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Confidential Information

12 age -- p

Car Test -- Hydrogen On Demand

(Pure hydrogen, not HHO)

Can pure hydrogen (H2) replace HHO to increase MPG?

Updated : 1/23/2012

By: Phillips Company Email: hp@valliant.net, Tel. 580 746 2430

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Contents
Car Test -- Hydrogen On Demand ...................... 1
Can pure hydrogen (H2) replace HHO to increase MPG? ........... 4
Technology comparison; HHO system and H2 system ................................................. 4

The need for pure hydrogen (this invention).................................. 6

Confidential Information

Problem and solution ....................................................................................................... 6 The present invention for hydrogen production improves the state of the art .......... 6 Catalytic Carbon (CC) is intended for the high-production-rate, large-volume production of hydrogen. ................................................................................................... 7

Chemical reactions............................................................................ 7
The present invention uses simple and well-known chemical reactions ..................... 7 High rates of hydrogen production are possible using the present invention ............ 8 Hydrogen production rates: Hydrogen was produced at rates up to 4 LPM in small reaction chambers. ...................................................................................................... 8 The present invention produces by-products that are fully recoverable using existing commercial methods for producing aluminum metal. ...................................... 9 Fuel: The use of lower-cost, lower-purity aluminum is a novel aspect of the present invention. ...................................................................................................................... 9 Fuel: The use of water from almost any source is a novel aspect of the present invention. ....................................................................................................................... 10 The use of salt water makes the present invention suitable for marine applications and as an energy source for coastal areas. .............................................................. 10 Catalytic Carbon (CC) can be used with the most desired materials to produce hydrogen. .................................................................................................................... 11 Safety: Catalytic Carbon (CC) can be used with the worlds safest materials to produce hydrogen. ..................................................................................................... 11

First pure-hydrogen road test using CC ....................................... 12 First test run: 37 MPG .................................................................. 14 The government says this Buick should get 26 MPG (highway driving) ........................................................................................ 15
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Analysis: 32% increase in gas mileage ......................................... 15 Engineering design concepts. ........................................................ 16 Summary ......................................................................................... 16 How to evaluate this new H2 system ............................................. 17

Confidential Information

How to evaluate this new H2 system

Might you be interested to evaluate this new method of producing hydrogen? Please see the following information, online at

www.PhillipsCompany.4T.com/MCC.pdf

Phillips Company Email: hp@valliant.net, Tel. 580 746 2430

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Can pure hydrogen (H2) replace HHO to increase MPG?

Technology comparison; HHO system and H2 system

Confidential Information
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Confidential Information

Aluminum hydroxide, aluminum oxide and recycling

The following video interview explains how bauxite (aluminum oxide) is mined, refined and smelted to produce aluminum.
http://video.foxbusiness.com/v/1244405353001/booming-franchise-european-wax-center/ ?playlist_id=87185

The byproducts from the CC method of producing hydrogen have a special characteristic -- they are identical to the MOST PURE form of refined bauxite.

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The need for pure hydrogen (this invention)

A hydrogen-based economy is the only long-term, environmentally-benign energy alternative for sustainable growth. The increasing demand for hydrogen arises from the impending paradigm shift to a hydrogen-based energy economy. This change will become needed as the worldwide need for more electricity increases, greenhouse gas emission controls tighten, and fossil fuel reserves wane.

Problem and solution The future increasing need for hydrogen fuel has created a problem: the problem is the lack of a hydrogen-supply infrastructure that is necessary for the proliferation of the use of hydrogen. The present invention provides a simple solution, in that hydrogen on demand (HOD) is available at any desired high production rate. This makes it unnecessary to store hydrogen in a pressurized tank for release later at a high rate. The present invention makes it possible to control and sustain the continuous production of hydrogen with no requirement for any external energy. The controlled, sustained production of hydrogen has been achieved in our laboratory so long as water, aluminum and Catalytic Carbon (CC) are provided to the hydrogen-production cell.

Confidential Information

The present invention for hydrogen production improves the state of the art The common method to recover hydrogen from water is to pass electric current through water and to reverse the oxygen-hydrogen combination reaction, i.e. water electrolysis. Another method involves extraction of hydrogen from fossil fuels, for example from natural gas or methanol. This method is complex and always results in residues, such as carbon dioxide. And, there is worldwide limit to the fossil fuel available for use in the future. In these reforming methods the resulting hydrogen must be somehow stored and delivered to the user, unless the hydrogen generation is performed on-board, close to the point of use. The safe, reliable, low-cost hydrogen storage and delivery is currently one of the bottlenecks of the hydrogen-based economy. The present invention addresses this problem through safe, on-board/on-demand production of hydrogen close to the user systems, using simple, safe and pollution-free metal oxidation reacting with water and Catalytic Carbon (CC).

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Catalytic Carbon (CC) is intended for the high-production-rate, large-volume production of hydrogen.

Confidential Information

Although about 20% of air is oxygen, there is no easily-accessible, safe source of hydrogen available. The current invention addresses and solves this problem. This invention relates to a novel method of generating hydrogen from water. Water consists of two elements: oxygen and hydrogen. A relatively large amount of energy is released when these two elements react to form water. This energy may be captured and may be used as a heat source, a combustion fuel, or it can be efficiently converted to electricity in fuel cells. One novel aspect of this invention is that the high production rate of hydrogen makes previously-impossible applications technically feasible for the first time, especially for high-energy-consumption applications. Because of the straightforward scale-up of the production rate of hydrogen using the present invention, the use of Catalytic Carbon (CC) makes it feasible to use high-production-rate hydrogen as fuel for commercial power plants, trans-oceanic ships and remote locations, including thirdworld population centers and outposts on other planets so long as water, aluminum and Catalytic Carbon (CC) are provided to the hydrogen-production cell. In the later potential application, an important advantage of this invention is that only water and water vapor (nothing else) is released when oxygen and hydrogen react using Catalytic Carbon (CC). Consequently, the hydrogen-oxygen reaction is potentially a pollutionfree source of energy.

Chemical reactions
The present invention uses simple and well-known chemical reactions 2Al + 6H2O + CC => CC + 2Al(OH)3 + 3H2 where Aluminum and water are fuels and the only by-product is aluminum hydroxide Al(OH)3 . In this reaction, CC is a catalyst which is not consumed or chemically transformed in the reaction. The same reaction can be written as 2Al + 3H2O + CC => CC + Al2O3 + 3H2 where Aluminum and water are fuels and the only by-product is aluminum oxide, Al2O3 . In this reaction, CC is a catalyst which is not consumed or chemically transformed in the reaction.
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Aluminium hydroxide, Al(OH)3 is found in nature as the mineral gibbsite (also known as hydrargillite) and its three polymorph forms: bayerite, doyleite and nordstrandite. [Ref Wikipedia] Closely related to aluminium hydroxide is aluminium oxide, Al2O3, differing only by loss of water. These compounds together are the major components of the aluminium ore bauxite. [Ref Wikipedia] Aluminum, a fuel used for producing hydrogen, comes from bauxite. Bauxite is an aluminium ore and is the main source of aluminium. This form of rocky ore consists mostly of the minerals gibbsite Al(OH)3, boehmite AlO(OH), and AlO(OH), in a mixture with the two iron oxides goethite and hematite, the clay mineral kaolinite, and small amounts of anatase TiO2. [Ref Wikipedia]
Confidential Information

High rates of hydrogen production are possible using the present invention Most methods of producing hydrogen (electrolysis, thermo-forming) produce hydrogen at low rates when measured in units of volume per minute (LPM) per gram aluminum per joule of required energy, or LPM/gm per joule. Using this benchmark for production rate evaluation quickly leads to the conclusion that electrolysis and thermo-reforming are poor performers simply because of the energy required to drive the processes. Our invention is much better than electrolysis or thermo-reforming processes (for hydrogen production). This is because our invention uses a process that only needs external heat to start the reaction, usually in the temperature range of 150F to 190F. Once started, the reaction, because it is fundamentally exothermic, provides enough heat to sustain the reaction. The only external energy required is for cooling, if needed to limit the production rate to some desired target value.

Hydrogen production rates: Hydrogen was produced at rates up to 4 LPM in small reaction chambers. In our laboratory we carried out more than 50 experimental runs in which we obtained hydrogen production rates of 400 mL/minute to 4 LPM with a hydrogen cell charged with 10 to 40 gm of powdered aluminum. These experimental cells had reactionchamber volumes ranging from 100 mL to 1 liter, made from plastic bottles and glass containers. Higher rates were demonstrated in our laboratory and we believe rates exceeding 100 LPM can be easily achieved using larger cells in non-laboratory
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(industrial) conditions because the scale-up of the present invention has no known fundamental barriers. The controlled, sustained production of hydrogen was achieved in our laboratory so long as water, aluminum and Catalytic Carbon (CC) was provided to the hydrogen-production cell.

The present invention produces by-products that are fully recoverable using existing commercial methods for producing aluminum metal. The by-products from our hydrogen-production method are desirable because they are pure, and contain no contaminants including bauxite, gibbsite, boehmite, goethite, hematite, kaolinite, and TiO2. We reason that the large volume of by-products of our invention, pure Al(OH)3 and pure Al2O3, will be 100% recycled to produce more aluminum metal. Recycling of aluminum hydroxide and aluminum oxide makes the present invention economically viable for large-volume hydrogen generation. An excellent discussion of the process for primary aluminum production, as well as worldwide values for the energy requirements for aluminum smelting, can be found on a web site produced by the International Aluminium Institute (www.world-aluminium.org). Aluminum refining from aluminum-bearing bauxite ore uses the Bayer process chemistry which forms a hydrate which is essentially the same as the reaction product in the proposed aluminum-water reactions described above. [Ref DOE paper, 2010] The hydrate is then calcined to remove the water to form alumina. The alumina is electrolytically reduced into metallic aluminum at about 900 oC using the Hall-Heroult Process, producing a metal with 99.7% purity.

Confidential Information

Fuel: The use of lower-cost, lower-purity aluminum is a novel aspect of the present invention. For a given mass of aluminum in the reaction, the hydrogen production rate is approximately proportional to the surface area of the aluminum metal. The aluminum used in our experiments was powdered aluminum. The higher surface-to-volume ratio of powdered fuel makes it suitable for higher-rate hydrogen production. More course fuel, in the form of pellets or granules can be used, but at a lower production rate of hydrogen for any given amount of aluminum.

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The present invention uses aluminum and water for fuel. The process latitude for this process is excellent. The use of pure aluminum is not required, making possible the use of lower cost, less-pure aluminum in our hydrogen-production process.

Fuel: The use of water from almost any source is a novel aspect of the present invention. The present invention uses aluminum and water for fuel. The use of pure water is not required. Therefore it is not necessary to use expensive water such as distilled water or de-ionized water for the production of hydrogen. This has been proven in our laboratory using tap water, dirty water, high-calcium water, salt water, alkaline water, and acidic water. All water samples used in our laboratory experiments have worked well during our work to produce hydrogen. Although not required, some forms of water, including salt water and alkaline water, perform somewhat better in our process than more pure forms of water such as deionized water. When producing hydrogen with the present invention, more design latitude and freedom is available to the hardware design engineer in the selection of materials, water and water ingredients to minimize corrosion of the materials used in the construction of the cell and associated parts of the system. The excellent process latitude for water purity makes it possible to use a wider range of materials with the probable result of cost reduction for equipment designed for use with the present invention.

Confidential Information

The use of salt water makes the present invention suitable for marine applications and as an energy source for coastal areas. As noted above, salt water can be used to produce hydrogen using the present invention. This means that the present invention is naturally suited for use in producing fuel in all parts of the world where human settlements are located near any seashore, including remote islands. Many island nations, including Japan, can use the present invention to decrease fuel costs and reduce or eliminate the need for tanker-ship import of fossil fuels. Other island groups, including Hawaii, can improve the local economy by reducing fuel costs using the present invention to reduce or eliminate the need for tanker-ship import of fossil fuels.

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Catalytic Carbon (CC) can be used with the most desired materials to produce hydrogen. There are only a few materials that can produce abundant hydrogen and these include hydrocarbons and water. Of these, the only pollution free source of hydrogen is water. One of the problems that must be addressed before the new hydrogen economy replaces the current oil/gas/coal/nuclear economy, is finding a safe, environmentally benign and cost-effective method of generation of hydrogen at any desired rate. The solution of this problem is the primary focus of the present invention.
Confidential Information

Safety: Catalytic Carbon (CC) can be used with the worlds safest materials to produce hydrogen. Carbon, water, aluminum, aluminum oxide and aluminum hydroxide are the safest materials known to humanity (e.g. they are commonly used in foods, drugs, cosmetics and other safe to use/handle products). The present invention works well using a wide range of pH, and this includes neutral pH values in the range of 6 to 8. The use of neutral pH chemistry eliminates the threat of acid burns or alkali burns to human skin and eyes. Alkali-burn damage to the eyes, due to an accidental splash, is a safety hazard when using electrolysis to produce hydrogen. Electrolysis fundamentally requires the use of a strong electrolyte to increase the electrical conductivity of the water, whereas the present invention produces hydrogen chemically, without the use of electrolysis and without the requirement for electrolyte additives. The present invention promises to be safe and manageable by simple means.

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First pure-hydrogen road test using CC

2004 Buick Park Avenue

Confidential Information

Fill plug and inspection port Hydrogen output Bubbler (called the dirty bubbler) Water gravity flow Fill cap and inspection port Hydrogen from cell, up to the bubbler Glow plug (startup heater) Mounting bracket

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Instrumention is mounted on the rear view mirror. In a commercial system this would not be needed or included. This apparatus is to give a visual indication of hydrogen flow rate during road tests.

Confidential Information

Fill cap Hydrogen input from cell Hydrogen output to solenoid valves (switches to engine or to vent) Tube from clean bubbler to flow rate meter Clean bubbler Flow rate meter

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First test run: 37 MPG

First test run on 7/29/2011: 37 MPG on a Buick that usually gets a MAXIMUM of 30 MPG, even on long road trips. Typical highway gas mileage for this car is about 26 to 28 MPG. T = 0 minutes: Cell charged with 2 HTsp Al powder. and heating element was switched on. Heatup and hydrogen flow required about 5 minutes. 37 MPG
Confidential Information

T = 5 minutes: Buick engine was started with hydrogen flowing. The EFI computer trained open loop to closed loop with hydrogen flowing. Speed = 55 MPH. Max hydrogen flow rate estimated = 0.3 LPM.

35.7 MPG

T = 10 minutes: Flow rate decreased with time, as the small-particle aluminum was consumed (along with some water). Solenoid valve was switched so that hydrogen was vented (not piped to engine). Mileage dropped 6.7%; from 35.7 MPG to 33.3 MPG. Even so, this is a higher gas mileage than usual for this car.

33.3 MPG

35.9 MPG
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After driving 5 miles, the hydrogen flow was switched to VENT. On the return trip, the mileage was higher than usual WITHOUT any hydrogen flowing to the engine. Why? Could the EFI computer have been trained on hydrogen in a way that it somehow chose a set point that is leaner than usual, thereby causing the gas mileage to be greater than usual even when hydrogen was no longer supplied to the engine? Page 14

The government says this Buick should get 26 MPG (highway driving)

Confidential Information

http://www.fueleconomy.gov/feg/noframes/19829.shtml

Analysis: 32% increase in gas mileage

My experience with this Buick is that it gets better gas mileage (26 to 28 MPG) under normal highway driving conditions; unleaded fuel. To be conservative, lets assume that the normal, no-hydrogen highway gas mileage is 28 MPG for this car. The first road test WITH hydrogen showed a gas mileage of 37 MPG with a hydrogen flow rate of 0.3 LPM (estimated). This is considered a low flow rate, because independent calculations suggest that best performance at 60 MPH with hydrogen might require about 3 LPM (10 times greater than the flow rate for this first test). Using these numbers, an ESTIMATED improvement in gas mileage for this first test was (37 - 28) / 28 = Wow!

32% increase in gas mileage

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Engineering design concepts.

1. We need a way to deliver the fuel (water and aluminum) to the cell in a variable and controlled way. Rough calculations indicate that the right delivery rate would be about 1 mL per minute to 2 mL per minute of thick liquid. Variation over this range would be like varying the rate of diesel to the engine. The Al/water mix might be somewhat thick -- something like syrup. This will be the feed to the hydrogen cell. 2. We need a good way to control the temperature of the cell. A. STARTUP: Heat the cell quickly, up to about 180F and start the "feed" of fuel to the cell. B. SUSTAINED OPERATION ON THE ROAD: Keep the cell cool as the reaction produces heat (this is called an exothermic chemical reaction). C. SHUTDOWN: Cool the cell down and stop the "feed" of fuel to the cell. This is very much like how a normal diesel engine works. It uses a glow plug to quickly heat the cylinder; then fuel is fed to the combustion chamber at a rate that varies depending on changing speed and power required; and temp control (cooling) is provided by circulating water driven by the water pump.

Confidential Information

Summary
We have discovered an amazing new method for producing hydrogen on demand. Pure hydrogen (no oxygen) at any flow rate, 1 LPM, 2 LPM -- to 10 LPM. No EFIE or EFII required. No oxygen sensor or EFI changes needed. Current required = 0 Amperes. No electrolyte. No corrosion of anode or cathode (none at all!). pH is neutral. Chemistry is safe.

Who are we?

We are not an automotive products company; we are a pharmaceutical company. Our web site is: www.PhillipsCompany.4T.com We just happened to have the catalytic chemistry capability needed for splitting water with very little energy required. So, we need a strategic alliance who is in the automotive products business.

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How to evaluate this new H2 system

Might you be interested to evaluate this new method of producing hydrogen? Please see the following information, online at

www.PhillipsCompany.4T.com/MCC.pdf

Phillips Company Email: hp@valliant.net, Tel. 580 746 2430

Confidential Information
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