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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: [email protected], Tel. 580 746 2430

See Car Test Results --

page 13

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Contents

Car Test -- Hydrogen On Demand...................... 1Section 1 -- Hydrogen Cell Initial Results, 2011. 4Can pure hydrogen (H2) replace HHO to increase MPG?...........5Technology comparison; HHO system and CC-HOD H2 system................................5Aluminum hydr oxide, aluminum oxide and recycling.................. 6The need for pure hydrogen (this invention).................................. 7Problem and solution.......................................................................................................7The present invention for hydrogen production improves the state of the art ..........7Catalytic Carbon (CC) is intended for the high-production-rate, large-volume pro-

duction of hydrogen....................................................................................................8Chemical reactions............................................................................ 8The present invention uses simple and well-known chemical reactions.....................8High rates of hydrogen production are possible...........................................................9Hydr ogen production rates: Up to 4 LPM in small reaction chambers....................9Hydr ogen production rates: Up to 35 gallons/minute in large reaction chambers.

10By-products are fully recoverable using existing commercial methods for producing

aluminum metal. ........................................................................................................10Fuel: The use of lower-cost, lower-purity aluminum .................................................11Fuel: The use of water from almost any source is a novel aspect of the present in-

vention. .......................................................................................................................11The use of salt water makes the present invention suitable for marine applications

and as an energy source for coastal areas...............................................................11Catalytic Carbon (CC) can be used with the most desired materials to produce

hydrogen.....................................................................................................................12Safety: Catalytic Carbon (CC) can be used with the world’s safest materials to

produce hydrogen......................................................................................................12First pur e-hydrogen road test using CC.......................................13

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First test run: 37 MPG .................................................................. 15The government says this Buick should get 26 MPG (highway

driving) ........................................................................................16Analysis: 32% increase in gas mileage.........................................16Engineering design concepts......................................................... 17Summary .........................................................................................17

Section 2 -- Hydrogen Cell Design and Fabrica-tion, 2012...........................................................18

2012 Prototype cell design update.....................19Installation of hydr ogen system.........................30Problems and comments................................................................ 31

Operation of the hydrogen system....................32We used both CC/Al fuel and CA fuel ..........................................33How to evaluate this new H2 system.............................................34

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Section 1 --

Hydr ogen Cell InitialResults, 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 hydr oxide, aluminum oxide and recyclingThe 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 specialcharacteristic -- 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 energyalternative for sustainable growth. The increasing demand for hydrogen arises from theimpending paradigm shift to a hydrogen-based energy economy. This change willbecome 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 useof hydrogen. The present invention provides a simple solution, in that hydrogen ondemand (HOD) is available at any desired high production rate. This makes itunnecessary 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 productionof 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-volumeproduction of hydrogen.

Although about 20% of air is oxygen, there is no easily-accessible, safe source ofhydrogen available. The current invention addresses and solves this problem. CC-HODrelates to a novel method of generating hydrogen from water. Water consists of twoelements: 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 asa 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 fuelsupplement -- 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 usingCatalytic 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 + 6H2O + CC => CC + 2Al(OH)3 + 3H2 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 + 3H2O + CC => CC + Al 2O3 + 3H2 whereAluminum and water are fuels and the only by-product is aluminum oxide, Al 2O3 . 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 as

hydrargillite) and its three polymorph forms: bayerite, doyleite and nordstrandite. [RefWikipedia]

Closely related to aluminium hydroxide is aluminium oxide, Al2O

3, 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 analuminium 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 mixture

with the two iron oxides goethite and hematite, the clay mineral kaolinite, and smallamounts of anatase TiO

2. [Ref Wikipedia]

High rates of hydrogen production are possible

Most methods of producing hydrogen (electrolysis, thermo-forming) produce hydrogenat 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 (forhydrogen production). This is because our invention uses a process that only needsexternal 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 heatto sustain the reaction. The only external energy required is for cooling, if needed tolimit the production rate to some desired target value.

Hydr ogen 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 ratesexceeding 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 longas water, aluminum and Catalytic Carbon (CC) was provided to the hydrogen-productioncell.

Hydr ogen production rates: Up to 35 gallons/minute in large reaction chambers.

130 LPM of hydrogen was produced during scale-up experiments. For moreinformation, please see

www.PhillipsCompany.4T.com/CA.pdf

By-products are fully recoverable using existing commercial methods for producingaluminum metal.

The by-products from our hydrogen-production method are desirable because they arepure, and contain no contaminants including bauxite, gibbsite, boehmite, goethite,hematite, kaolinite, and TiO2. We reason that the large volume of by-products of ourinvention, pure Al(OH) 3 and pure Al 2O3, will be 100% recycled to produce morealuminum metal. Recycling of aluminum hydroxide and aluminum oxide makes thepresent invention economically viable for large-volume hydrogen generation. Anexcellent discussion of the process for primary aluminum production, as well as world-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 processchemistry 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 iselectrolytically 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 isapproximately 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 useof 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 presentinvention.

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 acidicwater. 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 pureforms of water such as deionized water. When producing hydrogen with the presentinvention, more design latitude and freedom is available to the hardware design engineerin 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. Theexcellent process latitude for water purity makes it possible to use a wider range ofmaterials 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 applicationsand 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, includingremote 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 fossilfuels. Other island groups, including Hawaii, can improve the local economy byreducing fuel costs using the present invention to reduce or eliminate the need fortanker-ship import of fossil fuels.

Catalytic Carbon (CC) can be used with the most desired materials to producehydrogen.

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 toproduce hydrogen.

Carbon, water, aluminum, aluminum oxide and aluminum hydroxide are the safestmaterials 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 ofneutral 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 pur e-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 viewmirror. In a commercial system this wouldnot be needed or included. This apparatusis to give a visual indication of hydrogenflow rate during road tests.

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37 MPG

35.7 MPG

33.3 MPG

35.9 MPG

T = 0 minutes: Cell charged with 2 HTspAl powder. and heating element wasswitched on. Heatup and hydrogen flowrequired about 5 minutes.

T = 5 minutes: Buick engine was startedwith 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 withtime, 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 WITHOUTany hydrogen flowing to the engine. Why?Could the EFI computer have been trainedon hydrogen in a way that it somehow chosea “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 (highwaydriving)

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, becauseindependent 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 1mL 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" offuel to the cell.

B. SUSTAINED OPERATION ON THE ROAD: Keep the cell cool as thereaction 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 variesdepending on changing speed and power required; and temp control (cooling) isprovided 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 littleenergy required. So, we need a strategic alliance who is in the automotive products business.

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Section 2 --

Hydr ogen Cell Designand Fabrication, 2012

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2012 Prototype cell design update

The following information is an update, giving information that has been learned anddemonstrated in our R&D project during 2012.

The Buick test vehicle has had many cell designs installed for evaluation. The “shelf”on the front bumper makes system change-out easy. The grill has been removed for thesame reason -- to make system change-out and engine access easy.

This system uses a cell design that overcomes one problem in earlier cell designs; Weuse low-level electrolysis (less than 0.1 Ampere) to dissociate the aluminum hydroxideand keep it from “clumping” in the cell. More info: www.PhillipsCompany.4T.com/AE.pdf

The major fuel is water. This cell design includes a water tank.

The gravity-flow water tank is higher than the cell.

Pumps are not needed in this design. The water tank serves a dual purpose -- itfunctions as a bubbler to prevent material from the cell entering the hydrogen-outputplastic tube. Note that the output line is clean and clear of both carbon and aluminumparticles.

A check valve (one way) is shown in the red circle.

The hydrogen from the cell goes through a normally-off solenoid which is powered by12 VDC only when the ignition is ON. This stops hydrogen from entering the enginecompartment when the engine is off.

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The hydrogen goes from the solenoid to the engine.

The electrical control contains three things that would not be needed for a commercialsystem, but are helpful for engineering diagnostics in prototype systems. These threethings are (1) a current meter to measure total current draw from the battery; (2) a 30Ampere circuit breaker, and (3) a switch to control the anode current in the cell.

In a commercial system, a 30 Ampere fuse could be used to eliminate the cost of acircuit breaker.

A cell cover is used in this design. It is made from a section of thin-wall PVC pipe.

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The cell is lower than the gravity-flow water tank.

The cell cover serves two purposes: (1) The cell is in a glass jar, which is protected fromgravel and other “might break” problems, and (2) the cell cover conserves heat whichwould be lost from air cooling if the cell were exposed to the wind. The cell temperatureis controlled by a digital temperature controller which switches power OFF to theelectrical cell heaters when the cell temp reaches the desired temperature (180F to 190F,typically). The cell will continue to produce hydrogen as long as the cell temperatureremains in the desired operating range, so the cell cover saves electrical power used forheating.

The cell is contained in a glass jar. This is a simple 1-quart canning jar.

Glass cell. Don’t do this.

Don’t use glass for a container. Remember this is just a prototype system. A non-glass

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container for the cell is a safety precaution that will prevent glass shards from flyingabout in the event of a hydrogen explosion in the cell. This has never happened to us inour work, but surely it will happen to someone one day, and safety design is thereforerecommended.

A glass container was used to provide “see through.”

The cell is shown above with water (no CC and no CA) so that the internal elements canbe seen.

This design uses 6” to 8” of connector cable. This cable is usually coiled neatly in thecell during normal operation. But, when the cell lid is removed, inspection is easy withno need to remove the heating element, which is usually embedded in the semi-solid bedof aluminum or CA fuel.

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Two tubes in/out of cell.

This design has two tubes, as shown. One tube (copper pipe) carries water into the cell.The other tube (plastic Tygon tubing) is used for flowing hydrogen out of the cell. Thecopper pipe provides a rigid structure so that it can be easily pushed into the semi-solidaluminum (or CA) fuel bed.

Filter on the end of the copper pipe.

The copper pipe (water input) must be below water level for proper operation. Thatmeans that it is in the semi-solid material in the cell, which can result in clogging of thecopper tube. Our prototype cells have experimented with shorter copper tubes, withlimited success. This has been a challenge, and better designs are needed to prevent thisclogging problem.

This design uses a lead strip for an anode. Lead is corrosion resistant, which is onereason it is used in lead-acid batteries. In this design, there is virtually no corrosion, fortwo reasons: (1) The liquid is pH neutral, with no electrolyte added, and (2) the currentis very low (less than 0.1 Ampere). The anode potential is 12 VDC. The assembly is

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bound by epoxy. We have used J-B weld epoxy with good results.

Heater assembly also used for

electrolysis.We use immersion heaters which are manufactured for use in heating a cup of tea orcoffee. They are available as 12-volt products, which we find convenient because thatvoltage is readily available from the automobile battery. The outer tube of the heaterelement is electrically insulated from the internal heating unit (resistance wire). Thiselectrical insulation allows for wiring the outer tube of the heater element to ground, sothat it serves as the cathode surface.

There is a second advantage of the low-current electrolysis. Most water-splitting andhydrogen production occurs near the heater elements, because that is where the water

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temperature is warmest. When the water is split, the H atom is positive (+) and the OHgroup is negative ( - ). The electric field tends to separate the two, thereby reducing theprobability of recombination.

The figure shows how the electric field tends to separate the H+ from the OH- ions, byapplying a force to the ions. Separating the two ions immediately after the water-splitting event reduces the probability of recombination.

If recombination occurs [ H + OH --> H2O ], the hydrogen production rate is lower.Therefore, the electric field provided by the electrolysis system is helpful. Almost noHHO is generated by the low-current electrolysis -- almost all the gas produced will behydrogen. The hydrogen is produced according to

2Al + 6[H2O] + CC = CC + 2[Al(OH)3] + 3[H2]

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The control system is described in the following photo.

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The following designations are used in the figure:HCC = Hydrogen Cell ControllerTS = Temperature Sensor, a thermistor; part of the DTC.DTC = Digital Temperature ControllerVDC = volts, DCA = Ampere+Ign = +12 volts when ignition switch is ON.

Not shown in the figure is the 12 volt power relay which is under the meter assembly.S1 is a circuit breaker. S2 is control for the anode. The circuit diagram for the controlleris shown on the previous page.

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The temperature controller is available from eBay sellers:

The controller is described in the manual, available online:Manual: http://www.willhi.com/Documents/WH7016Cdatasheet.pdf

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Installation of hydr ogen system

Installation of the hydrogen system is made simple and straightforward because onlyhydrogen is delivered from the system to the engine. The following illustration

The only connection to the engine fuel system is shown ( red circle O ) in the above

figure. The only additional connections to the engine are the 12 volt connections to thebattery and to the ignition system.

Note: When pure hydrogen (not HHO) is used, no modifications to the engine arerequired. Oxygen sensors are not modified. Tuning of the engine is not required.“Air/fuel ratio” adjustments ar e not required. “Timing” adjustments are notrequired.

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The temperature controller is mounted for clear viewing, near the instrument cluster. Ascan gauge is also used to provide accurate miles per gallon (MPG) data.

The temperature controller provides ON/OFF switching capability so that the entirehydrogen system can be switched OFF during driving, if/when desired.

Problems and comments

Our designs used glass jars for hydrogen containers. This is not a good idea, because ofsafety concerns. Better materials can be used.

We occasionally experienced clogging of the water line that delivers water (fuel) fromthe water tank to the hydrogen cell. We used only a simple screen to limit material fromentering the copper-pipe. Surely, better filters or screens are available.

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This is only a prototype system, intended to obtain performance data. We are not amechanical company. We have no machine shop in our company. Surely, others canimprove on the shabby mechanical characteristics of our prototype.

Our design heats slowly. From a cold start, about 10 minutes is required to heat thecontents of the cell to the desired operating temperature range = 180F to 195F. A betterdesign might use a better heating system.

Our design uses electrical energy from the battery for heating. Other builders may wantto use heat from the exhaust system or heat from the engine coolant system. Eithersource of heat may be useful, if the cell contents can be rapidly heated to the desiredoperating temperature range = 180F to 195F.

For high-hydrogen-flow-rate systems, a cell larger than a quart jar may be useful. Thismay be the case for larger engines, such as diesel engines for trucks. We do not have adiesel-truck test vehicle, so we leave this experimentation to others.

Our prototype is much larger than it needs to be, and other system builders will, nodoubt, build smaller systems. Our prototype was mounted outside the car, for convenientaccess during the experimental phase. There is no doubt that better systems can be builtand installed under the hood to make the installation virtually invisible.

Operation of the hydrogen system

The system operated without major problems for weeks at a time. Fuel replacementbecause of fuel depletion was not a problem, because much of our use was under verylow hydrogen generation rate conditions. We were surprised that 30% to 35% increasein gas mileage was obtained when operating the system with a hydrogen output of only30 to 50 milliliters per minute -- much less hydrogen than expected, by comparison withreports from HHO electrolysis system users.

The hydrogen flow rate output can be adjusted by changing the set-point temperature forthe temp controller. We had good operation at various set temps ranging from 170F to195F.

The temp controller displays temperature in degrees C. For that reason, we found thistemp-conversion table helpful:

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We used both CC/Al fuel and CA fuel

Both fuels work well in our prototype.

We prefer CA fuel because no mixing (CC / Al / water) is needed, making the fuelingprocess more convenient and with fewer variables that can affect performance of thesystem.

Another advantage of CA fuel is that it uses less than 2% CC (because of CC/Albonding) whereas the use of CC/Al/water typically requires that 20% to 30% of thevolume be made up of CC. Clearly, CC provides an advantage in that less CC is needed.

Because less CC is needed when CA fuel is used, the heating rate can be better becausethere is less material in the cell to be heated, for a given amount of aluminum in the cell.

More details about CC / Al / water fuel can be found online atwww.PhillipsCompany.4T.com/HYDROGEN.html

more details about CA fuel can be found online atwww.PhillipsCompany.4T.com/CA.pdf

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How to evaluate this new H2 system

Might you be interested to evaluate this new method of producing hydrogen? Please seethe following information, online:

Hydrogen and CC: www.PhillipsCompany.4T.com/HYDROGEN.html How to obtain Catalytic Carbon: www.PhillipsCompany.4T.com/MCC.pdf How to obtain Catalyzed Aluminum: www.PhillipsCompany.4T.com/MCA.pdf Hydrogen News: www.PhillipsCompany.4T.com/PRH6.pdf Catalyzed Aluminum (CA) info: www.PhillipsCompany.4T.com/CA.pdf Hydrogen tech business model: www.PhillipsCompany.4t.com/bmH.pdf

Phillips Company

Email: [email protected], Tel. 580 746 2430