U.S. patent application number 12/216025 was filed with the patent office on 2009-11-19 for gas generating apparatus.
This patent application is currently assigned to OIL DRUM LIMITED. Invention is credited to Stephen Martin, Darryl Watts.
Application Number | 20090283418 12/216025 |
Document ID | / |
Family ID | 39571310 |
Filed Date | 2009-11-19 |
United States Patent
Application |
20090283418 |
Kind Code |
A1 |
Martin; Stephen ; et
al. |
November 19, 2009 |
Gas generating apparatus
Abstract
A gas generating apparatus for use with an internal combustion
engine, the apparatus comprising a reactor including a housing, at
least one anode and at least one cathode located within the
housing, an electrolyte input and a gas output, wherein the at
least one anode and the at least one cathode are electrically
connected to an electrical energy source; the electrolyte input is
adapted to provide in use a flow of electrolyte such that a
substantially constant volume of electrolyte is maintained within
the reactor; and the gas output is in fluid communication with an
air inlet of the engine, whereby in use the electrolyte is broken
down to a gas in the reactor and the product gas is supplied to the
engine.
Inventors: |
Martin; Stephen; (Kent,
GB) ; Watts; Darryl; (Kent, GB) |
Correspondence
Address: |
FOLEY AND LARDNER LLP;SUITE 500
3000 K STREET NW
WASHINGTON
DC
20007
US
|
Assignee: |
OIL DRUM LIMITED
|
Family ID: |
39571310 |
Appl. No.: |
12/216025 |
Filed: |
June 27, 2008 |
Current U.S.
Class: |
205/464 ;
204/274; 204/278 |
Current CPC
Class: |
Y02T 10/121 20130101;
C25B 15/08 20130101; C25B 9/00 20130101; F02M 25/12 20130101; Y02T
10/12 20130101; C25B 15/02 20130101 |
Class at
Publication: |
205/464 ;
204/278; 204/274 |
International
Class: |
C25B 1/00 20060101
C25B001/00; C25B 9/00 20060101 C25B009/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 14, 2008 |
GB |
0808727.2 |
Claims
1. A gas generating apparatus for use with an internal combustion
engine, the apparatus comprising a reactor including a housing, at
least one anode and at least one cathode located within the
housing, an electrolyte input and a gas output, wherein the at
least one anode and the at least one cathode are electrically
connected to an electrical energy source; the electrolyte input is
adapted to provide in use a flow of electrolyte such that a
substantially constant volume of electrolyte is maintained within
the reactor; and the gas output is in fluid communication with an
air inlet of the engine, whereby in use the electrolyte is broken
down to a gas product in the reactor and the product gas is
supplied to the engine.
2. A gas generating apparatus according to claim 1, wherein the
electrolyte input includes a pump to provide the flow of
electrolyte into the reactor.
3. A gas generating apparatus according to claim 2, wherein the
apparatus further includes an electrolyte vessel located above the
reactor, the electrolyte vessel being in fluid communication with
the electrolyte input whereby the pump is a gravity pump.
4. A gas generating apparatus according to claim 3, wherein the
apparatus further includes an electrolyte reservoir in fluid
communication with the electrolyte vessel, such that the
electrolyte volume in the electrolyte vessel is maintained
substantially constant.
5. A gas generating apparatus according to claim 3, wherein the gas
output is connected to the engine air inlet via the electrolyte
vessel, whereby at least some of the electrolyte entrained within
the gas flow from the reactor is returned to the electrolyte
vessel.
6. A gas generating apparatus according to claim 1, wherein the
apparatus further includes a gas purifier located between the gas
output and the engine air inlet, the gas purifier being capable of
removing residual electrolyte from the gas product.
7. A gas generating apparatus according to claim 1, wherein the
apparatus further includes a cooling system capable of maintaining
the temperature of the reactor within a desired range.
8. A gas generating apparatus according to claim 1, wherein the
apparatus further includes a controller which is adapted to
energise the reactor only when the engine is running.
9. A gas generating apparatus according to claim 1, wherein the
electrolyte is water and the gas product comprises a mixture of
hydrogen and oxygen.
10. A method of generating a combustion-enhancing gas for use in an
internal combustion engine, the method including providing a flow
of electrolyte to a gas generating apparatus according to claim 1
and removing the gas product from the gas output.
11. A method according to claim 10, wherein the electrolyte is
water and the combustion-enhancing gas comprises a mixture of
hydrogen and oxygen.
12. A method of increasing the efficiency of an internal combustion
engine, the method including generating a combustion-enhancing gas
according to claim 10 and introducing the gas into the air inlet of
the engine.
Description
[0001] The present invention relates to gas generating apparatus
for use with internal combustion engines and to methods for
generating a combustion-enhancing gas and for increasing the
efficiency of internal combustion engines.
[0002] It is known that the addition of hydrogen gas to the air
inlet of an internal combustion engine can increase the efficiency
of that engine in terms of the amount of fuel it needs to burn to
generate a given power output. In addition, it is known that
hydrogen can be generated from water by the process of
electrolysis.
[0003] According to a first aspect, the present invention provides
a gas generating apparatus for use with an internal combustion
engine, the apparatus comprising a reactor including a housing, at
least one anode and at least one cathode located within the
housing, an electrolyte input and a gas output, wherein the at
least one anode and the at least one cathode are electrically
connected to an electrical energy source; the electrolyte input is
adapted to provide in use a flow of electrolyte such that a
substantially constant volume of electrolyte is maintained within
the reactor; and the gas output is in fluid communication with an
air inlet of the engine, whereby in use electrolyte is broken down
to a gas product in the reactor and the product gas is supplied to
the engine.
[0004] The present invention generates the product gas and supplies
it directly to the engine. This avoids the need to store
potentially flammable and/or explosive gases, often under pressure,
in the vehicle. The generated product gas is consumed as it is
generated and it is typically maintained as a relatively low
pressure gas between generation and supply to the engine.
[0005] By having a reactor which includes an electrolyte input
providing a flow of electrolyte into the reactor, it is possible to
generate a product gas from the electrolyte at a high flow rate
from a relatively small reactor. For example, a gas flow rate of at
least 3.5 litres per minute of product gas may be generated from a
reactor having a capacity of less than one litre of
electrolyte.
[0006] In addition, the conversion of electrolyte to product gas is
maintained at a substantially constant rate compared with
electrolysis reactors which are only periodically topped up with
electrolyte. In such reactors, the conversion rate of electrolyte
to product gas starts off being relatively high as the anode(s) and
cathode(s) are completely covered by the electrolyte. However, as
the electrolyte is consumed by conversion to the product gas, the
electrolyte level drops and progressively less surface area of the
anode(s) and cathode(s) is available for the electrolytic
conversion process. This results in an approximately exponential
reduction of the conversion rate as the electrolyte fluid level in
the reactor is reduced.
[0007] A further known problem with the electrolysis process is the
build up of heat in the reactor. This can be a significant issue
where the product gas is a potentially flammable or explosive
mixture. The arrangement of the gas generating apparatus as claimed
addresses also this problem. In particular, the flow of electrolyte
into the reactor via the electrolyte input helps to reduce the
temperature build-up within the reactor as relatively cool fluid is
flowing into the reactor.
[0008] As the gas generating apparatus is for use with internal
combustion engines, the electrical power source for the reactor is
conveniently the same as the electrical power source for the
engine. Thus, the power source may be one or more batteries which
typically have an output of twelve or twenty four volts.
[0009] In an embodiment of the invention, the electrolyte input
includes a pump to provide the flow of electrolyte into the
reactor. Optionally the pump is a mechanical pump or a gravity
pump. By the term "gravity pump", it is meant that electrolyte is
urged into the reactor by the action of gravity. Thus, for
embodiments employing a gravity pump, a source of electrolyte is
located above the reactor whereby it has a greater potential
energy. The pump ensures that a suitable flow of electrolyte into
the reactor is maintained.
[0010] Suitably, the electrolyte input pump is a gravity pump and
the apparatus further includes an electrolyte vessel located above
the reactor, the electrolyte vessel being in fluid communication
with the electrolyte input of the reactor. A gravity pump increases
the reliability of the apparatus as there are no moving parts
within a gravity pump to wear or fail. However, a gravity pump
requires that there is sufficient free area in the engine space to
mount the electrolyte vessel above the reactor. If this is not
possible within the space restraints, then a mechanical pump may be
used to provide the electrolyte flow to the electrolyte input of
the reactor.
[0011] The skilled person will appreciate that the term "above"
does not require the electrolyte vessel to be located directly or
immediately above the reactor, but that the electrolyte in the
electrolyte vessel simply must have a greater potential energy than
the electrolyte in the reactor such that the flow of electrolyte
under the action of gravity will be from the vessel to the
reactor.
[0012] In embodiments of the invention as defined anywhere above in
which the apparatus includes an electrolyte vessel and employs a
gravity pump to provide the flow of electrolyte to the input of the
reactor, the apparatus may further include an electrolyte reservoir
in fluid communication with the electrolyte vessel, such that the
electrolyte volume in the electrolyte vessel is maintained
substantially constant. In such an embodiment, the fluid pressure
provided to the electrolyte input by the gravity pump is maintained
substantially constant. In certain embodiments, the apparatus may
include a valve which permits flow of electrolyte from the
reservoir to the vessel when the volume of electrolyte within the
vessel reaches a pre-determined level. The valve may be controlled
by a fluid level detector which is capable of detecting the
electrolyte volume in the electrolyte vessel.
[0013] The product gas generated by the reactor is exhausted via
the gas output. It has been found that the flow of product gas may
have entrained therein a significant proportion of electrolyte. In
view of this finding, embodiments of the invention as defined
anywhere above which include an electrolyte vessel may be adapted
such that the gas output is connected to the engine air inlet via
the electrolyte vessel. In this arrangement, the action of bubbling
the product gas through the electrolyte contained within the
electrolyte vessel removes at least some of the electrolyte
entrained within the product gas flow and returns it to the
electrolyte vessel.
[0014] In order to remove remaining electrolyte from the product
gas flow, the apparatus as defined anywhere above may include a gas
purifier which is capable of removing at least some of the residual
electrolyte from the product gas. The gas purifier is suitably
located between the reactor and the engine air inlet.
[0015] In an embodiment of the invention as defined anywhere above,
the apparatus further includes a cooling system capable of
maintaining the temperature of the reactor within a desired range.
Such a cooling system may include a fan which is arranged to direct
a flow of air over the reactor and/or the electrolyte input. It may
further include one or more temperature sensors which are capable
of sensing the temperature of the electrolyte. The temperature
sensors may form part of a cooling system controller, which is
capable of controlling the operation of the cooling system.
[0016] In a further embodiment of the invention as defined anywhere
above, the apparatus includes a reactor controller which is adapted
to energise the reactor only when the engine is running. This
results in an apparatus that generates the product gas only when it
is needed: a so-called "on demand" system. In such an embodiment,
the problem of storing the product gas or the waste involved by
venting it to the atmosphere is avoided and the reactor generates
only a flow of product gas that is suitable for use in the engine.
The reactor controller may connect the at least one anode and the
at least one cathode to the electrical energy source only when the
engine is running.
[0017] The product gas typically includes hydrogen. As one of the
cheapest and most plentiful sources of hydrogen is water, the
electrolyte is suitably water. In embodiments of the invention in
which the electrolyte is water, the product gas is a mixture of
hydrogen and oxygen.
[0018] In a further embodiment of the invention as defined anywhere
above, the anode and the cathode are metallic plates. Suitably the
reactor contains a plurality of anode plates and a plurality of
cathode plates. There may be an insulating element located between
the anode plates and the cathode plates. The insulator is suitably
formed from a polymeric material.
[0019] The skilled person will appreciate that it is possible to
combine one or more of the optional features defined above in
connection with specific embodiments. Thus, all such combinations
of optional features are included within the scope of the
invention. For example, the term "embodiment of the invention as
defined anywhere above" means the invention as defined in its
broadest sense or as defined in any embodiment thereof.
[0020] According to a further aspect of the invention, there is
provided a method of generating a combustion-enhancing gas for use
in an internal combustion engine, the method including providing a
flow of electrolyte to a gas generating apparatus as defined
anywhere above and removing the gas product from the gas
output.
[0021] The method may include generating a product gas which
includes hydrogen, in which case the electrolyte is suitably water
and the product gas comprises a mixture of hydrogen and oxygen.
[0022] According to a yet further aspect of the invention, there is
provided a method of increasing the efficiency of an internal
combustion engine, the method including generating a
combustion-enhancing gas as defined above and introducing the gas
into the air inlet of the engine.
[0023] An embodiment of the invention will now be described in
detail, by way of example only, with reference to the accompanying
drawings in which:
[0024] FIG. 1 is a schematic cross-sectional view of an apparatus
according to the invention.
[0025] The exemplified apparatus includes a reactor 2, an
electrolyte vessel 4, an electrolyte reservoir 6 and a gas purifier
in the form of a drying unit 8.
[0026] The reactor 2 includes of a plurality of anode plates 12, a
plurality of cathode plates 14 and an insulating plate 16 formed
from a non-conductive polymeric material located between the anode
plates and the cathode plates. FIG. 1 shows three anode plates 12
and three cathode plates 14, but the skilled person will appreciate
that the number of anode and cathode plates is not an essential
feature of the invention.
[0027] The anode plates 12 and the cathode plates 14 have a
rectangular cross section and are made from a suitable electrically
conductive material such as 316 grade stainless steel. Each of the
anode plates 12 are spaced from the neighbouring anode plates 12 by
one or more suitable spacers (not shown) and similarly, each of the
cathode plates 14 are spaced from the neighbouring cathode plates
14 by one or more suitable spacers (not shown). The skilled person
will be familiar with the spacing of anode and cathode plates in
electrolysis reactors and as such, the specific spacing arrangement
will not be described in more detail.
[0028] The anode plates 12 are electrically connected together and
are connected to a positive terminal of a controller 60. Similarly,
the cathode plates 14 are electrically connected together and are
connected to a negative terminal of the controller 60. The
controller 60 is in turn connected to suitable positive and
negative terminals of the electrical power source for the internal
combustion engine, which is typically one or more twelve or twenty
four volt batteries. The controller 60 operatively connects the
anode plates 12 and the cathode plates 14 to the electrical power
source when the engine is running, provided that a "kill" signal
has not been sent to the controller 60. The "kill" signal will be
discussed further below.
[0029] The anode plates 12, the cathode plates 14 and the
insulating plate 16 are housed within a reactor housing 11. The
reactor housing is made from a suitable material, such as a
chemical-resistant polymer (e.g. polypropylene).
[0030] The reactor housing 11 includes an electrolyte input in the
form of an inlet conduit 22 in fluid communication with the
electrolyte vessel 4 and a gas output in the form of an output
conduit 24 which is also in fluid communication with the
electrolyte vessel 4.
[0031] The electrolyte vessel 4 includes a vessel housing 30 formed
using the same polymeric material as the reactor housing 11, the
vessel housing 30 including an electrolyte output port 31, which
opens into the reactor inlet conduit 22; a product gas inlet port
33, which opens into the reactor output conduit 24; an electrolyte
inlet port 35, which opens into a reservoir electrolyte conduit 32;
and a product gas exhaust port 37 which opens into an exhaust
conduit 34.
[0032] The vessel housing 30 also includes an electrolyte level
sensing switch 36, which is operatively connected to an electrolyte
flow control valve 39 located in the reservoir electrolyte conduit
32, a first temperature sensor 38 and a second temperature sensor
40. The first temperature sensor 38 is operatively connected to a
cooling system (not shown) comprising a fan arranged to direct a
flow of air over the reactor 2 and the reactor inlet conduit 22.
The second temperature sensor 40 is operatively connected to the
controller 60.
[0033] The electrolyte reservoir 6 comprises a housing 42 capable
of storing electrolyte 10, an outlet port 41 which opens into the
reservoir electrolyte conduit 32, and a removable cap 44. The
reservoir housing 42 is made from a suitable material, such as a
polymeric material which is inert to the electrolyte 10.
[0034] The product gas drier 8 is a conventional gas drying vessel
and includes an inlet port 51, which opens into the exhaust conduit
34; an outlet port 53, which opens into an engine supply conduit
50; and an electrolyte collection portion 55. As the gas drying
vessel 8 is a component that would be well known to those skilled
in the art, it will not be described in more detail herein.
[0035] The controller 60 controls the operation of the reactor 2.
It is adapted to provide electrical power to the anode plates 12
and cathode plates 14 only when the engine is running. In addition,
it is adapted to interrupt the power to the reactor if the
temperature of the reactor 2, as sensed by the second temperature
sensor 40, increases above a pre-determined value or if there is
insufficient electrolyte in the apparatus. Thus, if the temperature
sensor 40 senses that the temperature within the electrolyte vessel
4 has risen above a pre-defined threshold value, a "kill" signal is
sent to the controller 60, which disconnects the reactor 2 from the
electrical power source, thereby shutting down the reactor 2.
[0036] In use, the reservoir cap 44 is removed and the reservoir 6
is filled with electrolyte 10, which in the case of this example is
distilled water. The electrolyte level sensing switch 36 causes the
electrolyte flow valve 39 to open and electrolyte 10 flows into the
electrolyte vessel 4 via the reservoir conduit 32 and the
electrolyte inlet port 35. The electrolyte 10 also flows into the
reactor 2 via the electrolyte output port 31 and the reactor inlet
conduit 22, and initially the gas output conduit 24. The
electrolyte 10 continues to flow from the reservoir 6 into the
reactor 2 and the electrolyte vessel 4 until the desired level in
the electrolyte vessel 4 is achieved, at which point the
electrolyte level sensing switch 36 causes the flow valve 39 to
close. The reservoir 6 is filled with additional electrolyte 10 and
the cap 44 is replaced.
[0037] When the internal combustion engine is started, the
controller 60 connects the anode plates 12 to a positive terminal
of the engine's electrical power source and the cathode plates 14
to a negative terminal of the electrical power source and the
charged plates 12, 14 cause electrolysis of the water to generate
hydrogen gas at the cathode plates 14 and oxygen gas at the anode
plates 12. The gases generated by the electrolysis process form the
product gas which rises to the top of the reactor 2 and exits via
the gas output conduit 24.
[0038] As the electrolyte 10 is consumed by the electrolysis
process and converted to hydrogen and oxygen gas, fresh electrolyte
10 is introduced into the reactor 2 from the electrolyte vessel 4
by a gravitational force acting on the electrolyte 10 in the
electrolyte vessel 4. This steadily reduces the volume of the
electrolyte 10 in the electrolyte vessel 4 until it reaches a
pre-determined level, whereupon the electrolyte level sensing
switch 36 causes the electrolyte flow valve 39 to open and permit
the flow of electrolyte 10 into the electrolyte vessel 4 from the
reservoir 6 via the reservoir conduit 32 and inlet port 35. Once
the electrolyte level in the electrolyte vessel 4 has been
topped-up from the electrolyte reservoir 6, the electrolyte level
sensing switch 36 causes the flow valve 39 to close.
[0039] This arrangement results in a certain minimum head of
pressure being maintained in the electrolyte vessel 4, which urges
fresh electrolyte 10 into the reactor 2 to replace the electrolyte
10 which has been consumed by the electrolysis process.
[0040] As mentioned above, the product gas, namely hydrogen and
oxygen, flows out of the reactor 2 via the gas output conduit 24.
However, the gas flow has entrained within it a significant volume
of electrolyte. In order to strip at least some of the entrained
electrolyte from the gas flow, the product gas is bubbled through
the electrolyte 10 contained within the electrolyte vessel 4. This
bubbling action removes some of the electrolyte 10 from the product
gas and returns it to the electrolyte vessel 4 for it to be
recycled back into the reactor 2.
[0041] The product gas exits the electrolyte vessel 4 via the
product gas exhaust port 37 and exhaust conduit 34.
[0042] The product gas flows through the exhaust conduit 34 and
into the product gas drier 8 via inlet port 51. The gas drier 8
removes further electrolyte from the product gas and the dried gas
exits the gas drier 8 via the outlet port 53 and the engine supply
conduit 50. The engine supply conduit 50 transports the flow of
product gas to an air inlet of the internal combustion engine (not
shown). The electrolyte removed from the product gas is collected
in the electrolyte collection portion 55 of the drier 8.
[0043] The first temperature sensor 38 senses the temperature of
the electrolyte 10 within the electrolyte vessel 4, which is an
indicator of the temperature within the reactor 2, as the
electrolyte 10 is able to cycle between the electrolyte vessel 4
and the reactor 2. When the temperature sensed by the first sensor
38 reaches a first pre-set threshold value, the temperature sensor
38 causes a cooling fan to generate a flow of cooling air over the
reactor 2 and the reactor inlet conduit 22.
[0044] The second temperature sensor 40 operates as part of a
safety cut-out system. If the temperature of the electrolyte 10
within the electrolyte vessel 4 reaches a second pre-set threshold
value, the controller 60 disconnects the anode plates 12 and the
cathode plates 14 from their electrical power supply, thereby
shutting down the apparatus.
[0045] The electrolyte reservoir is typically sized to contain
sufficient electrolyte to generate the product gas needed for at
least one week's operation of the engine, optionally at least two
week's operation of the engine and suitably at least one month's
operation of the engine.
[0046] The apparatus may further include an electrolyte level
sensor (not shown) located within the electrolyte reservoir which
is capable of indicating to a user how much electrolyte is
contained within the reservoir. The electrolyte level sensor in the
reservoir may be capable of causing a "kill" signal to be sent to
the controller 60 such that the reactor 2 is shut down in the event
that there is insufficient electrolyte in the reservoir to ensure
the safe operation of the reactor 2.
* * * * *