PROCESS AND APPARATUS FOR GENERATING HYDROGEN ENRICHED FUEL

The present invention relates generally to the production of an improved fuel source and particularly to the production of hydrogen enriched fuel for use in internal combustion engines.

DESCRIPTION OF THE PRIOR ART

Currently, the overwhelming majority of internal combustion engines are powered by fossil fuels and in particular derivatives of petroleum, including petrol, diesel and natural gas. Many alternatives for the powering of internal combustion engines have been proposed, including solar energy and ethanol. However, to date there is no viable alternative to fossil fuel products. Moreover, the cost of fuels derived from fossil fuels has increased dramatically in recent times. Accordingly, the efficiency of internal combustion engines is becoming increasingly important.

The present invention seeks to improve the fuel efficiency of internal combustion engines.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a process for generating hydrogen enriched fuel for an internal combustion engine, comprising the steps of: 1. providing a solution of water;

2. separating and removing hydrogen from the water solution;

3. providing a primary fossil fuel source;

4. frothing the fuel; and

5. mixing the removed hydrogen with the frothed fuel.

The present invention therefore provides a process for converting primary fuel (such as petrol, diesel, natural gas, bunker or coal) into a more efficient fuel.

Prior to mixing the fuel with the liberated hydrogen, the fuel is "frothed" by subjecting it to turbulence in order to improve the efficiency of the subsequent mixing step.

When hydrogen saturated fuel formed in accordance with the present invention is introduced into a combustion chamber two processes occur:

1. normal combustion of the fuel; and

2. fusion between the hydrogen and heated nitrogen in the atmospheric air introduced into the chamber.

By using hydrogen saturated fuel the power produced with each combustion cycle is increased and accordingly the fuel required in the combustion chamber to achieve the same power output is reduced compared to conventional fuel sources.

The water solution used for the generation of hydrogen molecules may comprise tap water. By this is meant water which is available directly from a domestic or commercial water supply.

Prior to the hydrogen extraction step the water may be softened. Water may be treated with any substance which lessens its hardness, usually by precipitating or absorbing calcium and magnesium ions. For example, magnesium sulphate may be used as a water softening compound.

When water molecules (H ₂ O) are broken down to produce hydrogen, oxygen molecules are co-produced in the reaction 2H ₂ O ► 2H ₂ +O ₂ In some embodiments oxygen liberated during this reaction is recycled together with the water solution and re-used for the hydrogen generation reaction.

The hydrogen generation step may comprise an electrolysis step in which diatomic hydrogen molecules are dissociated from oxygen molecules. This may be achieved by passing a pulsating direct current (DC) to an anode and a cathode

submerged in a solution of water.

The ratios of primary fuel to hydrogen are important and affect the efficiency of mixing and the level of saturation. In one embodiment hydrogen is mixed with fuel at a rate of 5 ppm per litre.

After the hydrogen enriched fuel is produced it may be delivered directly to an internal combustion engine. Alternatively, the fuel may be stored prior to delivery to an internal combustion engine.

According to a second aspect of the present invention there is provided apparatus for generating hydrogen enriched fuel for an internal combustion engine, comprising; a solution chamber for storing a solution of water; a hydrogen generation chamber for receiving water from the solution chamber and separating and removing hydrogen molecules from oxygen molecules; a fuel frothing means for creating turbulence in a primary fossil fuel; and a mixing chamber for receiving separated hydrogen and frothed fuel to produce hydrogen enriched fuel.

The fuel frothing means is for creating turbulence in fuel prior to mixing with

separated hydrogen. In one embodiment, the mixing chamber includes a perforated tubular structure through which fuel is introduced. As the fuel passes

through the perforations it is subjected to turbulence and this improves the subsequent mixing.

The hydrogen generation chamber may comprise an electrolysis chamber. In this case, water received from the solution chamber is subjected to a pulsating current to break down the water into hydrogen and oxygen molecules. The speed of this reaction and thus the rate of gas production can be controlled by varying the voltage supplied to the electrolysis apparatus.

The apparatus may further comprise a water softening chamber for treating water to form the water solution. Therefore, water can be introduced into the water softening chamber prior to transport to the solution chamber.

The apparatus may further comprise means for re-circulating oxygen molecules together with water solution from the electrolysis chamber back to the solution chamber. When hydrogen is separated and removed from the water solution the remaining solution and co-produced oxygen molecules may be pumped and returned to the solution tank/chamber.

The apparatus may further comprise a catalytic outlet chamber for allowing hydrogen to pass out of the hydrogen generation chamber but preventing the

passage of oxygen.

The apparatus may further comprise a hydrogen collector for purifying hydrogen and storing it prior to transport to the mixing chamber.

The apparatus may further comprise a storage chamber for storing hydrogen enriched fuel from the mixing chamber. Accordingly, enriched fuel leaving the mixing chamber could either be transported directly to an internal combustion engine or to the storage chamber for storage before onward transport to the internal combustion engine.

The apparatus may further comprise a bypass arrangement for causing fuel to bypass the mixing chamber if hydrogen generation fails. If a failure of the hydrogen generation is detected, fuel is not supplied to the mixing chamber but rather is supplied directly into the internal combustion engine, in which case the engine would run at its normal fuel consumption rate.

According to a third aspect of the present invention there is provided an internal combustion engine fuel supply system comprising apparatus for generating hydrogen enriched fuel as described herein.

According to a fourth aspect of the present invention there is provided an internal combustion engine arrangement including a fuel supply system as described

herein.

BRIEF DESCMPTION OF THE DRAWINGS

The present invention will now be more particularly described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a flow diagram illustrating a process for generating hydrogen enriched fuel according to the present invention;

Figure 2 is a schematic diagram of a fuel converter formed according to the present invention;

Figure 3 is a schematic diagram illustrating the electrical components operating in the converter of Figure 2; Figure 4 is a perspective view of a water softening chamber forming part of the converter of Figure 2;

Figure 5 is a perspective view of a solution chamber forming part of the converter of Figure 2;

Figure 6 is a perspective view of an electrolysis chamber forming part of the converter of Figure 2 shown with a cover removed;

Figure 7a is a longitudinal section of a catalytic outlet chamber forming part of the converter of Figure 2;

Figure 7b is a section of the chamber of Figure 7a taken along line X-X; Figure 8 is a section of a hydrogen collector forming part of the converter

of Figure 2;

Figure 9a is a section of a mixing chamber forming part of the converter of Figure 2;

Figure % is a plan view of the mixing chamber of Figure 9a; and Figure 10 shows an internal combustion engine fuel supply system formed according to the present invention.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Referring first to Figure 1 there is shown a process for generating hydrogen enriched fuel generally indicated 10. A water supply 12 provides tap water which is softened with industrial salt 14 in the form of magnesium sulphate to provide a water solution 16.

The water solution 16 is electrolysed at step 18 by subjecting it to a pulsating direct current 20 provided by a variable 12 volt power supply 22.

The result of the electrolysis step 18 is the separation of hydrogen gas 24 and oxygen gas 26.

The oxygen gas 26 is recycled back to the water solution 16.

The hydrogen gas 24 is separated from the water solution 16 and mixed at step 28 with a fossil fuel source 30.

The mixing step 28 results in hydrogen enriched fuel 32. The fuel 32 can either be transported to a storage unit 34 or supplied directly to an engine 36.

Referring now to Figure 2 there is shown a fuel converter apparatus generally indicated 50.

The apparatus 50 generally comprises: a water softening chamber 55; a water solution chamber 60; an electrolysis chamber 65; a catalytic outlet chamber 70; - a hydrogen collection chamber 75; and a mixing chamber 80.

The water softening chamber 55 is provided with a water inlet 56 for receiving a quantity of domestic tap water. The chamber 55 includes a quantity of magnesium sulphate for softening water received from the inlet 56. Softened water exits the chamber 55 from an outlet 57.

The water softening chamber outlet 57 transports softened water into the water solution chamber 60 ready for use. A feed pump 61 transfers softened water from

the water solution chamber 60 into the electrolysis chamber 65 via a one-way valve 62.

Within the electrolysis chamber 65 the water solution is subjected to a pulsating DC current supplied to anode and cathode plates 66 submerged in the chamber 65. A liquid level sensor 67 monitors the amount of water solution in the chamber 65 and maintains the level using the water solution feed pump 61.

The electrolysis of the water solution in the chamber 65 causes the water molecules in the softened water to be broken down into hydrogen and oxygen. The hydrogen and oxygen pass into the catalytic outlet chamber 70. The chamber 70 only allows hydrogen to pass through and oxygen is prevented from escaping through the chamber 70. Oxygen is sent back to the electrolysis chamber 65 where it mixes back into the water solution and is pumped back to the water solution tank 60 via a one-way valve 71 by a return pump 72.

Hydrogen is pumped from the catalytic outlet chamber 70 to the hydrogen collection chamber 75 by a gas pulse pump 73. The hydrogen collection chamber 75 separates hydrogen from any other residual gases which may have been pumped from the electrolysis chamber 65. A pressure sensor 76 monitors the pressure of hydrogen present in the collection chamber 75 and a pressure gauge 76a displays the hydrogen pressure. A pressure release valve 75a is present in the hydrogen collection chamber as a safety feature.

Pure hydrogen gas is fed from the hydrogen collection chamber 75 into the mixing

cylinder 80 via one-way valve 84 at a pressure of approximately 34.47 kPa (5 psi).

Fuel is fed into the mixing chamber 80 through a fuel inlet 85 via a perforated tube 81 within the chamber 80 so that fuel is frothed as it enters the mixing chamber 80. Hydrogen enriched fuel exits the mixing chamber 80 via a fuel outlet 86.

The fuel inlet/outlet arrangement includes a bypass valve 87 which allows fuel to bypass the mixing chamber 80 in the event that hydrogen production fails.

Fuel from the fuel outlet 86 is supplied to the combustion engine fuel pump and to the fuel injection system.

Referring now to Figure 3 there is shown an electrical block diagram for the fuel converter 50 of Figure 2.

The following electrical components are represented: a power supply line 90; a voltage qualifier 91 ; a mini controller 92; water solution feed and return pump 93; - water solution feed and return solenoids 94; pressure switch 95; gas detection switch 96;

temperature gauge 97;

electrolysis chamber power supply card 98;

electrolysis chamber power supply 99; transducer 100; electrolysis chamber liquid level sensor 101; gas pulse pump power supply 102; and - bypass switch power supply 103.

Referring now to Figure 4 there is shown in more detail the water softening chamber 55. The chamber 55 comprises a generally parallelepiped body 55a including a water inlet 56 and a water outlet 57 in the same top wall. The approximate dimensions of the tank 55a are shown.

Referring now to Figure 5 the water solution chamber 60 is shown in more detail. The chamber 60 comprises a generally parallelepiped body 60a. The chamber 60 has a softened water inlet 63 in one side wall and a softened water outlet in the opposite side wall.

Referring now to Figure 6 the electrolysis chamber 65 is shown in more detail. Chamber 65 comprises a generally parallelepiped body 65a which in this embodiment is formed as a hard plastic casing. The body 65 is shown with a cover removed to reveal the internal components. The body 65 houses a cathode in the form of two rectangular plates 66a, 66b and an anode in the form of two

rectangular plates 66c, 66d, A softened water solution inlet 68 and a solution

return outlet 69 are provided at opposite ends of a side wall of the body 65 a. A gas outlet 69 is provided in a top wall of the body 65 a.

Referring now to Figures 7a and 7b the catalytic outlet chamber is shown in more detail. The chamber comprises a cylindrical copper casing 74a which houses a cylindrical body of aluminium mesh 74b. One end of the chamber 70 connects to the gas outlet 69 of the electrolysis chamber 65, the other end connects to the oneway valve 84.

Referring now to Figure 8 the hydrogen collection chamber 75 is shown in more detail. The chamber 75 comprises a generally cylindrical body 75a. The body houses a magnesium membrane 78 which receives gas from the catalytic outlet chamber through an inlet 77a. Purified hydrogen gas exits the chamber 75 through an outlet 77b. The chamber 75a includes a valve 79 which functions both as pressure release valve and a water dispersant valve.

Referring now to Figures 9a and 9b the mixing chamber 80 is shown in more detail. The chamber 80 comprises a generally cup-shape body 80a which is capped by a Hd 83. The lid 83 provides a gas inlet 82, a fuel inlet 85 and a fuel outlet 86.

The fuel inlet 85 leads to a tubular fuel conduit 81 which includes a plurality of holes 81a which allow fuel to pass from the tube 81 into the interior of the chamber

80 where it can mix with hydrogen. The lid 83 further comprises a pair of

mounting holes 83 a.

Referring now to Figure 10 there is shown a fuel supply system generally indicated

150. The system 150 includes a micro controller 192 for controlling the operation of the system. A water solution chamber 160 feeds softened water into an electrolysis chamber 165 using a feed pump 161. The hydrogen liberated in the electrolysis chamber 165 is fed through a catalytic supply line (not shown) to a hydrogen collection chamber 175. The collection chamber feeds pure hydrogen into a mixing chamber 180. Fuel from a vehicle fuel tank is supplied to a frothing cylinder 181 which in this embodiment is external to and separate from the mixing chamber 180. Frothed fuel is fed into the mixing cylinder 180, where it mixes with the pure hydrogen before the hydrogenated fuel is delivered to the vehicle fuel pump.

Testing of the fuel supply system utilising the process and apparatus in accordance with the present invention has resulted in significant increases in fuel efficiency, as shown below in Tables 1 and 2.

Table 2

* ^■ * ^• Normal fuel consumption value

* Data subject to evaluation

Nh2 - A fuel supply system in accordance with the present invention

As will be readily apparent to those skilled in the art, the present invention may easily be produced in other specific forms without departing from its scope or essential characteristics. The present embodiments are, therefore, to be considered as merely illustrative and not restrictive, the scope of the invention being indicated by the claims rather than the foregoing description, and all changes which come within therefore intended to be embraced therein.