Hydrogen and oxygen gases, produced on demand by electrolysis, as a partial hybrid fuel source for internal combustion engines

Abstract

A process encompassing hydrogen and oxygen gases as a partial fuel source when utilized together with a fossil-based fuel to power conventional internal combustion engines. Hydrogen and oxygen gases are produced by electrolysis in an electrolyser unit(s), on-demand and on-board a vehicle, or in stationary applications, eliminating the need of highly-pressurized hydrogen storage tanks When said gases are introduced into the combustion chamber of the engine, via the air intake assembly, they increase the efficiency of the combustion burn by enriching the air to fuel ratio, resulting in a reduction of the fossil-based fuels required for optimum engine performance, said gases effectively becoming a partial hybrid fuel source. The process includes scalability for all size and types of installations, cold-weather applications and longer operating capabilities. As an additional benefit, in direct correlation, this process reduces carbon dioxide emissions, and, in varying quantities, other greenhouse gas emissions.

1 : Consists of a method of use of an apparatus referred to as a hydrolyser unit, for the production of hydrogen and oxygen gases by means of electrolysis and subsequent delivery system, of the resulting hydrogen and oxygen gases, to be installed into the air intake system of existing internal combustion engines, for use as a partial fuel source when added to the fossil-based fuels used in the operation of any internal combustion engine in applications such as in motor vehicles or stationary applications, which use internal combustion engines, such as stationary electrical generating stations (Gen-Sets), the hydrolyser unit and delivery system comprised of:
 a hydrolysis chamber, the hydrolysis chamber being a cubicle enclosure functioning as a containment module, fabricated in a plastic-based compound, and compatible with an electrolytic solution, constructed in scalable and proportional sizes and formats so as to accommodate installation for end-use requirements, having a removable access panel in order to perform regular maintenance of the internal plate assemblies, other internal components and maintenance of the electrolytic solution;   a water-based electrolytic solution comprised of steam distilled water, demineralised water or regular municipally-supplied tap water, together with an electrolytic agent such as potassium hydroxide, to activate the process of electrolysis, when a direct current (DC) electrical charge is introduced, the electrolytic solution acting as a catalyst for the electrolysis process; the electrolytic solution partially filling the hydrolyser containment module so as to cover the internal plate assemblies to maximize production of hydrogen and oxygen gases, and such that the hydrogen and oxygen gases formed shall have adequate space above the level of the electrolytic solution within the hydrolyser module, for dissemination into a tube located at the uppermost section of the hydrolyser module, for delivery of the hydrogen and oxygen gases into the air intake system of the internal combustion engine;   one internal plate assembly or multiple internal plate assemblies, consisting of individual metallic-based plates, such that the individual plates are interconnected in a manner that allows one or multiple positive-charged anode and negative-charged cathode electrodes to be installed to the plate assemblies; positioning of the inter-connecting plates, one positively charged and one negatively charged plate, intermittently, so that the total number of individual plate configuration accommodates the scalable and size requirements of the particular installation; these intermittent plates so placed as to create a space between the alternately placed positive-charged anode plates and negative-charged cathode plates forming a cell assembly, allowing for the process of electrolysis to separate the hydrogen and oxygen gas molecules and atoms from the water content of the electrolytic solution, when the anode and cathode electrodes are fully or partially submerged in the electrolytic solution; the plate assemblies consisting of a minimum of one anode and one cathode charged metallic plate and a maximum number of multiple anode and cathode charged plates in proportion to the scalability for the end-use requirement, and such that when multiple and separate plate assemblies are used, the positive and negative electrodes are inter-connected in series, with the two main electrodes, one positive and one negative, being connected directly to the main electrical DC source ;   one or more internal plate assemblies are secured to the sides or top of the hydrolyser containment module as determined by the size, scalability and end-use; the internal plate assemblies held together by highly, electrically conductive bolts which are also used as the anode and cathode posts, so as to provide a continuous flow of intermittent positive and negative current through all the plates forming each assembly, and further secured by one or multiple, non-conductive plastic-based bolts, spacers and nuts which secure the required number of plates which form the complete internal plate assembly;   one or more splash guards within the containment module;   a commercially available pressure release valve;   a commercially available liquid-level sensor with a remote light signal conveniently located to alert the user when the level of hydrolytic solution has reached the critical level at the top of the plate assembly or plate assemblies inside the hydrolyser containment modules; in applications, where water reservoirs are installed, the liquid-level sensor with a remote light signal is installed on the reservoir, alerting the user when the system requires additional water;   in certain applications, a system incorporating two separate commercially available float switches are installed on the interior walls inside the hydrolyser containment module and used to maintain a safe hydrolytic solution level, where one valve is activated when the hydrolytic solution reaches a critical low level, activating the water from the central reservoir to flow into the hydrolyser containment module, the other float sensor used to signal the stoppage of the flow of water from the reservoir into the hydrolyser unit; this process incorporating a solenoid valve that is set to open or close when receiving a signal from the float switches;   a direct current (DC) electrical charge, either originating from the vehicle's own battery or from an auxiliary and independent DC electrical source such as a second battery used exclusively to provide the necessary voltage and amperage to the plate assemblies within the hydrolyser module, this auxiliary battery being recharged by the vehicle's alternator, and which battery is fully charged, maintained and controlled by a commercially available battery isolator that is required when charging multiple batteries from a single alternator; the electrical charge required for the process of electrolysis, either originating from the vehicle's own battery or from the secondary auxiliary battery to be used with a commercially available relay switch so as to generate electrical power to the hydrolyser only when the engine is actually operating; the relay required in certain applications when using a DC to DC converter (hereinafter referred to as a power supply pack); or when connecting the hydrolyser units, in series, directly to the electrical source without the use of a power supply pack, the relay connected to a start signal, such as an oil pressure switch or ignition switch within the vehicle or Gen-Set, and utilized as a signal to start the electrolysis process only when the engine is running; the relay and accompanying fuse link apparatus serving as a safety precautions to ensure hydrogen and oxygen production only when the engine is running;   wherein the hydrolyser unit is powered by a constant DC current in specific applications and controlled by a power supply pack; and, in certain applications, the electrical output as controlled by the power supply pack, adjusted automatically, dependent on the speed of the vehicle as dictated by the RPM's of the engine, thereby increasing or reducing the amount of hydrogen and oxygen gases used as a partial fuel source when these gases enter into the combustion chambers, directly adjusting, and in proportion, reducing the amount of fossil fuels required for the operation of the internal combustion chamber;   in certain larger-scale applications and installations, where very high levels of hydrogen and oxygen gas output is required, the use of multiple hydrolyser containment modules containing one or multiple internal cell assemblies, or where a single hydrolyser containment module with multiple internal cell assemblies are incorporated into a single containment module, then the anode and cathode posts of each internal cell assembly are connected in series, this procedure eliminating the need for power supply packs to control the step-down and step-up current functions normally provided by the power supply pack, thereby allowing a direct connection of the anode and cathode posts directly to the battery but protected by a fuse link apparatus;   in larger-scale applications and installations, such as class 4 to class 8 trucks and buses, locomotives, large boats, and in stationary applications such as Gen-Sets, the system employs a separate additional water reservoir to allow for extended operation of the hydrolyser, the reservoir constructed from a plastic-based compound or in a metal such as stainless steel, in either single-wall construction for warm-climate applications or in double-walled insulated construction for use in cold-climate applications; this reservoir containing a sufficient supply of water for extended operations, as calculated by the projected consumption of the water content in the hydrolytic solution and in consideration of the number of internal cell assemblies; this water transferred into the hydrolyser containment module via a plastic-based tube connected from a discharge outlet via a fitting in the reservoir to a connection at the top entry point of a gravity-based, mechanical, float-operated valve, from which water disperses into the hydrolyser unit, this system delivering water so as to maintain a pre-determined and sufficient level of hydrolytic solution, that continuously covers the plate assemblies; the mechanically operated valve constructed in a plastic-based compound compatible with the electrolytic solution; the system further consists of either a screw or ratchet type tube clamp apparatus, an apparatus using a screw or wheel to squeeze the sides of the tube together, the tube located between the reservoir and the top of the valve in order to mechanically lower the water pressure, leaving only a minute opening for the water to flow through from the reservoir into the valve; this, further regulates the gravitational flow of water from the reservoir into the hydrolyser containment module, in a manner similar to that of a medical intravenous feed, whereby, for example, when one drop of water content of the hydrolytic solution is consumed in the electrolysis process, one drop of water will be released into the containment module from the reservoir, this pre-regulated, at a rate approximately equal to the decreasing consumption rate of the water content of the hydrolytic solution during the process of electrolysis, with the water from the reservoir being released into the hydrolyser unit at approximately the same rate, allowing for a constant level of hydrolytic solution being maintained in the hydrolyser containment module and further maintaining a constant level of concentration of hydrolytic agent within the hydrolytic solution, since the process of electrolysis consumes only the water content within the hydrolytic solution and whereby the hydrolytic agent is not consumed in the electrolysis process, thereby, by adding water, as required to maintain the pre-determined level to the hydrolytic solution, the concentration level will also remain constant ;   in certain applications, and more specifically, in installations under the hood of vehicles or on class 4 to class 8 truck frames, or on the tailpipe support bracket, and in certain applications such as refrigerated truck trailers, where an auxiliary reservoir is not possible, the hydrolyser containment module is constructed in such a size, scale and format as to allow for additional, pre-mixed hydrolytic solution, to be included in the containment module, requiring an adjustment of the concentration level of the electrolytic agent, in effect, lowering the percentage of the concentration level, in a sufficient quantity, to accommodate the additional water supply, but to allow for the maximum output of hydrogen and oxygen gases, and to further allow sufficient concentration of the hydrolytic agent in the hydrolytic solution so as not to freeze in cold-climate applications; this process allowing for the lowering of the level of hydrolytic solution as the process of electrolysis takes place, effectively resulting in a higher concentration of the hydrolytic agent as the water content of the hydrolytic solution is consumed and lowered, this increases the concentration of the hydrolytic agent, therefore, the pre-mixing of the concentration level of the hydrolytic agent is pre-calculated so as not to increase the maximum concentration of hydrolytic solution to higher than required levels; in this format, the hydrolyser module contains the necessary plate assemblies, the additional space to accommodate the extra hydrolytic solution effectively acting as a self reservoir, a self-contained moisture collector and discharge system of the moisture and hydrolytic agent back into the hydrolyser module, internal splash guards, and eliminates the need for power supplies in specific applications most notably, when an independent battery DC electrical source is utilized;   consisting of an atmospheric water recovery system based on the process of dehumidification, whereby the moisture, in the surrounding warm atmosphere of the dehumidification apparatus, said moisture would be extracted from the surrounding air mass and said moisture would accumulate in a self-contained reservoir, thereby providing a continuous supply of water into the hydrolyser containment modules, this system including the mechanical, gravity-based, automatically-operated valve and pre-determined feeder tube and further controlled by a tube clamp apparatus; this system employing an automatic shut-off valve within the dehumidification apparatus, so as not to cause an overflow of water produced from the dehumidification process, essentially, this process used in larger applications such as locomotives, large boats and Gen-Sets;   where a single or double-walled reservoir is utilized, heating of the water in cold-climate temperatures is necessary to prevent or unfreeze the water, this by diverting the vehicle's anti-freeze or coolant from the radiator system through an auxiliary heater tank unit constructed of a highly conductive metal, and which, through a combination of a conductive and convective heat transfer process, will heat the sides of the reservoir that are in direct contact with the sides of the heater tank unit, which contains a steady flow of heated radiator coolant flowing through the heater unit, constructed with an internal, baffle-type maze of separators inside the heater tank unit, allowing the coolant to flow freely from an exit point within the coolant system of the vehicle into an entry point in the heater unit by a high-heat resistant tubing and fitting, and then returned back into the main coolant cycle of the vehicle via an exit point from the heater unit, via a high-heat resistant tubing and fitting;   where a single or double-walled reservoir is utilized, and heating of the water in the reservoir in cold-climate temperatures is necessary to prevent or unfreeze the water, this, by diverting part of the vehicle's own exhaust from the vehicle's main exhaust tailpipe pipe, by inserting an adjustable, metal based, sleeve-type apparatus, in the portion of tailpipe between the engine and the muffler; this apparatus having a lever, adjustable by hand, as required for use in cold-climate conditions, for maintaining an open or closed position, of a semi circle-shaped divider, which fits inside the circumference of the interior of the tailpipe, effectively having the capability of diverting approximately half or the desired amount of flow of exhaust from the engine; when the lever is set in a fully open position, this process will then allow the hot exhaust gases to flow freely from the engine, through the lower exhaust pipe, through the sleeve-type apparatus, through the muffler and subsequently into the atmosphere from the open end of the tailpipe; when the lever is set in a close position, it will close off half or less of the opening in the tailpipe, allowing only a partial flow of hot exhaust into the atmosphere, while the other half, or less, will be diverted through a tube, fitted to the lower part of the sleeve-type apparatus, below the level of the half-circle divider, the hot exhaust partially being diverted into the heater unit, circulating through the interior baffle construction and exiting from an exit position into a tube connected to the upper portion of the sleeve-type apparatus, above the level of the half-circle divider, returning the hot exhaust gases back into a re-entry point in the sleeve type apparatus and into the exhaust pipe; through conductive heat transfer and convective heat transfer, the heat generated from the heater unit walls, which are in direct contact with the reservoir walls, will cause the water stored in the reservoir to melt when the vehicle is running and in operation;   a spiral-type arrangement of highly heat-conductive metal strips arranged in such a manner as to coil around the exhaust pipe or the engine manifold, depending on the location of the installation, both of which are sources of free heat, with the other end of the multi-strip metallic coil arrangement, which strapped directly around the reservoir unit so as to keep the water in the reservoir from freezing or to melt the water by conductive heat transfer;   where an AC current from a plug-in source is readily available such as is the case when trucks are normally parked and not operating, a block heater unit inserted into the reservoir, so as to keep the water from freezing when the vehicle is parked and an AC plug-in current is available;   consisting of a dust-filtering attachment to a main box-type container constructed in weather-resistant diamond plate aluminum or a high impact plastic composite, this container used to store all the major components of the system to further protect parts of the delivery system from the weather, and to prevent dust and road dirt from penetrating the components of the hydrolyser containment module and other components including electrical connections and in certain applications, the power supply packs; this box-type container similar to a saddle-type battery or storage boxes, or cylindrical air filter type enclosures that are normally attached to the frame of a truck, these containers also constructed in a format to fit onto the muffler bracket of a class  8  truck where installations warrant;   a gas relay device, when multiple hydrolyser units are used in certain applications, allowing the hydrogen and oxygen gases being generated to be introduced, via tubular connections and fittings, from multiple hydrolyser units into a single container type apparatus, which also contains moisture filtering materials and stainless steel shavings used as a spark or flame arrestor, and thereafter, having one or more exit points for re-diverting the hydrogen and oxygen gases to the engine's air intake assembly with increased pressure;   a manually dischargeable moisture collector device containing a filtering substance to prevent moisture and hydrolytic agent contamination from entering the tubing leading to the air intake system, a cluster of stainless steel shavings inserted into the device to act as a spark or flame arrestor, a two-ended nipple connector with drain holes in the part that screws into the moisture collector device; this device installed directly, via the nipple connection, to the top of the hydrolyser containment module and serving as the exit point for the hydrogen and oxygen gases while trapping the moisture and hydrolytic agent contaminant, and subsequently allowing the moisture and contaminant to flow back into the containment module through the drain holes; this device used, where adequate space is available for installation of the system; where space does not permit the device to be attached directly to the top of the containment module, the moisture collector device may be installed and secured in a separate position above the containment module with an adequate length of tubing connected to a fitting at the bottom of the device and to a fitting on the top of the containment module, effectively allowing the hydrogen and oxygen gases to flow into the device and causing the moisture and any contaminant from the hydrolytic agent to be trapped in the filter substance and causing the moisture and contaminants to flow back into the containment module by the force of gravity but allowing the hydrogen and oxygen gases to flow freely through the moisture collector device and into an exit tube; the moisture collector having an exit valve at the top of the device for the hydrogen and oxygen gases to be diverted to the air intake assembly of the internal combustion engine by a length of tubing;   a modification of the resistances on the vehicle's computer so as to allow for a leaner air to fossil-fuel mix by adjusting the vehicle's oxygen sensors and timing of the vehicle's fuel injector opening and closing sequences, allowing the hydrogen and oxygen gases to enter into the combustion chambers and become a partial fuel source;   a cluster of computer-based sensors capable of measuring the various Greenhouse Gas emissions as well as particulate matter, nitrous oxides and sulphur oxide emissions being generated by the burning of fossil fuels; this cluster of sensors installed in strategic locations on vehicles and stationary applications, to identify, qualify and quantify the emissions for the purpose of trading credits; all monitored and measured by an onboard computer and stored on a disc; or by an outside central computer with the collected data having been stored on a disc and then downloaded into a central computer.   
   
   
       2 . The apparatus and gas delivery system of  claim 1  encompasses a hydrolyser unit capable of sizing scalability of a cubicle containment module constructed, preferably of polypropylene co-polymer plastic, but not limited to, in scaled-down or scaled-up size formats suitable for installation in small or large applications, for example, from riding lawn mowers, to fork-lifts, to cars, vans, pick-ups, SUVs, to Class 8 trucks and buses, to locomotives, to boats, to Gen-Sets; in square, rectangular, cylindrical or variable shapes, as required. 
   
   
       3 . The apparatus and gas delivery system of  claim 1  includes a hydrolytic solution wherein the electrolytic agent is either potassium hydroxide, sodium bicarbonate or sodium hydroxide mixed with steam distilled water, or demineralised water or municipal tap water, at concentration levels of between 15% to 30% by volume of electrolyte to water content. 
   
   
       4 . The apparatus and gas delivery system of  claim 1  wherein the internal plate assemblies utilize type 304 or 316 stainless steel plates in solid flat, perforated, linear serrated or textured surfaces or plates with a surface baked ceramic-based compound containing stainless steel particles, in order to increase the plate surface without increasing the plate size to effectively produce higher levels of hydrogen and oxygen gases. 
   
   
       5 . The apparatus and gas delivery system of  claim 1  encompasses splash guards constructed of perforated or solid plastic based panels together with a rubber based perforated membrane inserted inside the hydrolyser containment modules over the plate assemblies to prevent or lower the amount of bubbles, formed by the agitation of the molecules of hydrogen and oxygen gases being produced through the electrolysis process, from entering into the gas delivery tubes. 
   
   
       6 . The apparatus and gas delivery system of  claim 1  comprising an auxiliary and independent power source using a separate 12 volt or 6 volt battery and battery isolator for recharging the independent battery, this system utilized in certain larger-scale applications eliminating the use of the vehicle's own battery. 
   
   
       7 . The apparatus and gas delivery system of  claim 1  using a DC to DC power supply pack as required in certain applications, is manufactured in such a manner as to supply the necessary electrical power to regulate the production capacity of the hydrogen and oxygen gases in relation to the RPM and speed of the vehicle when idling or when cruising at high speeds. 
   
   
       8 . The apparatus and gas delivery system of  claim 1  requiring high levels of hydrogen and oxygen gases in certain larger-scaled applications such as class 8 trucks or Gen-Sets, encompasses the use of multiple hydrolyser containment modules interconnected in series, and containing a high-gas output cell assembly or assemblies, or a single hydrolyser containment module incorporating multiple cell assemblies, all hydrolyser units connected in series; either format eliminating the use of power supply packs. 
   
   
       9 . The apparatus and gas delivery system of  claim 1  wherein single or double-walled, manually filled water reservoirs are installed and used to extend usage of the hydrolysis process in warm climates, or, in cold-weather climates, incorporating a heating system to melt frozen water or keep the water from freezing by using heating systems based on a convective and conductive heat transfer process incorporating the vehicle's own anti-freeze system or exhaust system; a heated coil system or block heater. 
   
   
       10 . The apparatus and gas delivery system of  claim 1  wherein an atmospheric water recovery system using a dehumidification process is used to automatically fill the hydrolyser containment module. 
   
   
       11 . The apparatus and gas delivery system of  claim 1  encompasses a hydrolyser containment module constructed in a format that allows for storage of additional hydrolytic solution, in lower concentration levels, for extended operations thereby eliminating the need for an additional reservoir, heating system and power supply and incorporating internal splash guards and built-in moisture collector and moisture return for applications on refrigerated trailers or truck tractors. 
   
   
       12 . The apparatus and gas delivery system of  claim 1  incorporates a valve constructed in a plastic-based compound using gravity to transfer water from the reservoir into the hydrolyser containment module, the valve using a float within its casing and a tube clamp apparatus to reduce the water pressure effectively filling the hydrolyser at the same rate as the water content of the hydrolytic solution is being depleted in the process of electrolysis. 
   
   
       13 . The apparatus and gas delivery system of  claim 1  includes a dust filtering unit utilizing a panel and filtering material attached to the sides of the main box-type container to prevent dust and road dirt in contaminating the system components enclosed. 
   
   
       14 . The apparatus and gas delivery system of  claim 1  utilizes a gas relay device, being a plastic based module with multiple fittings that serve as entry points of the hydrogen and oxygen gases being produced by the individual hydrolysers, including filters and flame arrestor incorporated inside the module and having one or more gas exit points with smaller fittings thereby increasing the pressure of the outgoing gases. 
   
   
       15 . The apparatus and gas delivery system of  claim 1  incorporates a manually dischargeable moisture collector unit, the unit being a plastic-based module that contains a filtering substance and a flame arrestor, this module serving as an exit conduit for the hydrogen and oxygen gases while trapping moisture and hydrolytic agent contaminant, potassium hydroxide powder for example, and causing the moisture to flow back into the containment module. 
   
   
       16 . The apparatus and gas delivery system of  claim 1  utilizes a modification of the vehicle's computer by adding a resistance to the main vehicle computer effectively lowering the time lapse of the injector opening and closing resulting in a leaner fossil fuel to air mix and less fuel entering the combustion chamber, with the hydrogen and oxygen gases being a partial fuel source. 
   
   
       17 . The apparatus and gas delivery system of  claim 1  includes a cluster of emission measuring sensors capable of measuring and monitoring emissions in certain applications of the system in order to qualify for carbon credits.