Hydrogen rich gas generator

Abstract

A method of improving the efficiency of continuous water electrolysis processes to produce a hydrogen rich gas. Improved efficiency is realized by minimizing and/or eliminating wasted current, current that does not convert water to a hydrogen rich gas, attaining approximately 100% Faradic efficiency. This improvement in current or Faradic efficiency is attained by electrically isolating the electrolyte solution contained in each electrolysis cell as well as electrically isolating the electrolyte solution contained in each cell from the supply of electrolyte solution. This invention also improves the efficiency of water electrolysis processes through the utilization of electrodes coated with electrode specific nanomaterials, improving voltage efficiency at current densities exceeding 100 mA/cm 2 . Overall efficiency improvements of about 20% have been obtained with the present invention over other hydrogen rich gas generators. The hydrogen rich gas produced by this invention is comprised of hydrogen, oxygen, and water.

1 . An electrolyzer generator apparatus for making a hydrogen rich gas comprising hydrogen, oxygen and water, said apparatus comprising:
 a generator enclosure comprising means for containing an electrolyte solution and a lid covering said enclosure, said enclosure configured to contain one or more electrolyzer assemblies, said enclosure further containing means for holding a supply of electrolyte solution wherein said electrolyte solution within said supply portion is physically separated from said one or more electrolyzer assemblies;   each of said one or more electrolyzer assemblies comprising two primary electrodes and zero or one or more secondary electrodes, each of said electrodes being made from a conductive material and separated from respective adjacent electrodes by an insulating material comprising an insulating separator constructed so as to allow an electrolyte solution used within said apparatus to overflow without mixing between adjacent cells formed between respective adjacent electrodes;   means for pumping said electrolyte solution from said supply portion to each of said one or more electrolyzer assemblies;   means for supplying a DC current circuit to said one or more electrolyzer assemblies; and   means for supplying electrical power to said means for pumping said electrolyte solution from said supply portion to each of said one or more electrolyzer assemblies.   
   
   
       2 . The apparatus according to  claim 1 , wherein said means for containing an electrolyte solution is comprised of a lower portion of the generator enclosure. 
   
   
       3 . The apparatus according to  claim 1 , wherein said means for containing an electrolyte solution is comprised of a separate electrolyte tank. 
   
   
       4 . The apparatus according to  claim 1 , wherein said means for holding a supply of electrolyte solution is comprised of a lower portion of the generator enclosure. 
   
   
       5 . The apparatus according to  claim 1 , wherein said means for holding a supply of electrolyte solution is comprised of a separate electrolyte tank. 
   
   
       6 . The apparatus according to  claim 1 , wherein said insulating separators are configured to have alternating high and low heights between adjacent electrodes and between adjacent cells. 
   
   
       7 . The apparatus according to  claim 1 , wherein said insulating separator separating said respective adjacent electrodes is U-shaped with one end being higher than an opposite end of said insulating separator. 
   
   
       8 . The apparatus according to  claim 1 , wherein each of said one or more electrolyzer assemblies are removably attached to an underside of said lid and configured such that a bottom of said one or more electrolyzer assemblies is separated from a top level of said electrolyte solution within said supply portion. 
   
   
       9 . The apparatus according to  claim 1 , wherein each of said one or more electrolyzer assemblies are disposed on a bottom of said housing such that said insulating material further physically separates said electrodes and cells within said one or more electrolyzer assemblies from said electrolyte solution within said supply portion. 
   
   
       10 . The apparatus according to  claim 1 , wherein said electrodes are coated with electrode specific nanomaterials to improve voltage efficiencies at current densities exceeding 100 mA/cm 2 . 
   
   
       11 . The apparatus according to  claim 1 , wherein an active area of a hydrogen producing side of each electrode is coated with a catalytic material comprising nickel and iron nanoparticles. 
   
   
       12 . The apparatus according to  claim 1 , wherein said means for pumping said electrolyte solution from said supply portion to each of said one or more electrolyzer assemblies comprises a submersible pump located within said supply portion or an external pump located outside said generator housing said submersible pump or external pump being in fluid communication with said electrolyzer assemblies. 
   
   
       13 . The apparatus according to  claim 1 , wherein a flow from said supply portion of said electrolyte solution to said electrolyzer assemblies is a predetermined pulsed stream or a continuous stream of said electrolyte solution directed to each electrolyzer assembly. 
   
   
       14 . The apparatus according to  claim 1 , wherein said means for supplying a DC current circuit to said one or more electrolyzer assemblies comprises a constant current source for supplying DC power to said primary electrodes. 
   
   
       15 . The apparatus according to  claim 8 , wherein when said flow is pulsed stream, said apparatus further comprises a low level sensor between adjacent electrodes for activating said pulsed stream and a high level sensor between adjacent electrodes for stopping said flow of said pulsed stream.