This project presents an innovative modification for atmospheric gasoline engines, designed to improve power and combustion efficiency through on-board hydrogen generation. Unlike traditional systems that rely on external hydrogen storage, this technology produces hydrogen directly within the engine using two key processes: steam reforming and thermolysis. Central to the design is the reactive cone, a catalytic component placed in the intake manifold before the throttle valve. The system leverages waste heat from exhaust gases to drive these chemical reactions, offering an efficient and sustainable solution. As an open-source initiative, it welcomes collaboration from engineers, researchers, and enthusiasts.

2. Technical Specifications and Design

2.1 Reactive Cone

• Material: Composed of an alloy with 80% nickel, 15% chromium, and 5% platinum/rhodium (Pt/Rh), chosen for its high-temperature resistance and catalytic capabilities.
• Location: Positioned in a narrowed section of the intake manifold before the throttle valve to utilize the Venturi effect.
• Design: A conical shape with a reactive surface, heated by exhaust manifolds, optimized for vaporization and steam reforming.
• Temperature Range: Operates between 100 °C and 800 °C, powered by recovered exhaust heat.

2.2 Liquid Dosing System

• Mechanism: Two nozzles are integrated into the narrowed intake section:
  • Water Nozzle: Activates at 100 °C, with an aperture of 0.1–0.3 mm.
  • Gasoline Nozzle: Activates above 700 °C, with an aperture of 0.3–0.5 mm.
• Regulation: Automatically controlled by the Venturi effect (based on airflow velocity) and the temperature of the reactive cone.
• Atomization: Nozzles are aerodynamically designed to produce a fine mist of water and gasoline.

2.3 Thermal Insulation

• Material: A 10 mm ceramic insert encasing the reactive cone.
• Purpose: Reduces heat loss and protects the intake manifold from excessive temperatures.

2.4 Exhaust Manifolds

• Material: Made from stainless steel 316L for durability and effective heat transfer.
• Design: Features flattened tubes to maximize contact with the reactive cone, enhancing heat delivery.

3. Chemical Processes

3.1 Steam Reforming (Above 700 °C)

• Principle: An endothermic reaction between water vapor and gasoline, catalyzed by the reactive cone, producing hydrogen (H₂) and carbon monoxide (CO).
• Conditions: Requires temperatures exceeding 700 °C, achieved through heat from the exhaust.
• Benefit: Enriches the air-fuel mixture with hydrogen, boosting engine power.

3.2 Vaporization and Thermolysis (100–700 °C)

• Vaporization: Water is converted into vapor on the reactive cone’s surface starting at 100 °C.
• Thermolysis: Water vapor decomposes into hydrogen (H₂) and oxygen (O₂) within the combustion chamber.
• Benefit: Enhances combustion efficiency and may reduce unburned hydrocarbon emissions.

4. Heat Recovery System

The system’s energy efficiency relies on recovering waste heat from exhaust gases, eliminating the need for external energy sources. Key features include:

• Exhaust Manifolds: Transfer heat (up to 800 °C) to the reactive cone via flattened tubes that increase contact area.
• Thermal Conductive Shell: A copper layer (thermal conductivity 400 W/m·K) surrounds the manifolds and cone, ensuring uniform heat distribution.
• Insulation: Ceramic wool wraps the system, minimizing heat loss and maintaining high temperatures within the reactive cone.

This heat recovery mechanism supports both vaporization (from 100 °C) and steam reforming (above 700 °C).

5. Venturi Effect and Dosing Regulation

• Definition: The Venturi effect occurs in the narrowed intake manifold section, where reduced pressure and increased airflow velocity draw liquids from the nozzles.
• Function: Liquid dosing adjusts automatically with engine load—higher airflow (e.g., at higher RPM) increases the intake of water and gasoline.
• Outcome: The atomized mist is directed onto the reactive cone, triggering the chemical reactions.

6. Benefits and Potential

• Power Increase: Hydrogen enrichment of the combustion mixture could enhance engine power by up to 20%.
• Efficiency: Automatic dosing simplifies the system, eliminating complex mechanical components.
• Sustainability: Improved combustion may reduce CO₂ and hydrocarbon emissions.
• Innovation: Combines heat recovery, the Venturi effect, and a catalytic reactive cone in a novel way.

7. Challenges and Future Development

• Nozzle Optimization: Achieving consistent liquid dosing across all engine conditions.
• Uniform Heating: Avoiding temperature variations across the reactive cone for reliable reactions.
• Testing: Conducting real-world engine tests to confirm theoretical performance.
• Durability: Assessing the long-term resilience of materials like stainless steel 316L under high heat and stress.

8. Conclusion

This engine modification system offers a cutting-edge approach to enhancing gasoline engine performance and efficiency through on-board hydrogen generation. By integrating heat recovery from exhaust gases, the system achieves energy self-sufficiency, while the reactive cone and Venturi effect enable seamless hydrogen production. As an open-source project, it invites collaboration to refine and implement this technology. For further details or to contribute, please feel free to reach out!