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GENERATOR
Submitted by
of
BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING
APRIL 2018
I
ANNA UNIVERSITY: CHENNAI 600 025
BONAFIDE CERTIFICATE
SIGNATURE SIGNATURE
Coimbatore - 62 Coimbatore - 62
II
ACKNOWLEDGEMENT
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 PRANESH, Assistant Professor, Department of
Mechanical Engineering for his kind guidance and encouragement during this
project.
III
ABSTRACT
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
the basic step in this project. The process which is electrochemical began for the
the solution, which is the combination of the catalyst with distilled water. If the
losses would be still outweigh for the economic gain from on board HHO
addition.
IV
TABLE OF CONTENT
PAG
CHAPTER
CONTENT E
NO
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 Acrylic box with tight cap fitting 3
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 PERFORMED 7
4.1 Cutting 7
4.2 Drilling 8
4.3 Grinding 8
5. WORKING METHODOLOGY 10
5.1 Principle 10
5.2 Construction 10
5.3 Working process 11
5.4 Design and consideration 12
V
5.5 Advantages 13
5.6 Limitation 13
5.7 Application 13
6 COST ESTIMATION 14
6.1 Table of cost estimation
7 RESULT AND CONCLUSION 15
7.1 Scope for future 15
REFERRENCE 15
PHOTOGRAPHY 16
VI
LIST OF FIGURES
FIGURE PAGE
TITLE
NO NO
3.1 Acrylic 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 7
3.9 Stainless steel bolt and nut 8
3.10 Teflon tapes 8
4.1 Cutting machine 9
4.2 Drilling machine 10
4.3 Grinding machine 11
5.1 Electrolysis principle 11
5.2 Block diagram 13
5.3 Flowchart of working process 14
VII
CHAPTER 1
INTRODUCTION
OBJECTIVES
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
1
CHAPTER 2
LITERATURE REVIEW
2
CHAPTER 3
COMPONENTS USED
3
3.2 Stainless steel plates
Stainless steels are notable for their corrosion resistance, which
increaseswith increasing chromium content. Molybdenum additions increase
corrosion resistance in reducing acid sand against pitting attack in chloride
solutions. Thus, there are numerous grades of stainless steel with varying
chromium and molybdenum contents to suit the environment the alloy must
endure. Thus stainless steels are used where both the strength of steel and
corrosion resistance are required .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.
4
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.
5
Nylon polymershavefound significant commercial applications in fabric
and fibers(apparel, flooring and rubberreinforcement), in shapes (moldedparts
for cars, electrical equipment,etc.), and in films (mostly for foodpackaging).
6
3.6 Battery
An electric batteryis a deviceconsisting of one or moreconnections
provided to powerelectrical devices such as flashlights,and electric cars.When a
battery is supplying electricpower, its positive terminal is thecathode and its
negative terminal isthe anode. The terminal markednegative is the source of
electronsThat when connected to an externalcircuit will flow and deliver energy
toan external device. When a battery isconnected to an external
circuit,electrolytes are able to move as ionswithin, allowing the
chemicalreactions to be completed at theseparate terminals and so deliverenergy
to the external circuit. It is themovement of those ions within thebattery which
allows current to flowout of the battery to perform work.Battery is the power
source used in this process. This battery gives the power from which the
electrolysis is taken places.
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3.7 POLYURETHANE TUBES
8
Fig 3.9 polyurethane tubes
It is used in the electrolyzer for the inlet and outlet of the gases
9
3.9 Stainless steel bolt and nut
10
3.10 Teflon tape
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CHAPTER 4
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 miller saws but with a steel cutting abrasive disk. Cutting torches
can cut very large sections of steel with little effort. An abrasive saw, also
known as a cut-offsaw or chop saw, is a power tool which is Cutting heavy steel
cable with a Husqvarna free hand saw typically used to cut hard materials,
suchas metals, tile, and concrete. The cutting action is performed by an
abrasive disc, similar to a thin grinding wheel. Technically speaking this is not a
saw, as it does not use regularly shaped edge (teeth) for cutting. These saws
are available in a number of configurations, including table top, freehand, and
walk behind models. In the table top models, which are commonly used to cut
tile and metal, the cutting wheel and motor are mounted on a pivoting arm
attached to a fixed base plate.
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Table top saws are often electrically powered and generally have a built-
in vise or other clamping arrangement. The free hand designs are typically
used to cut concrete, asphalt, and pipe on construction sites. They are
designed with the handles and motor near the operator, with the blade at the
far end of the saw. Free hand saws do not feature a vise, because the materials
being cut are larger and heavier. Walk behind models, sometimes called
flatsaws are larger saws which use a stand or cart to cut into concrete floors as
well as asphalt and concrete paving materials .Abrasive saws typically use
composite friction disk blades to abrasively cut through the steel. The disks are
consumable items as they wear throughout the cut. The abrasive disks for
these saws are typically 14 in(360 mm) in diameter and 7⁄64 in(2.8 mm) thick.
Larger saws use 410 mm(16 in) diameter blades. Disks are available for steel
and stainless steel. Abrasive saws can also uses uper abrasive (i.e., diamond
and cubic boron nitride or CBN) blades, which last longer than conventional
abrasive materials and do not generate a s hazardous particulate matter. Super
abrasive materials are more commonly used when cutting concrete ,asphalt,
and tile; however, they are also suitable for cutting ferrous metals.
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4.2 DRILLING
Drilling is a cutting process that usesa drill bit to cut a hole of
circularcross-section in solid materials. Thedrill bit is usually a rotary cutting
tool,often multi-point. The bit is pressedagainst the work-piece and rotated
atrates from hundreds to thousands ofrevolutions per minute. This forcesthe
cuttingedge against the workpiece,cutting off chips (swarf) fromthe hole as it
isdrilled.Drilling may affect the mechanicalproperties of the workpiece
bycreating low residual stresses aroundthe hole opening and a very thin layerof
highly stressed and disturbedmaterial on the newly formed surface.This causes
the workpiece to becomemore susceptible to corrosion andcrack propagation at
the stressedsurface. A finish operation may bedone to avoid these
detrimentalconditions.Drilling is used to produce holes in the objects. In this
project plates requires holes for making assembly.
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4.3 Grinding
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Chapter 5
Working methodology
Principle
Electrolysisis 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.Electrolysis is the
passing of a directelectric current through an ionicsubstance that is either
molten ordissolved in a suitable solvent, producingchemical reactions at the
electrodes andseparation of materials.The main components required toachieve
electrolysis. An electrolyte: a substance, frequentlyan ion-conducting polymer
thatcontains free ions, which carry electriccurrent in the electrolyte. If the ions
arenot mobile, as in a solid salt thenelectrolysis cannot occur.A direct current
(DC) electrical supply:provides the energy necessary tocreate or discharge the
ions in theelectrolyte. Electric current is carriedby electrons in the external
circuit.Two electrodes: electrical conductorsthat provide the physical
interfacebetween the electrolyte and theelectrical circuit that provides
theenergy.Electrolysis is also used in the cleaningand preservation of old
artifacts.Because the process separates the nonmetallicparticles from the
metallic ones,it is very useful for cleaning a widevariety of metallic objects,
from old coinsto even larger objects including rustedcast iron cylinder blocks
and heads whenrebuilding automobile engines. Rustremoval from small iron or
steel objectsbyelectrolysis can be done in a homeworkshop using simple
materials such asa plastic bucket, tap water, lengths ofrebar, washing soda,
baling wire, and abattery charger.In 1832.
16
Michael Faraday reported thatthe quantity of elements separated
bypassing an electric current through amolten or dissolved salt is proportionalto
the quantity of electric charge passedthrough the circuit. This became thebasis
of the first law of electrolysis
17
CONSTRUCTION
BLOCK DIAGRAM
18
WORKING PROCESS OF BROWN GAS GENERATOR
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 an
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 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.
19
The key process of electrolysis is the interchange of atoms and ions by
theremoval or addition of electrons from theexternal circuit. The desired
products ofelectrolysis are often in a differentphysical state from the
electrolyte andcan be removed by some physicalprocesses. For example, in
theelectrolysis of brine to produce hydrogenand chlorine, the products are
gaseous.These gaseous products bubble from theelectrolyte and are collected.
2 NaCl + 2 H2O → 2 NaOH + H2 + Cl2
The amount of electrical energy thatmust be added equals the change inGibbs
free energy of the reaction plus thelosses in the system. The losses can
(intheory) be arbitrarily close to zero, so themaximum thermodynamic
efficiencyequals the enthalpy change divided bythe free energy change of the
reaction.
20
Inmost cases, the electric input is largerthan the enthalpy change of the
reaction,so some energy is released in the form ofheat. In some cases, for
instance, in theelectrolysis of steam into hydrogen andoxygen at high
temperature, the oppositeis true and heat energy is absorbed. Thisheat is
absorbed from the surroundings,and the heating value of the producedhydrogen
is higher than the electric input.Oxidation of ions or neutral moleculesoccurs at
the anode. For example, it ispossible to oxidize ferrous ions to ferricions at the
anode.
+ 2 e− + 2 H+ →
DESIGN CONSIDERATION
22
Chapter 6
Cost Estimation
TOTAL 2720
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CHAPTER 7
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.
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.
[4] Michael Faraday (1833) develops his two laws of electrolysis, and
provides a mathematical explanation of his laws.
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