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3 April 2006 On - Demand Electrolysis Explained On-Demand Electrolysis converts Electrical Energy (Direct Current) into Molecular Energy (Hydrogen and Oxygen) as needed by a consumption entity, such as an internal combustion gas generator or Automobile Engine. The Energy is released by putting the Water Molecules "back together" inside the engines combustion chamber. Typically Commercial Electrolysis systems are designed with a fixed input voltage, rather than a variable "ondemand" process. Also, Commercial systems are usually designed to keep the Cathode and Anode physically separated, so that the gasses can be collected apart from each other. This type of design significantly reduces its efficiency, because the Electrical Energy must go a father distance through the electrolyte between the plates, increasing its resistance. This is why commercial systems add chemicals to the water to increase its conductivity. That type of design would not be practical for an "on board" portable system, such as I am describing. This system only requires distilled or clean "mineral free" tap water. Hydrogen is a "High Energy" Product The reason that Hydrogen gas works so well is because it's a High Energy product, meaning that a relatively small amount of benign Energy is needed to split the water molecules, but a tremendous amount of explosive Energy is release when the Hydrogen and Oxygen are put back together as H2O. Without the explosive characteristics of Hydrogen and Oxygen, the process would not be capable of driving an internal combustion engine. The Hydrogen and Oxygen gas is protected from accidental detonation by industry standard flashback arrestors, such as those used by Acetylene torches. Flashback arrestors are factory rated for use in Hydrogen and Oxygen applications. Affordability of conversion Unless pre-existing gas and diesel engines can be converted, which are already in use all around the world, there will be little hope of solving the Global Warming Crisis we are now facing. The process must be economically feasible enough so that even the most fiscally challenged citizen can afford to upgrade, since a very large number of vehicles are being driven by them. If they can't afford to convert, everybody on the planet loses. We all live on planet Earth, so we all must participate. I'm
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estimating an initial system to cost around $350.00, in mass produced kit form. Global competition saturation will ensure the highest quality product is made available at the lowest possible price. This Technology has been put in the "public domain", so that no single entity can limit access to any part of the Technology. If those building the product want to control market share they will need to provide the absolute best product for the least amount of money. Capitalism will finally serve those "doing the real work" in the Economy, instead of those that just handle the money. Skilled labor will be able to "name their price" due to widespread Global demand. Why use ABS (Acrylonitrile Butadiene Styrene)? The entire exterior body of the Electrolysis system's containment chamber is constructed using standard 3" ABS components. ABS is a high tech substance which is used in a wide variety of applications, including waste and sewer systems. It is impervious to corrosive chemicals and gases, in addition to possessing excellent pressurization capabilities. Long term longevity has verified that physical strains have little effect on the product. Components which have been in service for Decades have been examined and found to be in near perfect condition. These qualities make ABS ideal for a low pressure gas containment system like that of on-demand electrolysis. ABS is a dream to work with. Standard "off the shelf" components are either glued together or threaded. ABS can be drilled, and tapped for an infinite variety of connection products including pipe thread components and fittings. The tinsel strength of the product ensures that drilled sites resist ruptures and cracking making it highly reliable. Finally, ABS tolerates a wide temperature range without degradation. All these qualities make it an ideal platform for Home electrolysis systems. 3" ABS Cell Chamber design For the On-Demand product, a 3" X 16" long length of ABS pipe is fitted with a glue cap on the bottom, and a 3" male threaded adapter glued to the top. The 3" male threaded adapter is fitted with a matching 3" threaded female cap to allow easy access to internal components. The 3" Cap must be modified with a rubber gasket so it will be gas tight.

Electrolysis Cell Design The Electrolysis process in my design is accomplished through a series of 8 sets of stainless steel tubes. Each cell set is made up of a 1/4" tube suspended within a 7/16" tube using 4 x 40 nylon screws. The cells are 12" in length. All 8 cells are connected in parallel to ensure a constant balanced load is maintained. Each of the cells is enclosed within their own submerged 1/2" open ended PVC tube, mainly to encourage cryogenic circulation. The 8 - 1/2" X 14" long PVC tubes fit perfectly within the inside dimension of the 3" ABS containment chamber. The PVC Tubes also ensure that the 8 cells remain properly separated. Oxygen Electrode Preparation The Electrode which corresponds to the Oxygen collection must be Nickel plated to prevent oxidation. To plate stainless steel is somewhat involved and requires several highly toxic chemicals and Acids. According to my plating supplier (Rio Grande of Albuquerque New Mexico), there is a passive oxide on stainless steel that requires the use of a Stainless Steel Activator solution to permit electroplating. I followed there instructions and was successful. I don't recommend this operation though, unless you are well equipped and take proper precautions. Hydrochloric (Muriatic) Acid is required, and is very toxic. Muriatic Acid (available at swimming pool supply centers) emits toxic fumes that are lethal. You must treat it with respect. If you don't plate the stainless steel Anode (Positive), the oxygen generated by the electrolysis process will react with microscopic iron atoms and will foul the electrolyte. The only way I've found to stop it is to "lock in" the impurities by plating. I did some research and found that commercial systems also use Nickel plating for this reason. Electrolysis Process Power Regulation DC power to the cells is regulated using a modified PCM (Pulse Code Modulation) DC Motor speed controller. I was able to obtain an 110Amp MOSFET (Metal Oxide Semiconductor Field Effect Transistor) as a direct replacement to the much lower capacity MOSFET the board is equipped with. The higher capacity MOSFET, along with beefing up the power buss traces on the P.C. board, enables the device to safely regulate the 12 V from 0 - 30 Amps, which the combined cells consume at their maximum load. The speed controller regulates the DC throughput Current by varying the duty cycle input trigger of the MOSFET, using a 10K Potentiometer. The

longer the square wave stays "on" the more current flows through the MOSFET to the load. More current flow equals more gas production. A 30 Amp analog meter is included so that system's current consumption can be monitored. Engine consumption feedback will be used to control the MOSFET, where more engine demand will automatically increase the available current to the cells. As the Engine's RPMs fluctuate, electronics monitoring the Engine's ignition system will interpret whether more or less gas is needed. This is known as "feed back". Chamber pressure "feed back" will also be monitored as an indicator of gas consumption. Normally chemicals would be added to the water to increase its conductivity. This is not necessary in my design because of the close proximity of the tubular Cathode and Anode. The process is further enhanced by the encased nature of the "tube within tube" cell structure.

Electrolysis (input) Power Requirements The efficiency of the system is dependent on how much current is consumed to convert a given volume of water molecules to their base elements. The maximum power consumption of the on-demand system is 30 Amps at 12 volts. In ohms law, power consumption, expressed as Watts, is calculated by multiplying Amperage (I) by Voltage (E) IE: (P = I * E). To make it easy to remember, it has been given the nickname of "pie". In this case, maximum consumption is calculated by multiplying 30 Amps by 12 volts, which equates to 360 Watts. It has not determined as yet what the BTU yield will be for those 360 Watts when they are converted into molecular Energy. The amount of Hydrogen being produced for a given period of time is still to be determined. Energy production processes will need to be translated into scientific formulas for routine analysis. "Energy" output will most likely be expressed as Horse Power, as well as A.C. Wattage minus production requirements. In a perfect world, if a 6000 Watt gas generator were used, subtracting the 360 Watt input production requirement, the remainder would be 5,640 Watts available for utility use. In reality, "real world" losses will need to be considered. It's not known, as yet, exactly how much Hydrogen will be needed to produce 6000 Watts of generator output. This, as well as typical

thermodynamic losses in the generators engine and in the generator itself will be part of the equation. These are all typical "discovery" processes of any developing technology. Electrolyte Level Maintenance Due to the consumption processes of Electrolysis caused by the direct conversion of liquid H2O into H2 and O2 gasses within the cell chamber, an electrolyte monitor & maintainer is necessary. This is accomplished through the combination of a reed switch float device, solenoid input water valve, and a pressurized water reservoir tank. As the water level inside the system lowers, the float magnet engages a normally open reed switch, which energizes the solenoid valve to allow H2O from the reservoir to replace the depletion. As the electrolyte goes up in response, the float rises, disengaging the reed switch which turns off the solenoid valve stopping the flow of H2O. An L.E.D. monitor provides a visual green indication when the system is full as well as a yellow indication when electrolyte is being added. A spring loaded check valve is also needed to prevent reverse flow of contents from the containment chamber back into the water supply tank. The Nalgene water tank has been tested up to 120 PSI. Be sure to use Nalgene's rigid Lexan bottle. The bottle lid must be fused to the bottles opening to maintain an air tight seal. The solenoid coil must have a capacitor installed across its leads to prevent arcing of the float reed switch, and its eventual failure. If a capacitor is not incorporated, the switches contact will "weld" itself together shorting out the switch. Automatic Cryogenic Mixing of Electrolyte Each cell is located within its own 1/2" PVC tube enabling the heat generated by the Electrodes to "chimney effect" from bottom to top. This causes the electrolyte to continually, cryogenically, automatically mix. This prevents "hot spots" and inhibits any impurities in the supply electrolyte from clogging the space between the Cathode and Anode. This process increases reliability that would be more prone to degrade a static, non circulating system. Another positive aspect of the heat generated by the electrolysis process is that warm gas is injected into the combustion chamber, there by making use of the heat energy by the engine. This enhances the efficiency of the Engine by making use of an otherwise wasted by product. Instead of the heat being a problem it actually serves a useful purpose.

If excessive heat does prove to be a problem, heat sink fins can be installed on the outer surface of the ABS chamber. Also, a short piece of 3" aluminum pipe could be fitted around the ABS chamber for this purpose. Gas Drying and Moisture Retention A gas drying apparatus is also required due to the extremely high water content in the gas collection chamber. This is mainly a result of electrical energy acting on the water molecules, causing the temperature and humidity inside the chamber to increase. Unless some kind of moisture retention is designed into the system an unacceptable percentage of electrolytes will be lost through the gas delivery apparatus. This consequence is mitigated by forcing the gas to negotiate a semi permeable clear vinyl tubular chamber which is connected to the H2 and O2 regulator source connections. The input and output of the regulators are tapped for 1/8' pipe thread so gas tight seals can be maintained. The tubing in the apparatus is breached with a series of punctures which allow gasses to escape but restrict the escape of water vapor. This occurs because the tubing is composed of flexible, semi rigid vinyl, which when breached by small puncture holes, operate like tiny moisture inhibiting check valves. The valves function differently depending on which side of the valve the pressure is applied. I classify this as either internal or external source pressure. Since the tubing has semi rigid flexibility, the valves will only allow liquids to pass in one direction, but gasses will pass both ways depending on the internal vs. external pressure differential. The system pressure is either being applied to the internal surface of the tubing, or the outside surface. If the pressure is applied to the inside, the tubing expands in response, thereby pushing gases and liquids indiscriminately through the stretching valves. The valves close when the pressure equalizes. In the gas drying application, the pressure is applied to the external surface to the tubing. Since the pressure is applied to the outside of the tube, the tubing is compressed rather than stretched. This means that the valves are resistant to passing anything but gasses. Water vapor escape is inhibited, ensuring that most of the H2O is retained within the system for eventual molecular division. Gas Collection and Distribution Hydrogen and Oxygen are routed from the system gravitationally by directing the Hydrogen from the top end of the gas collection chamber,

while conversely removing the Oxygen at the lower end. Each of the exit points are equipped with regulators to ensure consistent appropriate pressure is maintained on the consumption side. Fuel Injection When a liquid fuel consuming engine is converted to a gaseous fuel, such as Hydrogen, fuel injection is a must. Gaseous substances must be metered out so they only flow when the intake valve is open to receive fuel. The fuel injection solenoid also prevents fuel from flowing while the engine is not running. Initially I am using a function generator to control the fuel injector relay. Once the parameters are established, a permanent controller will be designed. The point contacts of the engine's ignition cam will be used to control the Injector control board in addition to the consumption demand electronics. The "make-break" action is a direct feedback of the engine's real time operation and will ensure that an appropriate amount of H2 and O2 is supplied to the Engine intake system. ----------------------------------------------------------------------------Parts Suppliers Plumbing Supply 3" ABS female cap- threaded $2.41 each th 994 East 20 Street 3" ABS female cap-slip on $1.51 each Chico, California 95928 Ph: 530-891-1583 Plumbingsupply.com ------------------------------------------------------------------------------------------Part # Grainger.com 1/8" solenoid valve (1A574) $18.52 each 24volt coil for above (3A439) $19.39 each Wholesale only --------------------------------------------------------------------------------------Jameco Electronics PCM DC motor controller kit 1355 Shoreway Drive Part # 127829CK $19.95 each Belmont, California 94002-4100 PH: 1-800-831-4242 110 Amp MOSFET upgrade Jameco.com Part # IRF3205 $2.39 each

Other misc. electronic components can also be obtained from this company, such as: 30 Amp circuit breaker, 30 Amp VU meter, and the float switch. -------------------------------------------------------------------------------------------Weldingmart.com Flashback Arrestor set, torch end 3215 W. Lawrence Street Part # FA-10 $38.00 set Suite "B" Appleton, WI 54914-4274 -------------------------------------------------------------------------------------------Miscellaneous Items: 3 ABS pipe can be obtained for any plumbing supply house. The Nalgene (Lexan TM) water bottle can be obtained from any Big-5 sporting goods store. -------------------------------------------------------------------------------------------Kenyon Donald Williams P.O. Box 1611 Grants Pass, Oregon 97528 Cell Ph: 541-324-3652 ############################################################1

Electrolysis Explained (last updated 6 August 2007)