Innovative Engine Modification System for Hydrogen Generation

Introduction

This project introduces a revolutionary modification for atmospheric gasoline engines, aimed at enhancing power and combustion efficiency through on-board hydrogen generation. It eliminates the need for external hydrogen storage by producing hydrogen directly within the engine using steam reforming and thermolysis. The system features a reactive plate positioned in the intake manifold before the throttle valve, acting as a catalyst for these processes. Inspired by decades of engine technology experimentation, the project is open-source, inviting collaboration from engineers, researchers, and enthusiasts.

Technical Specifications and Design

The system is designed to efficiently utilize exhaust heat and automatically regulate liquid dosing (water and gasoline) based on airflow and plate temperature. Key components include:

• Reactive Plate
  • Material: Alloy of nickel (80%), chromium (15%), and platinum/rhodium (5% Pt/Rh) for high-temperature resistance and catalytic properties.
  • Location: Intake manifold before the throttle valve, in a narrowed section to leverage the Venturi effect.
  • Design: Expanding conical shape following the narrowed section, maximizing contact with atomized mist and slowing airflow for better droplet deposition.
  • Heating: Specialized stainless steel 316L exhaust manifolds transfer heat via the shortest path, achieving 100–800 °C.
  • Function: Catalyzes steam reforming (above 700 °C) and water vaporization (100–700 °C).
• Liquid Dosing
  • Mechanism: Two nozzles (capillaries) with fine apertures in the narrowed intake section, utilizing the Venturi effect for liquid suction.
    • Water Nozzle: Active from 100 °C, aperture 0.1–0.3 mm for fine mist formation.
    • Gasoline Nozzle: Active above 700 °C, aperture 0.3–0.5 mm to accommodate gasoline’s viscosity.
  • Regulation: Dosing is automatically controlled by airflow velocity in the narrowed section:
    • Low Load: Slow airflow limits liquid suction.
    • High Load: Fast airflow increases suction, matching engine needs.
  • Temperature Activation: Water nozzle activates from 100 °C, gasoline nozzle from 700 °C, controlled by heat-sensitive valves or bimetallic strips.
  • Nozzle Orientation: Aerodynamically shaped and angled to optimize atomization and direct mist toward the reactive plate.
• Thermal Insulation
  • Specification: 10 mm ceramic insert surrounding the reactive plate.
  • Purpose: Protects the aluminum intake manifold from overheating and ensures system stability.
• Exhaust Manifolds
  • Material: Stainless steel 316L.
  • Design: Optimized shortest path for heat transfer to the reactive plate, with adjustable intake routing to enhance thermal efficiency.

Chemical Processes

The system employs two processes to produce hydrogen:

1. Steam Reforming (above 700 °C)
   • Reaction: A water-gasoline mixture (C₇H₁₆ + H₂O) reacts on the plate, yielding hydrogen (H₂) and carbon monoxide (CO).
   • Outcome: These gases enrich the combustion mixture, increasing burn rate and engine power.
2. Vaporization and Thermolysis (100–700 °C)
   • Stage 1: Distilled water vaporizes on the plate (from 100 °C).
   • Stage 2: In the combustion chamber (2000–2500 °C), thermolysis splits vapor into H₂ and O₂.
   • Outcome: Additional hydrogen and oxygen enhance combustion quality and reduce emissions.

Benefits and Potential

• Power Increase: Theoretical models suggest up to a 20% power gain due to enriched combustion and hydrogen’s energy contribution.
• Efficiency: Automatic dosing via airflow eliminates complex mechanical systems, enhancing reliability and reducing costs.
• Practicality: Using gasoline from the fuel tank and simple nozzle designs makes the system adaptable to gasoline engines.
• Sustainability: Improved combustion may reduce CO₂ and unburnt hydrocarbon emissions.
• Innovation: The Venturi effect and conical plate design offer a novel approach to on-board hydrogen production.

Challenges...