DESIGN AND FABRICATION OF BROWN GAS

GENERATOR

A MINI PROJECT REPORT

Submitted by

MOHAMMED RAFEEK.A 711615114075

PRAVEEN KUMAR.V 711615114308

LINO MATHAI 711615114061

KRISHNA KRIBA KARAN.B 711615114060

in partial fulfilment for the award of the degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

KATHIR COLLEGE OF ENGINEERING, COIMBATORE

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2018

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 ANNA UNIVERSITY: CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report“DESIGN AND FABRICATION OF

BROWN GAS GENERATOR” is the bonafide work of “ MOHAMMED

RAFEEK A (711615114075), PRAVEEN KUMAR V (711615114308),

LINO MATHAI (711615114060), KRISHNA KRIBA KARAN B

(711615114060) who carried out the project work under my supervision.

SIGNATURE SIGNATURE
Dr. A.R. SURESH, M.E., Ph.D., Mr. A. GOGULAKRISHNAN,
M.E.,
HEAD OF THE DEPARTMENT SUPERVISOR
Mechanical Engineering Mechanical Engineering
Kathir College of Engineering Kathir College of Engineering
Coimbatore - 62 Coimbatore - 62

Submitted for the project Viva-Voce examination held on ……………….

Internal Examiner ExternalExaminer

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 ACKNOWLEDGEMENT

At this pleasing moment of having successfully completed our project, we wish

to convey our sincere thanks and gratitude to the management of our college
and our beloved chairman Mr. E.S.KATHIR and secretary Mrs. LAVANYA
KATHIR who provided all facilities to us.

We express our Sincere thanks to Dr. G.DORAISWAMY, CEO, Kathir

College of Engineering for providing us all the support towards this project.

We express our deep sense of gratitude to Dr. P. BANUMATHI, Principal,

Kathir College of Engineering, who gave opportunity to frame the project to full
satisfaction.

Our grateful thanks to Dr. A.R. SURESH, Head of the department for his
constructive suggestion & encouragement during our project.

With deep sense of gratitude, we extend our earnest sincere thanks to our
project guide Mr.ARUN , Assistant Professor, Department of Mechanical
Engineering for his kind guidance and encouragement during this project.

We extend our sincere thanks to Mr.GOKULAKRISHNAN, Assistant

Professor, Department of Mechanical Engineering our project coordinator for
his involvement and encouragement during our project.

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 ABSTRACT

This paper presents the development of hydrogen generator to produce brown gas
from electrolysis of water.The generator housing is made of cylindrical shaped Perspex with
screwed cover made of the same material.The electrodes were made from scrapped lead from
old battery lead terminals. The electrolyte is distilled water materials readily available.Brown
gas is also called as Hydrogen Hydrogen Oxygen (HHO). Electrolysis utilization, is the process
in which separation of watet as oxygen and hydrogen of two molecules of each is the basic step
in this project. The process which is electrochemical began for the separation of water
molecules, as a result of introduction of electrical voltage to the solution, which is the
combination of the catalyst with distilled water. If the BROWN GAS generator efficiency is
increased to 100% the engine’s thermal losses would be still outweigh for the economic gain
from on board HHO addition.

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 TABLE OF CONTENT

CHAPTER CONTENT PAGE NO

ABSTRACT

LIST OF FIGURES

LIST OF TABLES

1. INTRODUCTION 1

1.1 Objectives 1

1.2 Aim and purpose 1

2. Literature Review 2

3. Components required 3

3.1 Fibre box with tight cap 3

fitting

3.2 Stainless steel plates 4

3.3 Bubbler 5

3.4 Nylon bolt and nut 5

3.5 work holding vise 6

4. MACHINING PROCESS 7
PERFORMED

4.1 Cutting 7

4.2 Drilling 8

4.3Grinding 8

4.4 Assembling 9

5. WORKING METHODOLOGY 10

5.1 Principle 10

5.2 Construction 10

5.3 Working process 11

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 5.4 Design and consideration 12

5.5 Advantages 13

5.6 Limitation 13

5.7 Application 13

6 COST ESTIMATION 14

7 RESULT AND CONCLUSION 15

7.1 Scope for future 15

REFERRENCE 15

PHOTOGRAPHY 16

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 LIST OF FIGURES
FIGURE NO TITLE PAGE NO

3.1 Fibre box with cap 3

3.2 Arrangement of plates 4

3.3 Bubbler construction 5

3.4 Nylon bolt,nut&washer 5

3.5 Manual work holding vise 6

3.6 Battery 6

3.7 Polyurethane tubes 7

3.8 L-bow connectors 8

4.1 Cutting machine 9

4.2 Drilling machine 10

4.3 Grinding machine 11

5.1 Electrolysis principle

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5.2 Block diagram

5.3 Flowchart of working

process

VII
 LIST OF TABLES

TABLE NO DESCRIPTION PAGE NO

6.1 Cost estimation 14

VIII
IX
 CHAPTER 1
INTRODUCTION

The potential of hydrogen gas as an energy carrier is immense, though it carries

less energy than fossil fuel by volume. Its overall effect on the environment is minimal.Hydrogen
is the smallest and the most abundant element in the universe. It rarely exists in pure nature as
hydrogen gas (H2) but in compounds such as hydrides and hydrocarbons. One of the famous
early uses of hydrogen gas was for lifting in balloons, and later in airships. It is widely believed
that Hydrogen will be the energy carrier of the future economy.

OBJECTIVES

Basic objectives of this project work is to use Hydrogen gas as alternative for existing
fuels. Hydrogen fuel will be produced from water(H2O) using electrolysis process. This is a
reversible operation, Higher capacity utilization for stronger business cases. Giving a low cost
fuel to consumers. For optimizing emission control from engine exhaust. Potassium Hydroxide is
used as catalyst in electrolyte solution.

AIM AND PURPOSE

The aim of this work is to design and alternate fuel using water electrolysis process
and to do the process of metal cutting and welding process by the hydrogen gas produced in the
electrolysis process. It can also used as a alternate fuel

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 CHAPTER 2
LITERATURE REVIEW

In light of recent hydrocarbon shortage concerns, hydrogen is receiving increased attention

from the scientific community and the media for its potential role in a sustainable energy
system.Hydrogen, like electricity, is an energy carrier and not an energy source, and
significant research is underway to test the feasibility of a future transition to a total hydrogen
energy economy. To understand the implications of such an economy, the Iowa Energy
Center funded an extensive literature search over the summer of 2006. This search included
approximately 130 research reports, case studies, and other esteemed publications having to
do with important aspects of the hydrogen economy (i.e. production, efficiency,
electrochemical conversion, etc.). Findings of the search are focused on hydrogen production
by electrolysis, several storage and delivery methods, electrochemical conversion to
electricity in fuel cells, and process efficiencies.

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 CHAPTER 3
COMPONENTS USED

The construction of brown gas generator depends upon the following components

3.1 Fibre box with tight cap fitting

3.2 Stainless steel plates
3.3 Bubbler
3.4 Nylon bolts and nuts
3.5 Work holding vise
3.6 Battery
3.7 polyurethane tubes
3.8 L-bow connectors

3.1 Fibre box with tight cap fitting

This box is most important which acts as the case of this generator. The plates are
ordered and arranged inside this box where the electrolysis process undergoes through
the cap the battery terminals are given connection. There is a passage for inlet and also
outlet through which the water is supplied and produced gas is evolved.

Fig 3.1 Fibre box with cap

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3.2 Stainless steel plates

Stainless steel plates are cut into pieces of given dimensions and are arranged. This
plate is used as the anode and cathode in the electrolysis process.

Fig 3.2 Arrangements of plate

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 3.3 Bubbler
The PVC housing for the booster has two small-diameter angle pipe fittings
attached to it and a clear plastic tubing placed between them is called bubbler. so that the level
of the electrolyte can be checked without removing the screw cap.

Fig 3.3 Bubbler construction

3.4 Nylon bolts and nuts

These nylon bolts and nuts are used to arrange the plates.the nylon material is used
because it doesn’t conduct electricity.

Fig 3.4 Nylon bolt,nut& washer

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3.5 Manual work holding vise

The vise is a job or workpiece holding device. It is a mechanical apparatus used to secure an
object to allow work to be performed on it. Vises consists two parallel jaws, one fixed and the
other movable, threaded in and out by a screw lever.

Fig 3.5 Manual work holding vise

3.6 Battery

Battery is the power source used in this process. This battery gives the power from which the
electrolysis is taken places.

Fig 3.6 Battery

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3.7 POLYURETHANE TUBES

This tube is used to connect the electrolyzer and bubbler as the passage for gas
evolved to flow through and also this gas is collected through this tubes

3.8 L-BOWCONNECTOR

It is used in the electrolyzed for the inlet and outlet of the

gases

Fig 3.8 L-bow connecto

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 CHAPTER 4

MACHINING OPERATIONS PERFORMED

The operations performed to fabricate the brown gas generator are listed below

4.1 Cutting
4.2 Drilling
4.3 Grinding
4.4 Assembling

4.1 Cutting

The raw material has to be cut to size. This is done with a variety of tools. The most common way to
cut material is by Shearing (metalworking); Special band saws designed for cutting metal have
hardened blades and a feed mechanism for even cutting. Abrasive cut-off saws, also known as chop
saws, are similar to mitter saws but with a steel cutting abrasive disk. Cutting torches can cut very
large sections of steel with little effort.

Fig 4.1 Cutting machine

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4.2DRILLING

Drilling is used to produce holes in the objects. In this project plates requires holes for
making assembly. These holes are done by vertical type drilling machine.

Fig 3.2 Drilling machine

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4.3 Grinding

A grinding machine, often shortened to grinder, is any of various power tool or machine tool
used for grinding, which is a type of machining using an abrasive wheel as the cutting tool.
Each grain of abrasive on the wheel’s surface cuts a small chips. Grinding is used to finish
work pieces that must show high surface quality and high accuracy of shape dimensions.

Fig 4.3 Grinding

4.4 Assembling

After the grinding and arrangements are done. It is tested safely. Any
additional manufacturing specified by the customer is then completed. The
finished product is then inspected and shipped.

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 Chapter 5
Working methodology

Principle

Electrolysis is a technique that uses a direct electric current (DC) to drive an otherwise non
spontaneous chemical reaction. Electrolysis is commercially important as a stage in the separation of
elements from naturally occurring sources such as ores using an electrolytic cell. The voltage that is
needed for electrolysis to occur is called the decomposition potential.

Fig 5.1 Electrolysis principle

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CONSTRUCTION

The brown gas generator consists of booster, bubbler, tube connections, SS

plates.The main part in this equipment is the electrolyzer which is also called as booster.
The plates are cut into pieces drilled and arranged in their position as given in the circuit
and this plate arrangement is placed inside the booster or electrolyzer as anode and
cathode. During the electrolysis process, the gas produced comes out through the outlet
and goes to the bubbler placed

The outlet is connected to bubbler using tubes and then the this
booster is connected to the battery for power supply. The plate arrangements also can be
changed In different connections to give a higher production.

BLOCK DIAGRAM

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 Fig 5.2 block diagram of brown gas generator

WORKING PROCESS OF BROWN GAS GENERATOR

Fig 5.3 flowchart of working process

WORKING

This HHO kit electrolyze the hydrogen and oxygen atoms directly out of the
water, without separating them, creating a unique and energetic form of gas containing H,
O, H2, O2. The battery is switched on first as soon as the power is supplied from the
battery the electrolysis process starts, as a indication furious bubbles starts inside the
booster. The interchanging of atoms and ions takes place and the gases are produced.
These gases move out through the outlet and goes towards the bubbler construction
through the connected tubes. The main use of the bubbler is to avoid the explosion .
The evolved gas can be seen in the form of bubbles inside the the bubbler. The purest form
of the gases in the bubbler is collected in the outlet of the bubbler. The gas is stored or
used directly for the purpose.

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DESIGN CONSIDERATION

When designing our attachment, the following considerations were

taken into account. The device should be suitable for local manufacturing
capabilities. The attachment should employ low-cost materials and
manufacturing methods. Standard steel pieces such as steel plates, case,
bubbler, tubes that are locally available should be used. Standard tools used
in machine shop such as cutting, grinding, drilling machine should be
adequate to fabricate the parts needed for the brown gas generator.

ADVANTAGES

1. Giving a low cost alternate fuel

2. Very easy to operate
3. It is very cost efficient than any other machines

LIMITATIONS

1. Foam bubbles are produced during hydrogen production inside the

generator.
2. Equipment highly gets heated up during working process.
3. Salt sediments on the electrode reduces thae efficiency of the hydrogen
production.
4. Conductive materials cannot be used for the housing of the generator.
5. Cleaning of the tank is required in regular time interval.

APPLICATIONS
1. It can perform cutting operation of various materials

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2. It can also be used in welding operation
3. It can also be used as alternate fuel

Chapter 6

Cost Estimation

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s.no Name of the Material quantity amount
component
1. sheet metal Stainless steel 4 feet 450

2 Transparent case Fibre 1 550

3. Tubes plastic 3 metre 70

4. L shaped 40
connector plastic 6

5. Bolt, nut and Nylon 5+20 110

washer
6. Cuttng wheel Abrasive 3 70

7. Abrasive paper Abrasive 2 30

8 Bolt and nut Stainless steel 2

9. Washer Stainless steel 46 250

10. Labour charges

Total

Table 6.1 cost estimation

CHAPTER 7

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 RESULT AND CONCLUSION

The performance of the brown gas generator is tested successfully and also it is used for cutting the
materials. The machine cost effective compared to the other cutting machine. Also the machine
requires only battery for power supply no need of electricity which is the major plus point. The
machine is simple in design, reliable, and can be used in small scale industries, particularly in rural
areas. The only maintenance of the machine required is cleaning of the plates.

7.1 SCOPE FOR FUTURE

For smaller operations in particular areas like workshops and small scale industries it
can be used.as there is no electricity consumption it can be used effectively. It can also be used as
alternate fuel hence in future there may be low cost fuel available .

REFERENCE
[1] Martinus van Marum's(1785) electrostatic generator was used to reduce tin, zinc, and
antimony from their salts using electrolysis.

[2] William Nicholson and Anthony Carlisle(1800) (view also Johann Ritter),
decomposed water into hydrogen and oxygen.

[3] Lithium was discovered by the English chemist William Thomas Brande,(1821) who
obtained it by electrolysis of lithium oxide.

[4] Michael Faraday(1833) develops his two laws of electrolysis, and provides a
mathematical explanation of his laws.

[5] Paul Émile Lecoq de Boisbaudran(1875) discovered gallium using electrolysis.

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