WO2012046041A1

WO2012046041A1 - Improvements in or relating to hydrogen generators

Info

Publication number: WO2012046041A1
Application number: PCT/GB2011/051886
Authority: WO
Inventors: Kenneth John Douglas Bristow
Original assignee: Kenneth John Douglas Bristow
Priority date: 2010-10-04
Filing date: 2011-10-04
Publication date: 2012-04-12
Also published as: GB201106027D0; GB201109683D0

Abstract

The present invention relates to an improved hydrogen generator. In particular, it relates to a portable hydrogen generator for a light or heavy commercial vehicle.

Description

Improvements in or relating to hydrogen generators

The addition of hydrogen gas to petroleum or diesel fuel is a well known method of improving engine efficiency. A water electrolysis apparatus is traditionally mounted within an engine to generate hydrogen, which is mixed with air and fuel in the combustion chamber of the engine (with the aim of increasing engine performance). Usually, a hydrogen generator is designed to electrolyse a relatively small amount of water at a time, to avoid storage of flammable hydrogen gas within a combustion engine.

The present invention aims to provide a highly safe hydrogen generator system that is portable, robust, reliable, easy to install in an engine, simple to use and maintain, and that does not interfere with day-to-day running of the engine or affect any existing engine management system. In particular, the present invention aims to provide a system that incorporates a safety device to ensure that the hydrogen generator does not overheat.

In its broadest aspect, the present invention provides a hydrogen generator system suitable for use in an HGV or LGV engine. Suitably, the hydrogen generator system is formed substantially from stainless steel. Preferably, the hydrogen generator system further comprises a voltage fluctuator switch.

In one aspect, the present invention provides a hydrogen generator system comprising a water electrolysis hydrogen generator and a voltage fluctuator switch.

In one embodiment, the hydrogen generator comprises a water electrolysis chamber and a condensing chamber, the condensing chamber allowing for removal of water vapour from a hydrogen gas mixture generated by the electrolysis chamber.

Preferably, the system further comprises a header tank for containing distilled water. Advantageously, the header tank comprises, or is connected to, a float switch. In a preferred embodiment, the system comprises a float switch which is operable when the system comprises a pre-determined low level of water. Suitably, the float switch is connected to a relay. Conveniently, the relay prevents electric current from reaching the hydrogen generator in the event that the system has a pre-determined low level of water.

Advantageously, in use of the system in a vehicle, the hydrogen generator is connected to an alternator.

In one embodiment, in use of the system in a vehicle, the system is connected to, and powered by, a battery of the vehicle. Suitably, in use, the battery is connected to the hydrogen generator system via a fuse element. Conveniently, the system further comprises a warning light or an audible warning signal, to indicate a failure within the system. Preferably the warning light or audible warning signal is receivable in a cab of a vehicle in which the system is installed.

Preferably, the system comprises a voltage reducer.

Ideally, the system comprises at least one relay.

In one embodiment, the relay prevents electrical current entering the system from a battery unless an alternator to which the system is connected is operating.

In a preferred embodiment, the system comprises a polypropylene baffle to receive a portion of an internal component of the hydrogen generator. Suitably the baffle is situated in the condensing chamber. The above and other aspects of the invention will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:

Figure 1 is a diagrammatic view of an embodiment of a hydrogen generator system in accordance with the present invention; Figure 2 is a cross-sectional view of an embodiment of a hydrogen generator in accordance with the present invention;

Figure 3 is a diagrammatic view of an alternative embodiment of a hydrogen generator system in accordance with the present invention;

Figures 4 & 5 are photographic views of the embodiment of Figure 2 installed in a vehicle; and

Figure 6 shows a perspective, cross-sectional and plan view of an embodiment of a baffle component of the embodiment of Figure 2. Figure 1 shows a representation of a hydrogen generator 10 and its electrical connections within a vehicle engine. The vehicle engine comprises a battery 11 and an alternator 12. The hydrogen generator is connected to a voltage fluctuator switch 13. Voltage fluctuator switch 13 ensures that hydrogen generator 10 is not continuously receiving electrical current from battery 11. In this way, overheating of the hydrogen generator can be avoided. Voltage fluctuator switch 13 is connected to a voltage reducer 14. Voltage reducer 14 reduces the voltage of the system from 24 volts (received from the vehicle's battery), to 12 volts. 12-volt current is conducted, via voltage fluctuator switch 13, to hydrogen generator 10. Voltage reducer 14 is also connected to alternator 12, via a relay 15. Relay 15 ensures that current from battery 11 only flows to hydrogen generator 10 when alternator 12 is operating, i.e. when the engine of the vehicle is running. This is a safety device. Relay 15 is connected to battery 11 - via a fuse holder 16, comprising at least one fuse. The fuse prevents current entering hydrogen generator 10 in the event of a failure within the system. Relay 1 is further connected to a float switch 16 in a header tank 17. Header tank 17 supplies hydrogen generator 10 with water for electrolysis. Header tank 17 comprises float switch 16 so that when the water in header tank 17 falls below a pre-determined low level, float switch 16 is operated, which in turn operates relay 15, which prevents current from battery 11 entering hydrogen generator 10.

Hydrogen generator 10 is connected to a warning light or audible signal, located in a vehicle cab. This warning light/signal alerts the vehicle driver in the event that there is a failure within the hydrogen generator system. An alternative embodiment of the system of Figure 1 is illustrated in Figure 3.

Figure 2 shows a cross section of hydrogen generator 10. The generator comprises a stainless steel filler 20, a stainless steel threaded bar 21, a nylon threaded stopper 22, a polypropylene restraining baffle 23, a stainless steel internal baffle 24 or series of baffles, a stainless steel tube 25, a stainless steel pressure relief valve 26, stainless steel drain taps 27, a stainless steel condensing chamber 28, plastic tubing 29, stainless steel hydraulic push fittings 30, and a stainless steel reaction chamber 32. Suitably, 316 stainless steel is used. Figure 2 also illustrates a plan view of restraining baffle 23.

Figure 6 illustrates a perspective view, a cross-sectional view and a plan view of polypropylene or polyamide restraining baffle 23. Restraining baffle 23 has recessed portions 40 for receiving stainless steel internal baffles 24 arranged generally concentrically. Alternative baffle arrangements are equally suitable. In use, restraining baffle 23 acts to maintain separation between internal baffles 24 and to maintain the alignment of internal baffles 24. That is to say, in use, restraining baffle 23 acts as a brace seat. One restraining baffle 23 is provided in a top portion of chamber 32 and one baffle 23 is provided in a bottom portion of chamber 32.

In use of the system of the present invention, hydrogen and oxygen are generated from water in reaction chamber 32. The gas mixture is piped to condensing chamber 28, which removes any water vapour from the gas mixture. The gas is then piped to an engine air intake. Once the gas enters the air intake, it is mixed with fuel. Figure 4 illustrates piping 50 for transferring gas from hydrogen generator 10 to the air intake of an engine.

Current is supplied to the hydrogen generator system, for electrolysis, when the engine of a vehicle in which the system is installed is running (by connection to alternator 12, via relay 15). The system stops receiving current in the event that the engine stops running or in the event that the water level in the system reaches a predetermined low limit (via float switch 16 connected to relay 15). Current received by generator 10 is not continuous. Current is switched on and off by voltage fluctuator 13. This safety mechanism ensures that current does not build-up in generator 10. Such build-up could result in overheating. Current is supplied to the system by battery 11 (24 volts). The current is reduced to 12 volts by voltage reducer 14 before it enters hydrogen generator 10.

The hydrogen generator system of the present invention - and particularly hydrogen generator 10 components 24, 26, 30, 32 - is formed substantially from stainless steel, ensuring that it is robust enough for use in an HGV or LGV engine.

The system of the present invention provides for improved fuel efficiency. In particular, the system provides an improvement in horsepower and engine torque, which generates increased fuel economy and lower carbon emissions.

The system works by separating hydrogen and oxygen molecules from distilled water by electrolysis. As the gases are formed they create a build-up of pressure in hydrogen generator 10, which ensures constant flow of gas into the air intake of an engine. The introduction of hydrogen gas to the air/fuel mixture of an engine reduces the combustion point of the fuel by a factor of 10. Accordingly, when the mixture is compressed and ignites in the combustion chamber of an engine, the presence of hydrogen causes a faster reaction giving a more efficient burn of the air/fuel mixture.

Trials of the system of the present invention have generated the following data:

Horsepower: readily increased by 5-10%; up to 60%

Fuel economy: readily increased by 10-15%; up to 70%

Carbon monoxide emission: lowered by up to 85%

Particulate matter emission: lowered by up to 85%

Nitrous oxide emission: lowered by up to 45%

Hydrocarbon emission: lowered by up to 70%

C0₂ emission: lowered by up to 35%

The system of the present invention allows some vehicles to be issued with LEZ certificates (London Low Emission Zone) by Transport for London. The system can be installed in a vehicle, up to 5 metres from the engine air intake. This means that there is minimal interference with the day-to-day operation of the vehicle. The hydrogen generator is wired directly to the vehicle's alternator, meaning that the generator is only active when the engine is running.

The hydrogen generator is fitted with an external sight level to provide an operative with a visual indication of when the system needs re-filling with water. The generator will consume approximately 2 litres of water per 1000 miles. A 7-litre header tank provided with the system of the present invention allows for a range of 3500 miles. It is anticipated that the system will require topping up and/or checking every 6-7 days when used in the haulage industry.

In some trials users reported speed increases (due to increased horsepower) on long inclined roads of in excess of 60% (from a typical speed of 50km/h without the present invention to around 80km/h with the present invention). Fuel efficiency increases of 70% have been obtained, with, in one example, a normal consumption of 34 litres per 100km being reduced to 20 litres per 100km.

Claims

1. A hydrogen generator system for a vehicle; the system comprising hydrogen generator (10) formed substantially of stainless steel and having an electrical power supply; wherein the electrical power supply includes a fluctuations switch (13) to provide a selectively non-continuous current supply to the generator (10) and wherein the hydrogen generator (10) comprises a hydrogen outlet in fluid communication an engine air intake part of the vehicle.

2. A system as claimed in claim 1 further comprising a relay (15) operatively couplable to an alternator (12) of the vehicle such that electrical current is provided to the generator (10) only when, in use, alternator (12) is operating.

3. A system as claimed in claim 1 or claim 2 wherein the system further comprises a water header tank (17) to provide a water supply to generator (10) and comprising a float switch (16) operatively coupled to relay (15) or a second relay to interrupt flow of electrical current to generator (10) in the event of water in header tank (17) falling below a predetermined level.

4. A system as claimed in any one of claims 1 to 3 wherein the hydrogen generator (10) comprises a reaction chamber (32) in fluid communication via a filler (20) with water header tank (17); wherein reaction chamber (32) includes at least one internal baffle (24).

5. A system as claimed in claim 4 wherein the hydrogen generator further comprises a condensing chamber (28) to remove water vapour from gases produced by electrolysis of water in reaction chamber (32).

6. A system as claimed in claim 4 or claim 5 wherein the reaction chamber (32) is formed of stainless steel.

7. A system as claimed in any one of claims 4 to 6 wherein the or each internal baffle is formed of stainless steel.

8. A system as claimed in any one of claims 4 to 7 further comprising upper and lower restraining baffles (23) including recessed portions (40) to support said at least one internal baffle (24) in a correct alignment and separation.

9. A system as claimed in claim 8 wherein said restraining baffles are formed of a polymeric material, preferably polypropylene or polyamide.