HYDROGEN_GENERATOR_BOOSTER

1. CONTENTS TOPICS PAGE NO 1. ABSTRACT.……………………………………………………………………………...3 2. INTRODUCTION………………………………………………………………………..4 3. LITERATURE REVIEW……………………………………………………………….5 4. PARTS NEED FOR HYDROGEN GENERATOR…………………………………..8 5. PROPERTIES OF HYDROGEN……………………………………………………….9 5.1 ATOMIC STRUCTURE………………………………………………………………………..9 5.2 PHYSICAL PROPERTIES…………………………………………………………...12 5.2.1 STATE………………………………………………………………………………………………....12 5.2.2 ODOR, COLOR AND TASTE………………………………………………………………………...14 5.2.3 TOXICITY……………………………………………………………………………………………..15 5.2.4 DENSITY AND RELATED MEASURES ………………………………………................................15 5.2.5 LEAKAGE……………………………………………………………………………………………..18 5.3 CHEMICAL PROPERTIES …………………………………………………………..19 5.3.1\REACTIVITY…………………………………………………………………………………………..19 5.3.2 ENERGY………………………………………………………………………………………………..20 5.3.3 FLAMMABILITY…………………………………………………………………………...................21 5.3.4 HYDROGEN EMBRITTLEMENT……………………………………………………………………21 6. EXPERIMENTAL CALCULATION BY ORSAT APPARATUS………………….22 7. ADVANTAGES……………………………………………………………………….....26 8. DISADVANTAGES……………………………………………………………………...26 9. SAFETY PRECAUTION………………………………………………………………..27 10. DESCRIPTION OF DIFFERENT PARTS ………………………………………….28 1

2. 9.1. CONTACT BREAKER……………………………………………………………………...28 9.2 .LED…………………………………………………………………………………………..28 9.3. BUBBLER ………………………………………………………………………………......29 11. DESIGN FEATURES USED IN THE GENERATOR………………………………30 12. BRIEF DESCRIPTION ON PARTS NEED FOR MAKING GENERATOR…….31 13. BUBBLER CONNECTIONS CLOSE UP…………………………………………….32 14. CONSTUCTION OF BUBBLER ……………………………………………………..47 15. HOW THE GENERATOR IS CONNECTED TO THE ENGINE………………….50 16. HOW TO POWER THE HYDROGEN GENERATOR …………………………….50 17. SETTING UP THE WATER IN THE GENERATOR……………………………….51 18. INSTALLING THE GENERATOR…………………………………………………..52 19. OUTPUT HOSE AND BUBBLER…………………………………………………….55 20. ADDITIONAL STUFF…………………………………………………………………59 21. THE COMPLETE INSTALLATION PICTURE…………………………………… 60 22 CONCLUSIONS................................................................................................................60 23 GROUP WORK ACTIVITIES…………………………………………………………61 24. REFERENCE…………………………………………………………………………...61 2

3. 1. ABSTRACT A hydrogen generation apparatus according to the present invention includes: a hydrogen generator configured to generate a fuel gas through a reforming reaction by using a raw fuel; a combustor configured to heat the hydrogen generator; an on-off valve configured to open/block a gas passage through which the gas that is sent out from the hydrogen generator is supplied to the combustor; a combustion air supply device configured to supply combustion air to the combustor; an ignition device provided at the combustor; and a controller. In a case where flame extinction has occurred at the combustor during generation of a hydrogen-containing gas in a start-up process, the controller performs an ignition operation of the ignition device with the on-off valve kept opened. Fig.1 [Circuit diagram of hydrogen generator booster] 3

4. 2. HYDROGEN GENERATOR BOOSTER INTRODUCTION The Hydrogen Generator is a piece of equipment which when installed correctly can increase the mpg performance of a car or motorcycle, or truck and reduces the harmful emissions dramatically. It does this by using some current from the cars battery and alternator to fracture water into a mixture of hydrogen and oxygen gasses called HHO hydroxy gas which is then added to the air which is being drawn into the engine. The HHO gas improves the quality of the fuel burn inside the engine cylinders, this can increase the engine power, cleans old carbon deposits off the inside of an old engine, reduces the unwanted exhaust emissions or smog and can improve the miles per gallon that your vehicle gets. Provided that the fuel computer does not try to pump excess fuel into the engine when it detects the much extra oxygen in the exhaust and the improved quality of the exhaust. This hydrogen generator is easy to make and the components don‘t cost much. The hydrogen output the generator is very good as it produces 1.7 to 2.0 litres of HHO gas per minute at a manageable amp current load. This is how to make and use it. 4

5. 3.LITERATURE REVIEW We need to stop burning fossil fuels. If we do so, it leaves us with two problems, namely, a way to generate power to run our electrical equipment and heat or cool our homes, and a way to power our vehicles. In this document, we will consider the question of powering vehicles. There are two main options. The first is to achieve a reduction in the amount of fossil fuel burnt. The second is to eliminate the use of fossil fuel altogether. Both have been achieved. As an example of the first option, consider a car powered by a petrol (gasoline) engine. In the average car, only 35% or so of the fuel is burnt in the cylinders of the engine, the remaining 65% burns in the catalytic converter or is pushed, unburnt, out of the exhaust pipe as major pollution. Reducing the fuel used: It is possible to reduce the amount of fuel used, by utilising any or all of the following: 1. Improving the quality of the burn. 2. Reducing the amount of fuel in the cylinder. 3. Introducing water vapour into the cylinder. 4. Improving the quality of the spark. 5. Improving the streamlining of the vehicle 1). The burn quality can be improved dramatically by replacing some or all of the air drawn into the engine, by a mixture of hydrogen and oxygen. This can be done by sacrificing a small amount of engine power to drive an electrolyser to split water into the hydrogen/oxygen mix needed, passing it through a safety ‗bubbler‘ and feeding the gas into the air intake of the engine. This causes a dramatic improvement to the burn, increases the power of the engine, reduces the pollution and improves the miles per gallon achieved. 2). The fuel mix can be made leaner. If more air is used, the engine will run hotter. If a hydrogen/oxygen (―hydroxy‖) mix is used, then there is a general improvement all round. If the vehicle has computer control of the fuel/air mix, it is necessary to add an extra circuit to prevent the computer injecting more fuel to offset the leaner mix required, and the companion document D17.pdf explains in considerable detail how to do this. 5

6. 3). Adding water vapour to the air intake can give a 25% improvement in the miles per gallon. 4). If the power of the spark is increased by adding extra circuitry to the electrical system, the fuel burn is improved. However, this tends to lead to greater plug wear. The ―Firestorm‖ plug gives a major improvement in burn quality 5) the car, and/or other passive devices can give a major improvement in fuel consumption through reduced the car, and/or other passive devices can give a major improvement in fuel consumption through reduced wind pressure. If using hydroxy gas to improve the burn quality and improve the mpg of a vehicle, no timing adjustments are normally necessary. However, all recent cars in the USA are fitted with an Electronic Control Unit and if nothing is done about that, a decrease in mpg may actually occur as the Controller may start pumping more fuel into the engine when it sees a change in the quality of the exhaust Stanley Meyer. On 17th December 1995, the Channel 4 television series ‗Equinox‘ ran a programme which included an interview with Stanley Meyer of Ohio, USA. I watched Stan demonstrate a new method of separating water into its components of hydrogen and oxygen. His method is some 17 times more efficient than conventional electrolysis. With conventional electrolysis, the temperature of the water (plus additives to help the process) rises substantially during the process. With Stan‘s method, the water temperature does not rise at all and no additives are needed. This strongly suggests that his method utilises zero-point energy to provide the extra power needed to break down the water. Zero-point energy shows a temperature drop as the current increases. Stan received several patents covering his process, including US 4,798,661; 4,936,961; 4,826,581; 4,798,661 and 4,613,304. His first patent was very difficult to obtain as the US Patent Office said it was impossible to do and demanded to see a working model. Stan gave them a demonstration but even then, they took a further three years of stalling before they issued the patent. 6

7. Henry Puharich. Henry also used a pulsed signal to split water molecules in an efficient manner. His technique is rather different in that he starts with a modulated audio sine-wave signal and uses half-wave rectification to cut off the negative voltage components Paulo Mateiro. It is reported that water has been efficiently split by Paulo Mateiro, using the most simple electrodes possible, with only 4.8 Volts from a 555 timer circuit. Different frequencies from 200Hz to 1,100Hz have been used and for the cell in the test, the optimum was 923Hz. The current was 300mA and the hydrogen production was so great that the bubbles were almost tossing the water out of the top of the Kiyoshi Inoue (Tokyo). Kiyoshi has been granted US Patent 4,184,931 for an efficient pulsed electrolysis system. His recommendation is for a pulse waveform which has an ―on‖ period of from 5 to 50 microseconds (500 microseconds at a push) and an ―off‖ time of 2 to 30 times the ―on‖ time. His circuit provides independent adjustment of both the ―on‖ and ―off‖ times (a simple circuit to do this is in the electronics tutorial section of this set of documents). Rothman Technologies. Since 2003 Rothman Technologies of Canada have been running a 12HP petrol motor on hydrogen produced by a chemical process. This is a cheap process in which metal is consumed and so, although of great interest, this is not a ‗free-energy‘ engine. A recent patent application by William Brinkley proposes a system where aluminium pipes are consumed by a 25% solution of Potassium Hydroxide heated to 180 degrees Fahrenheit. William remarks on the non-polluting nature of the system, but this is not really so in that a very large amount of energy has to be put into producing the aluminium metal in the 7

8. smelting and refining process, and the pollution is just moved from the end user to the industrial plant. Francis Cornish of the UK has a system where electrolysis of water is combined with a chemical process consuming aluminium wire. The system works well, but I have reservations about using consumables which tie you to industrial manufacturing, also concerns about the reliability of mechanical feed systems when they are being used by non- technical people (most car drivers). There is also the issue of removing and recycling the chemical residue generated by the process. 4 .PARTS NEED FOR HYDROGEN GENERATOR: Part, Quantity, Comment: 4-inch diameter PVC pipe, 12-inches long 1, this Forms the body of the generator. 4-inch diameter PVC pipe end-cap 1, this Closes the bottom of the generator. 4-inch diameter PVC pipe screw cap 1, this makes the top of the generator 90-degree Quick Connect Outlet fitting 1 3/8" O.D. Tube x 14" NPT (from Hardware store) Level indicator Nylon barbed tube fitting 2 1/4" Tube x 1/8" NPT (from your local hardware store Lowes or home depot) Quarter-inch I.D. Poly sight tube 8‖ Water-level indicator tubing (from Hardware store) Stainless steel switch covers 16 these make plate assembly components or stainless steel sheet metal flat pieces from eBay or steel yard Stainless steel straps 12-inches long 2 The electrical connections to the plates or stainless steel utensils like spoons or forks from cooking supply stores or dept. stores will work 3/4" Inside Diameter Clear poly tube 12-inch From your local hardware store or Lowes home depot 5/16‖ stainless steel bolts 1.25‖ long 2 Electrical strap connection to the top cap. 5/16‖ stainless steel nuts & washers 6 each To fit the steel bolts in the cap top. 5/16‖ diameter nylon threaded rod 8‖ min.  Nylon Threaded Rod 5/16"-18 Thread. 2 needed 8

9. 5/16‖ inch nylon washers 1.6 mm thick 1-pack Nylon 6/6 Flat Washer 5/16", pack of 100 5/16‖-18 s/s jam nuts (1/4" thick) 20 needed 90 degree Bubbler Fittings 2 1/4" Barbed Tube 1/2" NPT. Check valve 1 1/4" tube, aquarium shop or from your local Hardware store PVC glue 1 tube Same colour as the PVC pipe if possible 5/16" Neoprene sealing washer 2 needed from the local Hardware store Tool dip –tool coating, it‘s a liquid plastic used to dip tool handles in, sold at all hardware stores, Optional: Light Emitting Diode 1 10 mm diameter, red, with panel mounting clip Quarter-watt resistor 1 470 ohm (code bands: Yellow, Purple, Brown) 5. PROPERTIES OF HYDROGEN 5.1 ATOMIC STRUCTURE: Hydrogen is by far the most plentiful element in the universe, making up 75% of the mass of all visible matter in stars and galaxies. Hydrogen is the simplest of all elements. We can visualize a hydrogen atom as a dense central nucleus with a single orbiting electron, much like a single planet in orbit around the sun. Scientists prefer to describe the electron as occupying a ―probability cloud‖ that surrounds the nucleus some-what like a fuzzy, spherical shell. In most hydrogen atoms, the nucleus consists of a single proton, although a rare form (or ―isotope‖) of hydrogen contains both a proton and a neutron. This form of hydrogen is called deuterium or heavy hydrogen. Other isotopes of hydrogen also exist, such as tritium with two neutrons and one proton, but these isotopes are unstable and decay radioactively. Most of the mass of a hydrogen atom is concentrated in its nucleus. In fact, the proton is more than 1800 times more massive than the electron. Neutrons have almost the same mass as protons. However, the radius of the electron‘s orbit, which defines the size of the atom, is approximately 100,000 times as large as the radius of the nucleus! Clearly, hydro-gen atoms consist largely of empty space. Atoms of all elements consist largely of empty space, although all others are heavier and have more electrons. 9

10. HYDROGEN MOLECULE (H2) Electron Probability Cloud Nuclei Fig.2. [Atomic Structure of a Hydrogen Molecule] A proton has a positive electrical charge, and an electron has a negative electrical charge. Neutrons do not carry a charge. Together, the charges associated with the proton and electron of each hydrogen atom cancels each other out, so that individual hydrogen atoms are electrically neutral. Chemically, the atomic arrangement of a single electron orbiting a nucleus is highly reactive. For this reason, hydro-gen atoms naturally combine into molecular pairs (H2 in-stead of H). To further complicate things, each proton in a hydrogen pair has a field associated with it that can be visualized and described mathematically as a ―spin‖. Molecules in which both protons have the same spin are known as ―ortho-hydrogen‖. Molecules in which the protons 10

11. have opposite spins are known as ―Para hydrogen‖. Over 75% of normal hydrogen at room temperature is ortho-hydrogen. This difference becomes important at very low temperatures since orthohydrogen becomes unstable and changes to the more stable Para hydrogen arrangement, releasing heat in the process. This heat can complicate low temperature hydrogen processes, particularly liquefaction. COMPOSITION OF OTHER FUELS: It is natural for us to compare hydrogen to other hydrocarbon fuels with which we are more familiar. All hydrocarbon fuels are molecular combinations of carbon and hydrogen atoms. There are thousands of types of hydrocarbon com-pounds, each with a specific combination of carbon and hydrogen atoms in a unique geometry. fIg.3. [Chemical Structure of Common Fuels] The simplest of all hydrocarbons is methane, which is the principal constituent of natural gas. (Other components of natural gas include ethane, propane, butane and pentane as well as 11

12. impurities.) Methane has the chemical formula CH4, which means that each molecule has four hydrogen atoms and one carbon atom. Other common hydrocarbons are ethane (C2H6), propane (C3H8) and butane (C4H10). These are all considered light hydrocarbons since they contain less than five carbon atoms per molecule and therefore have low molecular weight (a carbon atom is almost 12 times as heavy as a hydrogen atom). Gasoline is composed of a mixture of many different hydro-carbons, but an important constituent is heptane (C7H16). Gasoline, diesel, kerosene, and compounds found in asphalt, heavy oils and waxes, are considered heavy hydrocarbons as they contain many carbon atoms per molecule, and therefore have high molecular weight. The lightest hydrocarbons are gases at normal atmospheric pressure and temperature. Heavier hydrocarbons, with 5 to 18 carbon atoms per compound, are liquid at ambient conditions and have increasing viscosity with molecular weight. Other chemical fuels include alcohols whose molecules com-bine an oxygen/hydrogen atom pair (OH) with one or more hydrocarbon groups. Common alcohol fuels are methanol (CH3OH) and ethanol (C2H5OH). 5.2 PHYSICAL PROPERTIES 5.2.1 STATE All substances exist on earth as either a gas, liquid or solid. Most substances will change from one of these states to another depending on the temperature and pressure of their surroundings. In general, a gas can be changed into a liquid by reducing its temperature, and a liquid to a solid by reducing its temperature further. To some extent, an increase in pressure will cause a substance to liquefy and solidify at higher temperature than would otherwise be required. The transition from liquid to gas is known as boiling and the transition from liquid to solid as freezing. Accordingly, each substance has a characteristic boiling temperature and freezing temperature (at a given pressure). The opposite transitions, from gas to liquid and solid to liquid, are known as condensation and melting respectively. 12

13. The condensation temperature is the same as the boiling temperature and the melting temperature is the same as the freezing temperature. The process of condensation is also known as liquefaction and the process of freezing is also known as solidification. Boiling and freezing temperatures are most meaningfully compared relative to ―absolute zero‖. Absolute zero (0 ºR; 0 K; –459.69 ºF; –273.15 ºC) is the lowest temperature in the universe at which all molecular motion stops. Hydrogen has the second lowest boiling point and melting points of all substances, second only to helium. Hydrogen is a liquid below its boiling point of 20 K (–423 ºF; –253 ºC) and a solid below its melting point of 14 K (–434 ºF; –259 ºC) and atmospheric pressure. Obviously, these temperatures are extremely low. Temperatures below –100 ºF (200 K; –73 ºC) are collectively known as cryogenic temperatures, and liquids at these temperatures are known as cryogenic liquids. The boiling point of a fuel is a critical parameter since it defines the temperature to which it must be cooled in order to store and use it as a liquid. Liquid fuels take up less storage space than gaseous fuels, and are generally easier to transport and handle. For this reason, fuels that are liquid at atmospheric conditions (such as gasoline, diesel, methanol and ethanol) are particularly convenient. The boiling point of a pure substance increases with applied pressure—up to a point. Propane, with a boiling point of –44 ºF (–42 ºC), can be stored as a liquid under moderate pressure, although it is a gas at atmospheric pressure. (At temperatures of 70 ºF (21 ºC) a minimum pressure of 111 psig (7.7 bar) is required for liquefaction). Unfortunately, hydro- gen‘s boiling point can only be increased to a maximum of -400 ºF (–240 ºC) through the application of approximately 195 psig (13 bar), beyond which additional pressure has no beneficial effect. 13

14. 5.2.2 Odour, Colour and Taste Pure hydrogen is odourless, colourless and tasteless. A stream of hydrogen from a leak is almost invisible in daylight. Com-pounds such as mercaptans and theophany‘s that are used to scent natural gas may not be added to hydrogen for fuel cell use as they contain sulphur that would poison the fuel cells. Hydrogen that derives from reforming other fossil fuels is typically accompanied by nitrogen, carbon dioxide, carbon monoxide and other trace gases. In general, all of these gases are also odourless, colourless and tasteless. 5.2.3 Toxicity Hydrogen is non-toxic but can act as a simple asphyxiate by displacing the oxygen in the air. Asphyxiation Oxygen levels below 19.5% are biologically inactive for humans. Effects of oxygen deficiency may include rapid breathing, diminished mental alertness, impaired muscular coordination, faulty judgement, depression of all sensations, emotional instability and fatigue. As asphyxiation progresses, dizziness, nausea, vomiting, prostration and loss of consciousness may result, eventually leading to convulsions, coma and death. At concentrations below 12%, immediate unconsciousness may occur with no prior warning symptoms. In an enclosed area, small leaks pose little danger of asphyxiation whereas large leaks can be a serious problem since the hydrogen diffuses quickly to fill the volume. The potential for asphyxiation in unconfined areas is almost negligible due to the high buoyancy and diffusivity of hydro-gen. Inhaled hydrogen can result in a flammable mixture within the body. Inhaling hydrogen can lead to unconsciousness and asphyxiation. Other Gases Accompanying Hydrogen Gases that accompany hydrogen when reforming other fossil fuels, such as nitrogen, carbon dioxide, carbon monoxide and other trace gases, can also act as asphyxiates by dis- 14

15. placing oxygen. In addition, carbon monoxide is a poisonous gas that is a severe health hazard. Carbon Monoxide The affinity of haemoglobin (in the blood) for carbon monoxide is 200–300 times greater than its affinity for oxygen. As a result, inhalation of carbon monoxide quickly restricts the amount of oxygen in the bloodstream and asphyxiation en-sues. Asphyxiation can continue for some time after a victim is moved to fresh air. Depending on levels and duration of exposure, the symptoms may include headache, dizziness, heart palpitations, weakness, confusion, or nausea, leading to convulsions, eventual unconsciousness and death. With repeated long-term overexposures, carbon monoxide can damage the central nervous system and possibly lead to hardening of arteries. Since carbon monoxide is odourless, colourless and tasteless, there is no warning of its presence other than the symptoms it causes. Published exposure limits vary somewhat depending on the regulating body. Typical values state that exposure to carbon monoxide becomes a health hazard when it exceeds the time weighted average of 25 molar ppm over 8 hours, or 100 molar ppm over 15 minutes. An exposure of 1200 ppm poses immediate danger without warning symptoms. Carbon monoxide is poisonous. Carbon monoxide is flammable over a very wide range of concentrations in air (12.5 – 74%). As a result, even small leaks of carbon monoxide have the potential to burn or explode. Leaked carbon monoxide can concentrate in an en-closed environment, thereby increasing the risk of combustion and explosion. The auto ignition temperature of carbon monoxide is 609 °C (1128 °F). Carbon monoxide has almost the same density as air and will therefore not diffuse by rising. Carbon monoxide burns with a characteristic blue flame. 5.2.4 Density and Related Measures Hydrogen has lowest atomic weight of any substance and therefore has very low density both as a gas and a liquid. 15

16. Density Density is measured as the amount of mass contained per unit volume. Density values only have meaning at a specified temperature and pressure since both of these parameters affect the compactness of the molecular arrangement, especially in a gas. The density of a gas is called its vapour density, and the density of a liquid is called its liquid density Substance Vapour Density (at 68 ºF; 20 ºC, 1 atm) Liquid Density (at normal boiling point, 1 atm) 4.432 lb/ft3 (70.8 kg/m3) Hydrogen 3 (0.08376 0.005229 lb/ft 3) kg/m Methane 3 3 3 (0.65 kg/ 26.4 lb/ft (422.8 kg/m ) 0.0406 lb/ft Gasoline 3 3 3 (700 kg/m 3) 0.275 lb/ft (4.4 kg/m ) 43.7 lb/ft Table 1- [Vapour and Liquid Densities of Comparative Substances] Specific Volume Specific volume is the inverse of density and expresses the amount of volume per unit 3/lb (11.9 m 3/kg) at 68 ºF (20 ºC) mass. Thus, the specific volume of hydrogen gas is 191.3 ft 3/lb (0.014 m 3/kg) at –423 ºF and 1 atm, and the specific volume of liquid hydrogen is 0.226 ft (–253 ºC) and 1 atm. 16

17. Specific Gravity A common way of expressing relative density is as specific gravity. Specific gravity is the ratio of the density of one substance to that of a reference substance, both at the same temperature and pressure. 3; 1.203 kg/m 3) is used as the reference For vapours, air (with a density of 0.0751 lb/ft substance and therefore has a specific gravity of 1.0 relative to itself. The density of other vapours are then expressed as a number greater or less than 1.0 in proportion to its density relative to air. Gases with a specific gravity greater than 1.0 are heavier than air; those with a specific gravity less than 1.0 are lighter than air. 3, has a specific gravity of 0.0696 and Gaseous hydrogen, with a density of 0.00523 lb/ft is thus approximately 7% the density of air. 3; 1000 kg/m 3) is used as the reference For liquids, water (with a density of 62.4 lb/ft substance, so has a specific gravity of 1.0 relative to itself. As with gases, liquids with a specific gravity greater than 1.0 are heavier than water; those with a specific gravity less than 1.0 are lighter than water. 3, has a specific gravity of 0.0708 and is Liquid hydrogen, with a density of 4.432 lb/ft thus approximately (and coincidentally) 7% the density of water. Hydrogen Content Even as a liquid, hydrogen is not very dense. Ironically, every cubic meter of water (made up of hydrogen and oxy-gen) contains 111 kg of hydrogen whereas a cubic meter of liquid hydrogen contains only 71 kg of hydrogen. Thus, water packs more mass of hydrogen per unit volume, be-cause of its tight molecular structure, than hydrogen itself. This is true of most other liquid hydrogen-containing com-pounds as well; a cubic meter of methanol contains 100 kg of hydrogen and a cubic meter of heptane contains 113 kg. Hydrocarbons are compact hydrogen carriers with the added advantage of having higher energy density than pure hydrogen. When used as vehicle fuel, the low density of hydrogen necessitates that a large volume of hydrogen be carried to provide an adequate driving ranges. 17

18. 5.2.5 Leakage The molecules of hydrogen gas are smaller than all other gases, and it can diffuse through many materials considered airtight or impermeable to other gases. This property makes hydrogen more difficult to contain than other gases. Leaks of liquid hydrogen evaporate very quickly since the boiling point of liquid hydrogen is so extremely low. Hydrogen leaks are dangerous in that they pose a risk of fire where they mix with air . However, the small molecule size that increases the likelihood of a leak also results in very high buoyancy and diffusivity, so leaked hydrogen rises and becomes diluted quickly, especially out-doors. This results in a very localized region of flammability that disperses quickly. As the hydrogen dilutes with distance from the leakage site, the buoyancy declines and the tendency for the hydrogen to continue to rise decreases. Very cold hydrogen, resulting from a liquid hydrogen leak, be-comes buoyant soon after is evaporates. In contrast, leaking gasoline or diesel spreads laterally and evaporates slowly resulting in a widespread, lingering fire hazard. Propane gas is denser than air so it accumulates in low spots and disperses slowly, resulting in a protracted fire or explosion hazard. Heavy vapours can also form vapour clouds or plumes that travel as they are pushed by breezes. Methane gas is lighter than air, but not nearly as buoyant as hydrogen, so it disperses rapidly, but not as rapidly as hydrogen. For small hydrogen leaks, buoyancy and diffusion effects in air are often overshadowed by the presence of air currents from a slight ambient wind, very slow vehicle motion or the radiator fan. In general, these currents serve to disperse leaked hydrogen even more quickly with a further reduction of any associated fire hazard. 18

19. When used as vehicle fuel, the propensity for hydrogen to leak necessitates special care in the design of the fuel system to ensure that any leaks can disperse with minimum hindrance, and the use of dedicated leak detection equipment on the vehicle and within the maintenance facility 5.3 Chemical Properties 5.3.1 Reactivity High reactivity is characteristic of all chemical fuels. In each case, a chemical reaction occurs when the fuel molecules form bonds with oxygen (from air) so that the final, reacted molecules are at a lower energy state than the initial, unreacted molecules. As the molecules react, the change in chemical energy state is accompanied by a corresponding release of energy that we can exploit to do useful work. This is true in both a combustive reaction (as in an internal combustion engine where the energy is released explosively as heat) or in an electrochemical reaction (as in a battery or fuel cell where the energy is released as an electrical potential and heat). This chemical energy release is analogous to that which occurs when water flows from a high level to a low level. The water at the high level has potential energy that is released as it falls to the low level. This energy can be harnessed to do useful work, such as turning a turbine. Once at the low level, the energy is spent and it cannot do further work at that level. In order to do further work, it must either fall to an even lower level, or be raised back to the high level through some external agency that inputs energy. 5.3.2 Energy Energy Content Every fuel can liberate a fixed amount of energy when it reacts completely with oxygen to form water. This energy fuel‘s higher heating value (HHV) and lower heating value (LHV). The difference between the HHV and the LHV is the ―heat of vaporization‖ and represents the amount of energy required to vaporize a liquid fuel into a gaseous fuel, as well as the energy used to convert water to steam 19

20. Higher Heating Value (at 25 ºC and 1 atm) Lower Heating Value (at 25 ºC and 1 atm) Fuel Hydrogen 61,000 Btu/lb (141.86 kJ/g) 51,500 Btu/lb (119.93 kJ/g) Methane 24,000 Btu/lb (55.53 kJ/g) 21,500 Btu/lb (50.02 kJ/g) 19,600 Btu/lb (45.6 kJ/g) Propane 21,650 Btu/lb (50.36 kJ/g) 19,000 Btu/lb (44.5 kJ/g) Gasoline 20,360 Btu/lb (47.5 kJ/g) 19,240 Btu/lb (44.8 kJ/g) 18,250 Btu/lb (42.5 kJ/g) Diesel [Table 2- Heating Values of Comparative Fuels] The higher and lower heating values of comparative fuels are indicated in Table 1-3. Although the terms HHV and LHV do not apply to batteries, the energy density of a lead acid battery is approximately 46 Btu/lb (0.108 kJ/g). Gaseous fuels are already vaporized so no energy is required to convert them to a gas. The water that results from both a combustive reaction and the electrochemical reaction within a fuel cell occurs as steam; therefore the lower heating value represents the amount of energy available to do external work. Both the higher and lower heating values denote the amount of energy (in Btu‘s or Joules) for a given weight of fuel (in pounds or kilograms). Hydrogen has the highest energy- to-weight ratio of any fuel since hydrogen is the lightest element and has no heavy carbon atoms. It is for this reason that hydrogen has been used extensively in the space pro-gram where weight is crucial. 20

21. Energy Density Whereas the energy content denotes the amount of energy for a given weight of fuel, the energy density denotes the amount of energy (in Btu‘s or Joules) for a given volume (in 3 or m 3) of fuel. Thus, energy density is the product of the energy content (LHV in our case) ft and the density of a given fuel. The energy density is really a measure of how compactly hydrogen atoms are packed in a fuel. It follows that hydro-carbons of increasing complexity (with more and more hydrogen atoms per molecule) have increasing energy density. At the same time, hydrocarbons of increasing complexity have more and more carbon atoms in each molecule so that these fuels are heavier and heavier in absolute terms. On this basis, hydrogen‘s energy density is poor (since it has such low density) although its energy to weight ratio is the best of all fuels (because it is so light). The energy density of comparative fuels, based on the LHV, is indicated in Table 1-4. The energy density 3 (324,000 kJ/m 3). of a lead acid battery is approximately 8700 Btu/ft 5.3.3 Flammability Three things are needed for a fire or explosion to occur: a fuel, oxygen (mixed with the fuel in appropriate quantities) and a source of ignition. Hydrogen, as a flammable fuel, mixes with oxygen whenever air is allowed to enter a hydro-gen vessel, or when hydrogen leaks from any vessel into the air. Ignition sources take the form of sparks, flames, or high heat. Flashpoint All fuels burn only in a gaseous or vapour state. Fuels like hydrogen and methane are already gases at atmospheric conditions, whereas other fuels like gasoline or diesel that are liquids must convert to a vapour before they will burn. The characteristic that describes how easily these fuels can be converted to a vapour is the flashpoint. The flashpoint is defined as the temperature at which the fuel produces enough vapours to form an ignitable mixture with air at its surface. If the temperature of the fuel is below its flashpoint, it can-not produce enough vapours to burn since its evaporation rate is too slow. Whenever a fuel is at or above its flashpoint, 21

22. vapours are present. The flashpoint is not the temperature at which the fuel bursts into flames; that is the auto ignition temperature. The flashpoint is always lower than the boiling point. For fuels that are gases at atmospheric conditions (like hydro-gen, methane and propane), the flashpoint is far below ambient temperature and has little relevance since the fuel is already fully vaporized. For fuels that are liquids at atmospheric conditions (such as gasoline or methanol), the flash-point acts as a lower flammability temperature limit. 5.3.4 Hydrogen Embrittlement Constant exposure to hydrogen causes a phenomenon known as hydrogen embrittlement in many materials. Hydrogen embrittlement can lead to leakage or catastrophic failures in metal and non-metallic components. The mechanisms that cause hydrogen embrittlement effects are not well defined. Factors known to influence the rate and severity of hydrogen embrittlement include hydrogen con-centration, hydrogen pressure, temperature, hydrogen purity, type of impurity, stress level, stress rate, metal composition, metal tensile strength, grain size, microstructure and heat treatment history. Moisture content in the hydrogen gas may lead to metal embrittlement through the acceleration of the formation of fatigue cracks 6. EXPERIMENTALCALCULATION BY ORSAT APPARATUS: The main components of the apparatus are: Burette used to measure volume of the flue gas sample. Bottle with coloured water, used as a driving medium by application of hydrostatic force. Two or three absorption bottles with capillary tubes where the individual components of the flue gas are absorbed. Block of valves providing access to individual absorption bottles. Three-way valve allowing connecting the burette to the incoming flue gas line or to the ambient air. 22

23. The general working principle is as follows: Certain amount of dry flue gas is delivered to the burette Flue gas is pumped to consecutive absorption bottles where individual flue gas components are absorbed. After absorption of each component, the volume of remaining gas mixture is verified, thus allowing determining volumes of individual components. Each apparatus at the Thermodynamics Laboratory has two absorption bottles: Bottle filled with potash lye (3), which absorbs carbon dioxide Bottle filled with pyro Gallic acid solution (4), which absorbs oxygen. After CO2 and O2 are absorbed, CO content may be determined using an Ostwald‘s diagram for the specific fuel. It could also be determined using a third reagent. Fig no.4.[ORSAT APPARATUS] 23

24. PROCEDURE: Open the atmospheric valve and collect the red solution in burette up to 100ml and close the valve. Now collect the exhaust gas of an automobile enters to the burette by closing atmospheric valve and solution valves. Now raise the outside beaker up to the level of 100ml in burette, so that the exhaust gas be outside the burette. Now open the solution valve & allowed to mix with first solution up to 1 minute. Now lower the outside beaker and match with the level. Now calculate the difference reading in the burette. Suppose initial burette reading is 100ml and after balancing the burette the reading is 96 ml. then 100-96=4ml is of co2 is present. Similarly continue the experiment for 2nd & 3rd solution and calculate the content of CO & O2. CHEMICALS REQUIRED: 1.NaoH 2.KOH 3.CUCL 4.pyro Gallic acid 5.Concent.HCL 6.Methyl Orange 7.concent.H2SO4 8.H2O 24

25. 6.1. Exhaust gas Analysis (Without Hydroxy gas) Initial Burette Reading (ml) After exhaust gas entering (ml) Final Burette Reading (ml) Absorbent Reading for CO in burette (ml) Value CO absorbed In burette(ml) of Absorbent reading for CO2 In burette(ml) Value CO2 absorbed In burette(ml) of Absorbent reading for O2 In burette(ml) Value O2 absorbed in burette(ml) of 100 54 46 52 52-46=6 50 48-46=2 54 50-46=4 6.2. Exhaust gas Analysis (With Hydroxy gas) Initial Burette Reading (ml) After exhaust gas entering (ml) Final Burette Reading (ml) Absorbent Reading for CO in burette (ml) Value CO absorbed In burette(ml) of Absorbent reading for CO2 In burette(ml) Value CO2 absorbed In burette(ml) of Absorbent reading for O2 In burette(ml) Value of O2 absorbed in burette(ml) 52 100 48 49.5 49.5- 48.5 48.5- 54.5 54.5- 48=1.5 48=0.5 48=6.5 TABLE NO-4 6.3. Fuel Consumption Time Analysis: Petrol in (litre) HHO Gas Time Consumption 1litre 1hour 20minutes Without use of HHO gas 1litre 1hour 35 minutes With use of HHO gas TABLE NO-5 25

26. 7. ADVANTAGES 1) They improve gas mileage. 2) They slowly clean out carbon deposits out of your engine. 3) The added hydrogen/oxygen produced acts like a catalysis to your fuel, a more complete burn and slightly cooler. The cell creates a clear clean more combustion able air, right into your air stream, so it is the safest addition of any added voltage gas to a car or truck, on the planet. 4) Add a FREE 120 octane booster to your air/fuel mix. 5) The ortho hydrogen and ortho oxygen created breaks apart the hydro-carbon chain of molecules, leaving a much cleaner emission. 6) Increases horsepower. 7) Will NOT damage your engine, all your doing is adding more combustion air to the air intake. 8.DISADVANTAGES 1) Hydrogen is a dangerous substance to handle. It‘s molecules are small enough to permeate through materials generally thought to be suitable for containing gases. 2) It can make metals brittle. 3) It is considered a ‗green‘ fuel because when it is burnt with oxygen, it does not produce carbon dioxide. While this is true, it is not the whole picture. 4) Hydrogen burnt with oxygen produces a flame inconveniently hot and in mobile applications, we have to carry the oxygen around as well as the hydrogen. Unfortunately, the flame temperature can be lowered conveniently by burning the hydrogen in air, which also dispenses with the need to carry the oxygen around. 26

27. 5) Burning hydrogen in air or an oxygen/air mixture produces nitrous oxide which is a major pollutant - and if you do that, it is no longer a ‗green‘ fuel (although it produces less pollution than petrol & diesel). 9.SAFETY PRECAUTION Before getting into the details of how to construct the booster, you must be aware of what needs to be done when using a hydrogen generator of any design. Firstly, hydroxyl HHO gas is highly explosive. If it wasn‘t, it would not be able to do its job of improving the gas mileage your vehicle is getting; hydroxy gas needs to be treated with care and caution. It is important to make sure that it goes intothe engine as designed and nowhere else.It is also important that it gets ignited inside the engine and nowhere else. To make this happen, a number of common-sense steps need to be taken. Firstly, the hydrogen generator must not make hydrogen gas when the engine is not running. The best way to arrange this is to switch off the electricity going to the booster. It is notenough to just have a manually-operated dashboard On/Off switch as it is almost certain to be forgotten one day. And the generator will be left on making gas while the engine is off Instead, the electrical supply to the booster is sent through the ignition switch of the car. That way, when the engine is turned off, we can be sure that the hydrogen generator is turned off. So as not to put too much amp load through the ignition switch, and to allow for the possibility of the ignition switch being on when the engine is not running, instead of wiring the hydrogen generator directly to the switch, it is recommended that you wire a standard automotive relay across the oil pressure sending unit and then the relay carry the amp load electricity. The fuel pump is powered down automatically when the key is off, and so this will also shut off the hydrogen generator. An extra safety feature is to allow for the (very unlikely) possibility of an electrical short-circuit occurring in the Hydrogen generator or its wiring. This is done by putting a fuse or contact-breaker between the battery and the new wiring you are installing as shown in the sketch. 27

28. Fig.5 [ BLOCK DIAGRAM OF A HYDROGEN GENERATOR] 10.DESCRIPTION OF DIFFERENT PARTS : As shown above the fig., the hydrogen generator contains a number of metal plates and the electricity passing through the water inside the generator between the plates, causes the water to fracture into HHO GAS. CONTACT BREAKER: We can choose to use a contact-breaker, and a light-emitting diode (―LED‖) with a current limiting resistor of 680 ohms in series with it, this can then be wired directly across the contacts of the circuit breaker. LED: The LED can then be mounted inside the car within view of the driver. As the contacts are normally closed, they short-circuit the LED and so no light shows. If the circuit- breaker is tripped, the LED will light up to show that the circuit-breaker is working. The current through the LED is so low that the hydrogen generator is switched off when the contact breaker opens. 28

29. Fig.6. shows a bubbler, a gas pipe, and a water level indicator BUBBLER: A very important safety item is the bubbler; the bubbler has a container with some water in it. The bubbler has the HHO gas coming in at the bottom and bubbling up through the water. A bubbler is a very simple, very cheap and very easy and should be installed. It also removes electrolyte fumes from the gas before it is passes into the engine. 29

30. The HHO gas collects above the water surface and is then drawn into the engine through an outlet pipe above the water surface. To prevent water being drawn into the hydrogen generator when the hydrogen generator is off and cools down, a one-way valve is placed in the pipe between the booster and the bubbler. If the engine happens to produce a backfire, then the bubbler stops the flame fire from going back through the tubing hose and igniting the gas being produced in the generator. If thegenerator is made with a tightly-fitting lid rather than a screw-on lid, then if the gas in the bubbler catches fire and burns back thru, it will just blow the lid off the bubbler and Stop the flame. We can notice that the wires going to the plates inside the electrolyser are both connected well below the water line inside the generator. This is to stop the possibility of a connection working loose while driving and causing a spark in the HHO gas filled region above the surface of the water, and this volume is kept as low as possible to aid in this cause. 11. DESIGN FEATURES USED IN THE GENERATOR [PARTS OF HYDROGEN GENERATOR] [Fig no-7] 30

31. 12. A BRIEF DESCRIPTION ON PARTS NEED FOR MAKING GENERATOR: The hydrogen generator is made from a length of 4-inch diameter PVC pipe, two caps, several metal plates, a couple of metal straps and some other various parts. Assembly is fairly straight forward, and this hydrogen generator can be built by anybody. There is a plastic tube added to the outside of the hydrogen generator, to show the level of the water inside the generator, so you don‘t have to unscrew the cap. Another nice thing is the compact see thru bubbler which is connected to the generator side and shows the gas flow coming from the generator. The main PVC pipe length can be adjusted to fit the space you have next to the engine. Two different types of bubbler are shown: Fig.8 [ PVC PIPES] 31

32. 12.Bubbler connections close up: [Fig.9] The generator uses cheap, standard electrical stainless steel wall switch plate covers from lowest or home depot or any hardware store and stainless steel straps, now you can cut stainless strips fromsheet metal 304 or 316L works well, or you can cut from thehandles stainless steel forks or spoons, buy them from any super market or kitchen supply store. 32

33. Fig.10 [ELECTRICAL COVER PLATES] The electrical cover plates are bolted together in a group of eight closely- spaced pairs. That need to drill the holes out to a larger size to fit the nylon bolts, the next step is optional, it‘s a lot of extra work for just a little more hydrogen, but we can chose to do it if we wish. Just hold the plates down dent them using a centre-punch andhammer. These indentations bring up the gas output from 1.5 lpm to 1.7 lpm as the both increase thesurface area of the cover plate and provide spots wherefrom which the gas bubbles can leave the cover more easily. Themore dents the better. The active surfaces of the plates - that is, the surfaces which are 1.6 mm apart from each other, need to be Prepared with sand paper. To do this, these surfaces are scored in an X- pattern using 36-grade coarse sandpaper. When we done this, it creates small sharp-edged bumps covering the entire side of each of these plates. This type of surface helps the HHO hydrogen bubbles leave the surface as soon as they are formed. It also increases the usable surface area of the plate by about 40%. Now we have found fingerprints on the plates of any generator plates seriously slows down the gas production this happens because we reduce the working area of the plate quite allot. We need to avoid all fingerprints (by wearing clean rubber gloves) or clean the plates of all grease and dirt, use a good solvent and then, wash that off afterwards with distilled water. 33

34. Wearing rubber gloves is the better choice; cleaning chemicals are not a good thing to be applying to these stainless steel surfaces. [Fig.11] 34

35. Fig.12 [INDENTATIONS MADE ON STAINLESS PLATE ] As shown in the above fig.. are the hand tools used to make the indentations on the stainless plates. The active plate surfaces that is, the plate surfaces that are 1.6 mm apart – are indented and then sanded. The stack of the prepared stainless plates is hung inside a Tube cut from a 4- inch (100 mm) diameter PVC pipe. The pipe is changed to a suitable container by using PVC glue to secure an end-cap on one end of the pvc pipe and a screw-cap fitting glued onto the other end. The container then has the gas-supply pipe fitting elbow fitted to the cap top, which is drilled with a pair holes to allow the connecting straps for the stainless steel plate assembly to be bolted to the cap, as shown here: 35

36. Fig.13 Fig .14 [TOP CAP OF BOOSTER WITH TREAD] 36

37. we need to make sure the stainless straps are tightly connected to the electric wiring, the stainless cap bolts are both located in the stronger thicker portion on the horizontal part of the cap, and bolted securely on both sides. A gasket from a piece of rubber or some silicone sealant is a good choice to seal the outside of the cap. If available, a steel washer with built in rubber face will also work. Fig.15 [Complete fig. of Generator Booster] As the stainless steel strap which connects the hydrogen generator plates to the negative terminal of the power supply connects to the center section of the stainless plate assembly, it is necessary to bend it inwards slightly. The angle used for this is in not important, but the strap should be vertical when it reaches the stainless electrical plates. 37

38. Fig.16 [STAINLESS WALL PLATE] The picture above shows the stainless wall plates and how the bubbler is attached to the side of the generator with super-glue or GOOP. It also shows the different pipe connections. The stainless steel switch-cover plates are 2.75 inch x 4.5 inch (70 mm x 115 mm) in size and their two mounting holes need to be drilled out to 5/16 inch (8 mm) diameter in order to take the plastic bolts used to hold the plates together to make as an assembly. After a year of constant usage, these plates are shiny and not corroded thanks to proper use of stainless parts two stainless steel straps that were made are used to attach the plate assembly to the screw cap of the booster. These straps are taken from the handles of cooking utensils or stainless strap steel that you cut, and they connect to three of the plates as the outside strap travels across the bottom of the plate assembly, clear of the plates, and connects to both outside plates as can be seen in both the above photographs and the diagram below. 38

39. Fig.17 [STRAP FORMATION BY PLATES] The plates are bolted in position by two plastic bolts which run through the mounting holes in the stainless plates. The arrangement is to have a small 1.6 mm gap between each of eight pairs of plates. These gaps are created by putting plastic washers on the plastic bolts between each pair of plates. The spacing is important is must be the 1.6 mm gap between the plates as this spacing has been found to be The best at the electrolysis hydrogen production. The way that the battery is connected is unusual in that it leaves most of the plate unconnected. 39

40. Fig.18 [STEEL PLATE ASSEMBLY] These plate pairs are called neutral plates and they do produce gas despite looking as if they are not electrically connected. Stainless steel nuts are used between each pair of plates and these form an electrical connection between Side by side plates. The plate assembly made in this way is cheap, easy to construct and both compact and robust. We can also constructs a plate assembly out of stainless steel flat pieces, such as stainless sheet metal, or corrugated stainless metal, We can also buy stainless plates off eBay for this, just take a look at a couple of possibilities in these pictures. 40

41. Fig.19 [PLATES BIENG MADE] Fig.20 41

42. Fig.21 [PLATES ARE BEING DEEPED IN THE ELECTROLYTIC SOLUTION] Fig.22 [TESTING FOR ELECTROLYSIS PROCESS] 42

43. Fig.23 ,24 [BOOSTER BEING MADE FOR ELECTROLYSIS POCESS] 43

44. Fig.25 The electrical straps are bolted to the screw cap at the top of the generator and this both positions the plate assembly securely and provides electrical connection to the bolts on the outside of the cap while maintaining an airtight seal for the holes in the top screw on cap. Another thing is that the stainless steel straps coming from the screw cap to the plate assembly, they need to be insulated so that electrical current does not leak between them through the electrolyte water. 44

45. Fig.25 [COMLETE ASSEMBLY OF PLATES] The same needs to happen to the section of the strap which runs underneath the plates. This insulating is best done with shrink wrap or tool plastic dip tool. dip works very well, but if neither of these choices can be used by us, then the insulating can be done by wrapping the straps in electrical tape. If we use this method, the tape needs to be wrapped tightly around the straps, being stretched slightly as you go along, The section running underneath the covers is insulated before the array is assembled. 45

46. Fig.26 The PVC housing for the generator has two small angle pipe fittings attached to it and a piece of clear plastic tubing attached between them so that the level of the water inside can be checked without removing the screw cap. The white tube on the other side of the generator is a bubbler which is glued or wire tied directly to the side of the generator using super-glue or wire ties in so that a single combined generator/bubbler. If space is limited we can mount the bubbler in a separate location. The bubbler position is shown here, spread out before gluing or tieing in place as this makes the method of attachment a little easier to view. 46

47. Fig.27 13. CONSTUCTION OF BUBBLER: The half-inch diameter 90 degree elbows at the ends of the one inch diameter bubbler tube have their threads coated with silicone before being pushed into position. This allows both of them to serve as pressure-relief pop-out fittings in the seldom seen event of the gas being ignited. This is an added safety feature of the generator. This generator is operated with a mix of Potassium Hydroxide also called KOH or Caustic Potash. We can also use baking soda if we prefer, most people have baking soda around the house, KOH will last longer and produce less brown water. To get the right amount in the generator, fill the generator to its normal liquid level with distilled water and add the Hydroxide or baking soda a little at a time, until the current through the booster is about 4 amps below the working current of 20 amps. This allows for the generator heating up when it is working and pulling more amps because the electrolyte water is hot. The amount of KOH is typically 2 teaspoonful‘s. It is very important to use distilled water as tap water has impurities in it which make a mess which will clog up the generator. Also, be very careful handling potassium hydroxide as it is highly caustic. If any gets on you, wash it off immediately with 47

48. large amounts of water, and if necessary, use some vinegar which is acidic and will offset the caustic splashes. Baking soda does not have this problem. The completed booster usually looks like this: Fig.28 BOOSTER OR Fig.29 14. HOW THE GENERATOR IS CONNECTED TO THE ENGINE: The final step is how the generator is connected to the engine. The normal mounting for the generator is close to the carb or throttle body so that a short section of tubing can be 48

49. used to connect the generator to the intake of the vehicle engine. We can hose to connect to the air box where the air filter is, or into the intake tubing. The closer we get it to the throttle plate the better it is, because for safety concerns, we want to reduce the volume of HHO gas lingering around in the intake system. We can drill and tap a 1/4" (6 mm) NPT fitting into the plastic inlet tubing with a barbed end for connecting the 1/4" (6 mm) hose. The shorter the length of tubing to the air intake of the engine, the better it is. Again, for safety concerns, we want to limit the amount of unprotected HHO hydrogen gas. If a long run of 3 feet (1 meter) or more must be used due to space limits, then it would be a good idea to add a second bubbler at the end of the tube, for additional fire safety. If we do this, then it is better to use a larger diameter outlet hose, chose 3/8"or 5/16‖ (10 mm or 8mm). The normal mounting for the generator is close to the carb or throttle body so that a short section of tubing can be used to connect the generator to the intake of the vehicle engine. We can choose to connect to the air box where the air filter is, or into the intake tubing. The closer we get it to the throttle plate the better it is, because for safety concerns, we want to reduce the volume of HHO gas lingering around in the intake system . We can drill and tap a 1/4" (6 mm) NPT fitting into the plastic inlet tubing with a barbed end for connecting the 1/4" (6 mm) hose. The shorter the length of tubing to the air intake of the engine, the better it is. Again, for safety concerns, we want to limit the amount of unprotected HHO hydrogen gas. If a long run of 3 feet (1 metre) or more must be used due to space limits, then it would be a good idea to add a second bubbler at the end of the tube, for additional fire safety. If you do this, then it is better to use a larger diameter outlet hose, chose 3/8"or 5/16‖ (10 mm or 8mm). 49

50. 15.HOW TO POWER THE HYDROGEN GENERATOR Use wire and electrical hardware capable of handling 20 amps DC, no less. Overkill is better in this case, It is recommended to use parts that can handle 30 amps. Run the power through the ignition circuit, so that it only powers up when the engine is on.  A 30 amp relay should be used to prevent damaging the ignition circuit and or switch, the switch is not designed for an extra 20 amp load. Make sure to use a properly rated fuse, 30 amps is best. Use a toggle switch for further operational control. Also can add this safety feature, run an oil pressure switch to the relay as well, so the unit operates only when the engine is actually started and running  It is very important that everything is tight, solder is better than, crimping. Any loose connections can cause heat and this could lead to a fire, so make sure that connections are of good quality , and be sure to check them every so often to make sure they have not worked loose 16. SETTING UP THE WATER IN THE GENERATOR Fill the generator with distilled water and baking soda or KOH. Clean it more often using baking soda First.  Fill the generator with distilled water about 2" from the top. Add a teaspoon of KOH or NaOH, or baking soda to the water and then slip the top into place.  Do not tighten it up for now, leave the top loose and resting in place.  Connect 12V power supply to the connectors and monitor the amp draw of the generator.  Striving for 16 amps flowing when the generator is cold. As the water heats up over time, the amp load draw will increase by about 4 amps until it reaches around 20 amps, and this is why you are trying for 16 amps when the generator is cold. If the amp draw is too high, pour out some of the water inside and add just a little more distilled water. 50