The present invention provides a simple solution, in that hydrogen on demand HOD is available at any desired high production rate.. The controlled, sustainedproduction of hydrogen has be
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Car Test Hydrogen On Demand
(Pure hydrogen, not HHO)
Can pure hydrogen (H2) replace HHO to increase MPG?
Updated : 11/2012
By: Phillips Company
Email: hp@valliant.net, Tel 580 746 2430
See Car
Test Results page 13
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Contents
Car Test Hydrogen On Demand 1
Section 1 Hydrogen Cell Initial Results, 2011 4 Can pure hydrogen (H2) replace HHO to increase MPG? 5
Technology comparison; HHO system and CC-HOD H2 system 5
Aluminum hydroxide, aluminum oxide and recycling 6
The need for pure hydrogen (this invention) 7
Problem and solution 7
The present invention for hydrogen production improves the state of the art 7
Catalytic Carbon (CC) is intended for the high-production-rate, large-volume pro-duction of hydrogen 8
Chemical reactions 8
The present invention uses simple and well-known chemical reactions 8
High rates of hydrogen production are possible 9
Hydrogen production rates: Up to 4 LPM in small reaction chambers 9
Hydrogen production rates: Up to 35 gallons/minute in large reaction chambers 10 By-products are fully recoverable using existing commercial methods for producing aluminum metal 10
Fuel: The use of lower-cost, lower-purity aluminum 11
Fuel: The use of water from almost any source is a novel aspect of the present in-vention 11
The use of salt water makes the present invention suitable for marine applications and as an energy source for coastal areas 11
Catalytic Carbon (CC) can be used with the most desired materials to produce hydrogen 12
Safety: Catalytic Carbon (CC) can be used with the world’s safest materials to produce hydrogen 12
First pure-hydrogen road test using CC 13
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First test run: 37 MPG 15
The government says this Buick should get 26 MPG (highway driving) 16
Analysis: 32% increase in gas mileage 16
Engineering design concepts 17
Summary 17
Section 2 Hydrogen Cell Design and Fabrica-tion, 2012 18
2012 Prototype cell design update 19
Installation of hydrogen system 30
Problems and comments 31
Operation of the hydrogen system 32
We used both CC/Al fuel and CA fuel 33
How to evaluate this new H2 system 34
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Section 1 Hydrogen Cell Initial
Results, 2011
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Technology comparison; HHO system and CC-HOD H2 system
Can pure hydrogen (H2) replace HHO to increase MPG?
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Aluminum hydroxide, aluminum oxide and recycling
The following online article explains how bauxite (aluminum oxide) is mined, refinedand smelted to produce aluminum
http://www.azom.com/article.aspx?ArticleID=3529
The by-products from the CC method of producing hydrogen have a special
characteristic they are identical to the MOST PURE form of refined bauxite
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The need for pure hydrogen (this invention)
A hydrogen-based economy is the only long-term, environmentally-benign energy
alternative for sustainable growth The increasing demand for hydrogen arises from theimpending paradigm shift to a hydrogen-based energy economy This change will
become needed as the worldwide need for more electricity increases, greenhouse gasemission controls tighten, and fossil fuel reserves wane
Problem and solution
The future increasing need for hydrogen fuel has created a problem: the problem is thelack of a hydrogen-supply infrastructure that is necessary for the proliferation of the use
of hydrogen The present invention provides a simple solution, in that hydrogen on
demand (HOD) is available at any desired high production rate This makes it
unnecessary to store hydrogen in a pressurized tank for release later at a high rate
The present invention makes it possible to control and sustain the continuous production
of hydrogen with no requirement for any external energy The controlled, sustainedproduction of hydrogen has been achieved in our laboratory so long as water, aluminumand Catalytic Carbon (CC) are provided to the hydrogen-production cell
The present invention for hydrogen production improves the state of the art
The common method to recover hydrogen from water is to pass electric current throughwater and to reverse the oxygen-hydrogen combination reaction, i.e water electrolysis.Another method involves extraction of hydrogen from fossil fuels, for example fromnatural gas or methanol This method is complex and always results in residues, such ascarbon dioxide And, there is worldwide limit to the fossil fuel available for use in thefuture In these reforming methods the resulting hydrogen must be somehow stored anddelivered to the user, unless the hydrogen generation is performed “on-board,” close tothe point of use The safe, reliable, low-cost hydrogen storage and delivery is currentlyone of the bottlenecks of the hydrogen-based economy The present invention addressesthis problem through safe, “on-board/on-demand” production of hydrogen close to theuser systems, using simple, safe and pollution-free metal oxidation reacting with waterand Catalytic Carbon (CC)
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Catalytic Carbon (CC) is intended for the high-production-rate, large-volume
production of hydrogen.
Although about 20% of air is oxygen, there is no easily-accessible, safe source of
hydrogen available The current invention addresses and solves this problem CC-HODrelates to a novel method of generating hydrogen from water Water consists of two
elements: oxygen and hydrogen A relatively large amount of energy is released whenthese two elements react to form water This energy may be captured and may be used as
a heat source, a combustion fuel, or it can be efficiently converted to electricity in fuelcells One novel aspect of CC-HOD is that the high production rate of hydrogen makespreviously-impossible applications technically feasible for the first time, especially forhigh-energy-consumption applications Because of the straight-forward scale-up of theproduction rate of hydrogen using the present invention, the use of Catalytic Carbon(CC) makes it feasible to use high-production-rate hydrogen as fuel or as a fuel
supplement for commercial power plants, trans-oceanic ships and remote locations,including third-world population centers and outposts on other planets so long as water,aluminum and Catalytic Carbon (CC) are provided to the hydrogen-production cell Inthe later potential application, an important advantage of this invention is that only waterand water vapor (nothing else) is released when oxygen and hydrogen react using
Catalytic Carbon (CC) Consequently, the hydrogen-oxygen reaction is potentially apollution-free source of energy
Chemical reactions
The present invention uses simple and well-known chemical reactions
2Al + 6H 2 O + CC => CC + 2Al(OH) 3 + 3H 2 where Aluminum and water are fuels andthe only by-product is aluminum hydroxide Al(OH) 3 In this reaction, CC is a catalystwhich is not consumed or chemically transformed in the reaction
The same reaction can be written as 2Al + 3H 2 O + CC => CC + Al 2 O 3 + 3H 2 whereAluminum and water are fuels and the only by-product is aluminum oxide, Al 2 O 3 Inthis reaction, CC is a catalyst which is not consumed or chemically transformed in thereaction
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Aluminium hydroxide, Al(OH)3 is found in nature as the mineral gibbsite (also known ashydrargillite) and its three polymorph forms: bayerite, doyleite and nordstrandite [RefWikipedia]
Closely related to aluminium hydroxide is aluminium oxide, Al2O3, differing only by loss
of water These compounds together are the major components of the aluminium orebauxite [Ref Wikipedia]
Aluminum, a fuel used for producing hydrogen, comes from bauxite Bauxite is an
aluminium ore and is the main source of aluminium This form of rocky ore consistsmostly of the minerals gibbsite Al(OH)3, boehmite AlO(OH), and AlO(OH), in a mixturewith the two iron oxides goethite and hematite, the clay mineral kaolinite, and small
amounts of anatase TiO2 [Ref Wikipedia]
High rates of hydrogen production are possible
Most methods of producing hydrogen (electrolysis, thermo-forming) produce hydrogen
at low rates when measured in units of volume per minute (LPM) per gram aluminumper joule of required energy, or LPM/gm per joule Using this benchmark for productionrate evaluation quickly leads to the conclusion that electrolysis and thermo-reforming arepoor performers simply because of the energy required to drive the processes
Our invention is much better than electrolysis or thermo-reforming processes (for
hydrogen production) This is because our invention uses a process that only needs
external heat to start the reaction, usually in the temperature range of 150F to 190F
Once started, the reaction, because it is fundamentally exothermic, provides enough heat
to sustain the reaction The only external energy required is for cooling, if needed tolimit the production rate to some desired target value
Hydrogen production rates: Up to 4 LPM in small reaction chambers.
In our laboratory we carried out more than 50 experimental runs in which we obtainedhydrogen production rates of 400 mL/minute to 4 LPM with a hydrogen cell chargedwith 10 to 40 gm of powdered aluminum These experimental cells had reaction-
chamber volumes ranging from 100 mL to 1 liter, made from plastic bottles and glasscontainers Higher rates were demonstrated in our laboratory and we believe rates
exceeding 100 LPM can be easily achieved using larger cells in non-laboratory
(industrial) conditions because the scale-up of the present invention has no known
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fundamental barriers
The controlled, sustained production of hydrogen was achieved in our laboratory so long
as water, aluminum and Catalytic Carbon (CC) was provided to the hydrogen-productioncell
Hydrogen production rates: Up to 35 gallons/minute in large reaction chambers.
130 LPM of hydrogen was produced during scale-up experiments For more
information, please see
hematite, kaolinite, and TiO2 We reason that the large volume of by-products of our
invention, pure Al(OH) 3 and pure Al 2 O 3, will be 100% recycled to produce more
aluminum metal Recycling of aluminum hydroxide and aluminum oxide makes the
present invention economically viable for large-volume hydrogen generation An
excellent discussion of the process for primary aluminum production, as well as wide values for the energy requirements for aluminum smelting, can be found on a website produced by the International Aluminium Institute (www.world-aluminium.org)
For more information, please see
www.PhillipsCompany.4T.com/AHA.pdf
Aluminum refining from aluminum-bearing bauxite ore uses the Bayer process
chemistry which forms a hydrate which is essentially the same as the reaction product inthe proposed aluminum-water reactions described above [Ref DOE paper, 2010] Thehydrate is then calcined to remove the water to form alumina The alumina is
electrolytically reduced into metallic aluminum at about 900 oC using the Hall-HeroultProcess, producing a metal with 99.7% purity
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Fuel: The use of lower-cost, lower-purity aluminum
For a given mass of aluminum in the reaction, the hydrogen production rate is
approximately proportional to the surface area of the aluminum metal The aluminumused in our experiments was powdered aluminum The higher surface-to-volume ratio ofpowdered fuel makes it suitable for higher-rate hydrogen production More course fuel,
in the form of pellets or granules can be used, but at a lower production rate of hydrogenfor any given amount of aluminum
The present invention uses aluminum and water for fuel The process latitude for thisprocess is excellent The use of pure aluminum is not required, making possible the use
of lower cost, less-pure aluminum in our hydrogen-production process
Fuel: The use of water from almost any source is a novel aspect of the present
invention.
The present invention uses aluminum and water for fuel The use of pure water is notrequired Therefore it is not necessary to use expensive water such as distilled water orde-ionized water for the production of hydrogen This has been proven in our laboratoryusing tap water, dirty water, high-calcium water, salt water, alkaline water, and acidic
water All water samples used in our laboratory experiments have worked well duringour work to produce hydrogen Although not required, some forms of water, includingsalt water and alkaline water, perform somewhat better in our process than more pure
forms of water such as deionized water When producing hydrogen with the present
invention, more design latitude and freedom is available to the hardware design engineer
in the selection of materials, water and water ingredients to minimize corrosion of thematerials used in the construction of the cell and associated parts of the system The
excellent process latitude for water purity makes it possible to use a wider range of
materials with the probable result of cost reduction for equipment designed for use withthe present invention
The use of salt water makes the present invention suitable for marine applications and as an energy source for coastal areas.
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As noted above, salt water can be used to produce hydrogen using the present invention.This means that the present invention is naturally suited for use in producing fuel in allparts of the world where human settlements are located near any seashore, including
remote islands Many island nations, including Japan, can use the present invention todecrease fuel costs and reduce or eliminate the need for tanker-ship import of fossil
fuels Other island groups, including Hawaii, can improve the local economy by
reducing fuel costs using the present invention to reduce or eliminate the need for
tanker-ship import of fossil fuels
Catalytic Carbon (CC) can be used with the most desired materials to produce
hydrogen.
There are only a few materials that can produce abundant hydrogen and these includehydrocarbons and water Of these, the only pollution free source of hydrogen is water.One of the problems that must be addressed before the new hydrogen economy replacesthe current “oil/gas/coal/nuclear” economy, is finding a safe, environmentally benign andcost-effective method of generation of hydrogen at any desired rate The solution of thisproblem is the primary focus of the present invention
Safety: Catalytic Carbon (CC) can be used with the world’s safest materials to
produce hydrogen.
Carbon, water, aluminum, aluminum oxide and aluminum hydroxide are the safest
materials known to humanity (e.g they are commonly used in foods, drugs, cosmeticsand other safe to use/handle products) The present invention works well using a widerange of pH, and this includes neutral pH values in the range of 6 to 8 The use of
neutral pH chemistry eliminates the threat of acid burns or alkali burns to human skinand eyes Alkali-burn damage to the eyes, due to an accidental splash, is a safety hazardwhen using electrolysis to produce hydrogen Electrolysis fundamentally requires theuse of a strong electrolyte to increase the electrical conductivity of the water, whereasthe present invention produces hydrogen chemically, without the use of electrolysis andwithout the requirement for electrolyte additives The present invention, based on CC,promises to be safe and manageable by simple means
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First pure-hydrogen road test using CC
2004 Buick Park Avenue
Fill plug and inspection port
Hydrogen output
Bubbler (called the “dirtybubbler”)
Water gravity flow
Fill cap and inspection port
Hydrogen from cell, up to thebubbler
Glow plug (startup heater)
Mounting bracket
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Fill cap
Hydrogen input from cell
Hydrogen output to solenoid valves(switches to engine or to vent)
Tube from “clean bubbler” to flow ratemeter
Clean bubbler
Flow rate meter
Instrumention is mounted on the rear view
mirror In a commercial system this would
not be needed or included This apparatus
is to give a visual indication of hydrogen
flow rate during road tests
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Al powder and heating element wasswitched on Heatup and hydrogen flowrequired about 5 minutes
T = 5 minutes: Buick engine was started
with hydrogen flowing The EFI computer
“trained” open loop to closed loop withhydrogen flowing Speed = 55 MPH Maxhydrogen flow rate estimated = 0.3 LPM
T = 10 minutes: Flow rate decreased with
time, as the small-particle aluminum wasconsumed (along with some water)
Solenoid valve was switched so thathydrogen was vented (not piped to engine).Mileage dropped 6.7%; from 35.7 MPG to33.3 MPG Even so, this is a higher gasmileage than usual for this car
After driving 5 miles, the hydrogen flow wasswitched to VENT On the return trip, themileage was higher than usual WITHOUT
any hydrogen flowing to the engine Why?
Could the EFI computer have been trained
on hydrogen in a way that it somehow chose
a “set point” that is leaner than usual, therebycausing the gas mileage to be greater thanusual even when hydrogen was no longersupplied to the engine?
First test run: 37 MPG
First test run on 7/29/2011: 37 MPG on a Buick that usually gets a MAXIMUM of 30MPG, even on long road trips Typical highway gas mileage for this car is about 26 to 28MPG
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http://www.fueleconomy.gov/feg/noframes/19829.shtml
The government says this Buick should get 26 MPG (highway
driving)
Analysis: 32% increase in gas mileage
My experience with this Buick is that it gets better gas mileage (26 to 28 MPG) undernormal highway driving conditions; unleaded fuel To be conservative, let’s assume thatthe normal, no-hydrogen highway gas mileage is 28 MPG for this car
The first road test WITH hydrogen showed a gas mileage of 37 MPG with a hydrogenflow rate of 0.3 LPM (estimated) This is considered a low flow rate, because
independent calculations suggest that best performance at 60 MPH with hydrogen mightrequire about 3 LPM (10 times greater than the flow rate for this first test)
Using these numbers, an ESTIMATED improvement in gas mileage for this first test was
(37 - 28) / 28 = 32% increase in gas mileage
Wow!
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Engineering design concepts.
1 We need a way to deliver the fuel (water and aluminum) to the cell in a variable andcontrolled way Rough calculations indicate that the right delivery rate would be about 1
mL per minute to 2 mL per minute of thick liquid Variation over this range would belike varying the rate of diesel to the engine The Al/water mix might be somewhat thick something like syrup This will be the “feed” to the hydrogen cell
2 We need a good way to control the temperature of the cell
A STARTUP: Heat the cell quickly, up to about 180F and start the "feed" of
fuel to the cell
B SUSTAINED OPERATION ON THE ROAD: Keep the cell cool as the
reaction produces heat (this is called an exothermic chemical reaction)
C SHUTDOWN: Cool the cell down and stop the "feed" of fuel to the cell.
This is very much like how a normal diesel engine works It uses a glow plug to quicklyheat the cylinder; then fuel is fed to the combustion chamber at a rate that varies
depending on changing speed and power required; and temp control (cooling) is
provided by circulating water driven by the water pump
Summary
We have discovered an amazing new method for producing hydrogen on demand Purehydrogen (no oxygen) at any flow rate, 1 LPM, 2 LPM to 10 LPM No EFIE or EFIIrequired No oxygen sensor or EFI changes needed Current required = 0 Amperes Noelectrolyte No corrosion of anode or cathode (none at all!) pH is neutral Chemistry issafe
Who are we?
We are not an automotive products company; we are a pharmaceutical company Our web site is:
www.PhillipsCompany.4T.com/HYDROGEN.html
We just happened to have the catalytic chemistry capability needed for splitting water with very little energy required So, we need a strategic alliance who is in the automotive products business.