can be used to run such a generator on water. With
this arrangement, there are no CO2 emissions and the vehicle is very environmentally
friendly. The batteries provide the necessary sudden acceleration demands and the
generator recharges the batteries during normal driving.

For the designed pulsed system has the following components:

1. An electrical connection to the vehicle’s electrical system (with

safety features built in).
2. An “inverter” which raises the electrolyzer voltage to 160
volts.
3. A specially designed circuit board which generates a
complicated water-splitting waveform.
4. A specially designed toroidal transformer which links main
circuit board to the electrolyzer.
5. Treated 100 stainless steel plates as electrodes.
6. A dual-protection system for linking the electrolyzer safely to
the internal combustion engine.

None of these items is particularly difficult to achieve, but each

needs to be done carefully and as designed for safety purpose.

1
 2.3.1 Building the Case:

The case for the electrolyzer accommodates 100 plates which cutted in 6” x 6”
size and arranged closely with the gap between plates are 1/8”. The plates
arrangement can be done by a milled aluminium slotted strip with 1/8” distance
between slots or using a small iron rod to place the plates with equally spaced
between them by 1/8”. From the testing in the lab with controlled input voltage, it is
founded that the closer distance between the electrodes, the higher the gas production
rate. Thus, 1/8” considered acceptable distance to produce optimal gas during the
process.

Figure 2 : Milled Body Case for Electrolyzer

The base and two sides of the cell could have grooves cut in them to take the
plates. This is not a good idea for various reasons, including the fact that the steel
plates expand when they warm up and are liable to crack the acrylic case unless the
slots are cut deeper than normal. Also, it is difficult to cut very accurate slots in
acrylic due to the heat of the cutting blade causing the acrylic to deform in the

1
immediate area. Grooved acrylic is very much weaker and breaks easily due to the
planes of weakness introduced into the material. Using Ultra High Molecular Weight
Poly Ethylene or High Density Poly Ethylene (food chopping-board material) strips
is a much better technique as that material does not have the same cutting heat
problem and it can also take the plate expansion much better, so it is the construction
method of choice. It is also a cheaper material. The grooves which are cut for the
plates should be three ten thousandths of an inch wider than the thickness of the
plates. A good plate thickness is 16 gauge sheet which is one sixteenth of an inch
thick or 0.0625 inch (1.5875 mm), so the recommended groove width for that is
0.0655 inches which is not a convenient fraction being about four and one fifth sixty-
fourths of an inch. Also, steel sheet thickness is not absolutely exact, so it needs to
be measured with a micrometer and averaged before the three ten thousandths of an
inch is added. (6) The grooves are 1/8” (3 mm) deep.

The supplier of the acrylic sheet needed for making the case, will be able to
supply “glue” specifically designed for joining acrylic sheets together. This glue
actually welds the plates together so that the sheets become one continuous piece of
acrylic along the joint. Start by mating the sides and the base. Insert two or three
plates into the slots to be quite sure that the alignment is spot-on during the joining
process. Line the ends up during jointing to be sure that the sides are completely
square when being joined to the base. Concerns have been expressed about the
strength of the acrylic casing under severe road conditions. So it has been suggested
that the acrylic components be constructed from sheet which is 3/4” to 1” thick (18
mm to 25 mm) and the corners reinforced with angle iron secured with bolts tapped
into the acrylic as shown below.

2
 Figure 3 : Reinforced Acrylic Iron to Corners

Figure 4 : Milled Plate Position in the Electrolyzer Housing

This housing looks very simple and straightforward, but this is highly
misleading and the materials are very expensive, so any error is costly. The
construction accuracy needed is very high indeed with many opportunities for a total
and expensive disaster. Ed Holdgate has built several custom fixtures to ease the
construction, but construction is still very difficult even with these specialist fittings
and his years of experience. Sikaflex 291 marine bedding compound is used to seal
between the two slotted sides and the slotted base, and between the slotted sides and
the two end inserts, in order to prevent any leakage between the acrylic and any of
these inserts. [6] The accuracy required for the slots to hold the stainless steel plates
is 0.0003” and the plates are tapered with a belt sander on both sides along all four
edges so that when they are forced into the slots they will not cut into the sides of the
slots. This produces excellent leakage characteristics, but don’t lose sight of the very
high accuracy of the slot cutting needed for this. The edges of the slotted inserts
receive a bead of Sikaflex marine bedding compound attaching them to the acrylic
box and the compound is allowed to cure before construction is continued. There are
cheaper marine bedding compounds, but don’t be tempted by them as Sikaflex is a
much superior product. The end plates with the stainless steel straps welded to them
are used to connect the electrical supply to the plates, keeping any connection which
could possible work loose and cause a spark, completely outside the housing. Even
though the straps are welded and there is no likelihood of them coming loose, the
welds are still kept below the surface of the electrolyte.
2
 2.3.2 Getting and Preparing the Plates:

A set of 101 plates is needed for the electrolyzer. The material used when
making the plates is very important. It should be 16-gauge 316L-grade stainless
steel as it contains a blend of nickel and molybdenum in the correct proportions to
make it a very good catalyst for the pulsing technique. The plates need to be flat to a
tolerance of +/- 0.001" after cutting and this is the most important factor. That level
of accuracy excludes any kind of flame cutting as it produces inevitable heat
distortion. With shearing, expect +/- 0.015" on the cuts and +/- 0.001" on flatness.
The plates are square: 6-inches by 6-inches, but that do not represent 36 square
inches of active surface area some plate area is inside the grooves and some of each
plate is above the surface of the electrolyte. Another point to remember is that 101
steel plates this size weigh a considerable amount and the completed electrolyzer
with electrolyte in it will weight even more. It is essential therefore to have a case
which is strongly built from strong materials, and if a mounting bracket is to be used,
then that bracket needs to be very robust and well secured in place. The preparation
of the plates is one of the most important steps in producing an electrolyzer which
works well. This is a long task, but it is vital that it is not skimped or hurried in any
way. Surprisingly, brand new shiny stainless steel is not particularly suitable for use
in an electrolyzer and it needs to receive careful treatment and preparation before it
will produce the expected level of gas output.

The first step is to treat both surfaces of every plate to encourage gas bubbles
to break away from the surface of the plate. This could be done by grit blasting, but
if that method is chosen, great care must be taken that the grit used does not
contaminate the plates. Stainless steel plates are not cheap and if you get grit
blasting wrong, then the plates will be useless as far as electrolysis is concerned. A
safe method which Bob much prefers is to score the plate surface with coarse
sandpaper. This is done in two different directions to produce a cross-hatch pattern.
This produces microscopic sharp peaks and valleys on the surface of the plate and
those sharp points and ridges are ideal for helping bubbles to form and break free of
the plate.

1
 Figure 5 : Sanded Electrolyzer Plate

For simplicity, the process of cleaning and treating the plate is as follows:
Plate
Conditioning
Cleansing
Sanding

Figure 6 : Plate Preparation for Electrolyzer

Installation
Electrolyzer
External
Construction
Case
onPlate
vehicles
of
Bench
Electronic
Assembly
Testing
system.
Treatment at
for
Circuit
Constructions
Bubbler Well
all the
Ventilated

area.Installation
Devices.

Error Detection and

Debugging
2.3.3 Electrolyzer Preparation Steps

3
Figure 8 : Installation Layout for Electrolyzer in Vehicles System

Figure 7 : Electrolyzer Preparation

Figure 10 : Water Supply to the Electrolyzer System

Figure 9 : Sensors Circuit for Water Level Detection in Tank

 CHAPTER 3
METHODOLOGY

3.1 Procedure Identification

Procedure identification comprise the step-by-step taken from the preliminary

work of the project till the construction of the prototype and through several
discussions with my supervisor, I am able to grasp the abstract of the topic. Further
researches were performed by referring to books, journals and the internet which have
been very beneficial in gathering information regarding the project. However the
information is being continuously updated and the exact information is difficult to
obtain.Most of the information discussed different sub topics and need to be
correlated for each part and this needs to be done as soon as possible.

3.2 Project Work Flow

The following diagram shows the work flow of this project:

1
 EDXProposal
Identifying
Research
Collection
Pre-EDX
Construction
and & Approval
presentation
and
the
the
case
required
of
presentation
necessary
prototype
studyand
equipmentof FYP
oninformation
the
national
and
to internal
required
error
and title.
exhibition.
debugging
in
and
component
information.
regards
external
of
tofor
hghfdgdgfelectrolyser,
the
(Discussion
electrolyzer
working with
devices
and
examiners.
patent
supervisor
bench
for
documents
testing
optimality.
and lecturers)
equipment.
and design of
the system.

3
 Figure
Figure 11 12 : Workflow of The Project

3.3 Tools & Equipment.

3.3.1 Components :

R1 100 ohms C1 1000 microfarad 35 volt or higher

R2 1,000 ohms C2 330 microfarad 16 volt or higher
R3 10,000 ohms
R4 1,800 ohms D1 1N4001 or similar 100 volt or higher 1 amp
R5 18,000 ohms
R6 18,000 ohms Tr1 to Tr3 2N2222 or 2N2222A or similar
R7 3,900 ohms 40V, 800 mA, 500 mW, gain 100 - 300

5
 3.3.2 Equipment :

I. Multimeter
II. Voltmeter
III. Oscilloscope
IV. Multi Simulator
V. Matlab
VI. LabView 7.0

1.1.1 Hardware :

I. Electronics Components.
II. Electronic Board
III. Tin Melter
IV. Iron tube
V. Pressure gauge
VI. High pressure pipe
VII.Holding pin
VIII.Threaded Cap
IX. Leak Thread Insulator

1
 Chapter 1
RESULTS AND DISCUSSION

1.1 Data Gathering and Analysis

1.1.1 Normal Electrolysis Experiment

1.1.1.1 Equipment Setup

Prior to the startup of the project, normal electrolysis experiment was executed so that
we can compare the result with the to-be constructed advanced electrolyzer. We set
one small beaker with 2 open end and slot in 2 small balloons to measure the
produced gas per time. 5volt input seeded to the system. The terminals are using
carbon rod and we use salt as the catalyst for this normal process.

Figure 13 : Normal Electrolysis Setup

1.1.1.2 Data Collection

18
The experiment stated 26 31. 62. 6 7
and the following 2 4 54 64. 13
tables show the 27 32. 64. 8 0
collected gases in a 60 4 8 55 66 13
minutes span. 28 33. 67. 2
6 2 56 67. 13
T,m O2 H2 29 34. 69. 2 4
in 8 6 57 68. 13
1 1.2 2.3 30 36 72 4 7
2 2.4 4.7 31 37. 74. 58 69. 13
3 3.6 7.1 2 4 6 9
4 4.8 9.5 32 38. 76. 59 70. 14
4 4 8 8 2
5 6 11. 33 39. 79. 60 72 14
9 6 2 4
6 7.2 14. 34 40. 81.
4 8 6
35 42 84 Table 1 : Oxygen &
7 8.4 16.
8 36 43. 86. Hydrogen Collection in
8 9.6 19. 2 4
60 minutes (cm3)
2 37 44. 88.
9 10. 21. 4 8
8 6 38 45. 91.
10 12 24 6 2
11 13. 26. 39 46. 93.
2 4 8 6
12 14. 28. 40 48 96
4 8 41 49. 98.
13 15. 31. 2 4
6 2 42 50. 10
14 16. 33. 4 1
8 6 43 51. 10
15 18 36 6 3
16 19. 38. 44 52. 10
2 4 8 6
17 20. 39 45 54 10
4 8
18 21. 43. 46 55. 11
6 2 2 0
19 22. 45. 47 56. 11
8 6 4 3
20 24 48 48 57. 11
6 5
21 25. 50.
49 58. 11
2 4
8 8
22 26. 52.
50 60 12
4 8
0
23 27. 55.
51 61. 12
6 2
2 2
24 28. 57.
52 62. 12
8 6
4 5
25 30 60
53 63. 12

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From the obtained results, we can see that the production of both gases is slow and
taking long time to be accumulated to a certain usable volume. The electrolysis is
highly inefficient. The result in table 1 is then plotted shown in graph below,

Figure 14 : Oxygen & Hydrogen Gas Generation

From the above graph, we can see that rate of Gas production is really slow, which is
2.4cm3/min for Hydrogen, & 1.2cm3/min for oxygen.

1.1.2 Advanced Electrolyzer Experiment

As per now, we are unable to determine the result that will be produced by the
Electrolyzer, since the parts are still under fabrication process. We still able to expect
the produced gases will be more than the normal electrolysis.

1.1.2.1 Waveform Setup.

The electrolyzer is tested using DC and AC current supply with specific frequency of
50 and 60 Hz.

Waveform Type Frequency(Hz) Total Gas Volume Produced (m3)

60 0
Saw Tooth Wave
50 0
60 0
Sinusoidal Wave
50 0
60 0
Square Wave
50 0
DC wave (12 Volt , 20 ml/hour
60
60Hz) , Benchmark
DC Wave (12 Volt, 21.5 ml/hour
60Hz) , with 60
electrolyte
Table 2 : Waveform Setup for Electrolyzer Input

18
Further observation of the setup of benchmark (see appendices Figure 18) , I found
that the electrolyzer did not producing enough gas. As per described in the following
graph,

Figure 15 : Data Analysis of Test 1 of Benchmarking

The production rate of gas collected ,

Gas VolumeTime Taken = 40ml2hours=20ml/hour

While the expected gas volume should be,

Gas VolumeTime Taken = 120ml2hours=60ml/hour

Thus, the efficiency of the electrolyzer is,

ε=observationexpected×100%=2060×100%=33% efficiency
Thus, the system is reliable but needed to be improved on efficiency.

While the testing work continues, the system is then tested with added electrolyte of
Sodium Chloride. The following figure describe the result from the experimental
work done.

Figure 16 : Data Analysis of Test 2 with Electrolyte

The production rate of gas collected ,

Gas VolumeTime Taken = 43ml2hours=21.5ml/hour

While the expected gas volume should be,

Gas VolumeTime Taken = 122ml2hours=61ml/hour

Thus, the efficiency of the electrolyzer is,

ε=observedexpected×100%=21.561×100%=35% efficiency
The system is reliable but needed to be improved on efficiency.

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 1.1.2.2 Fabrication Work

Initial preparation is to cut all the available stainless steel plate into respected
rectangular units. One piece of plate (dimension 4.8cm x 10.2cm) cutted and used as
guide to cut through the master plate (dimension 29.7cm x 57.0 cm) . It is expected
that we will get 30 small plates. All these plates then separated equally and assembled
to form a row of plates attached together using long screw with spacing between
plates estimated to be around 3~4 mm. Then, these plates are combine and the anode
and cathode terminals are separated using silicate glue to avoid any contact between
the two. Then, a container is made using plastic wall and sealed using silicate glue.
Now, it is due to test the fabricated prototype in an open air lab with 3 type of signal
waveform.

As per planned, the circuit board to convert the current supplied from 12 V D.C
accumulator is fabricated using PCB board prototyping machine. The circuit is then
assembled using the material available in the lab.

1.2 Discussion

1.2.1 Problems Faced

During the fabrication work, the thick 1 inch Perspex plastic are hard to cut
using normal cutting machine. During the fabrication work, the equipment used did
not allow the Perspex Plastic to be cutted properly, thus resulting on leakage on the
final constructed electrolyzer. Temporary solution to fix the leakage during the testing
is by using plasticin to seal off the leaking area.

The is no equipment to change the frequency of the DC current supplied to the

electrolyzer system. As far as the system testing is concerned, the system should be
tested using 600Hz DC current with added pulse generator to give variable waveform
like square waveform, sinusoidal etc.

1.2.2 Limitation

18
 During fabrication work, all the resources are limited and subject to cost
restrictions. The unavailability of the electronic components are solved by replacing
them with another type of component that can produce required result .

Limited workmanship skills also contributes to the poor performance of the

system. The stainless steel did not cutted and trimmed properly and there is leaking in
the system due to the uneven connection edges. This can be fixed by reassemble again
the device and redo the required works properly and perfectly.

20
 CHAPTER 2
CONCLUSION AND RECOMMENDATION

2.1 Conclusion

The advanced electrolyzer can be used to replace the traditional electrolysis to

produce suffice amount of usable gas . The electrolyzer is workable and tested using
DC current but did not produce observable result using AC current. The system
required better construction modification as the current built one is having continuity
problem that tends to happen once in a while. From the current observation and
investigation, the constructed electrolyzer unit only able to produce a 3% efficiency
from the expected result due to leakage problem in the system.

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2.2 Recommendation

Essentially, the fabrication of the system should be done with full precaution
and care, especially during the bench testing of the electrolyzer system which may
contain highly explosive gas. Safety should be main concern in the system design.
Poorly designed system would have irregular performance and energy, time and
money are being wasted for refabricating and redesigning process. Some of the
recommended designs and features of the electrolyzer are as follows:

1. The system should able to run on only 12Volt DC, supplied by normal
vehicles wet battery.
2. It should be able to operate in normal condition; rated working
temperature for surrounding should be between 10ºC ~ 40ºC.
3. The entire electronic component should be rated to function at the
maximum voltage level of 200V, as the system would use an inverter to
produce square waveform of hundreds of volt.
4. An LED light to indicate condition of the system like, tripping breaker,
and water level is low etc. should also be installed for ease of the user.

18
 REFERENCES
[1] Patrick J. Kelly, Oxygen Company, 1998, “PracticalGuide to Free Energy

Devices”, pp. 23 ~56.

[2] Stephen Barrie Chambers, Alberta, Canada, Oct. 3, 2000,United States Patent,
Patent Number 6,126,794, "Apparatus For Producing Orthohydrogen And/or
Parahydrogen" , pp. 1~17.

[3] Stanley Meyer, May 2, 1989, United States Patent, Patent Number 4,826,581,
"Controlled Process for the Production of Thermal Energy from Gases and
Apparatus Useful Therefore", pp. 1~45.

[4] Archie H. Blue, Nov. 7, 1978, United States Patent, Patent Number 4,124,463,
"Electrolytic Cell", pp. 1~4.

[5] Dr. Andrija Puharic, 1996, United States, “Water Decomposition by AC

Supply”, pp1~ 167.

[6] Bob Boyles, Jan. 2006, United States Patent, Patent Number 5,124,553,
"Hydrogen Fuel", pp. 1~50.

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 APPENDICES

Experimental Work Setup

Figure 17 : Setup of Benchmark Test 1

Figure 18 : Setup of Test 2 with Electrolyte

20