Proposal for Partial
Hydrogen Injection Project
Wentworth Institute of Technology, 2010
By J. Bruyn, A. Cammorata, M. Moore, & C. Sandini
Introduction & Summary
Partial hydrogen injection (PHI) is the practice of feeding a small amount of hydrogen into an internal
combustion engine (ICE) through the air intake will result in a higher power output. This is due to a combination
of the reaction of hydrogen with the atomic makeup of the fuel as well as the higher temperature flame that
results from burning the hydrogen. The higher temperature promotes a more complete burn of the fuel in the
cylinder and passes less waste fuel off to the catalytic converter. The idea here is that an ICE can create the
same amount of power using less fuel when a PHI system is used because there is a more complete combustion
of the fuel.
Our plan is to research partial hydrogen injection, build an electrolyzer, and test the performance of
an ICE with and without assisted combustion. Our hope is that efficiency will increase.
Problem Definition
Internal combustion engines do not burn all of the fuel that is injected into the cylinders prior to
ignition. As a result, these engines are not as efficient as they could be.
Background Research
Water electrolysis is one of the many ways to produce hydrogen and is done so by placing two
electrically conductive solids (electrodes/plates) with opposing charges in a hydrogen rich, electrically
conductive medium and passing a current from the positive to the negative electrode (see Figure 1 on pg.2 for
diagram). The main components of the electrolyzer are the electrodes, the electrolyte (conductive medium),
the containment vessel, and the power supply used to apply the electric current. It is important to note that the
housing, or containment vessel, must be an electric insulator. Hydrogen production can be increased two ways,
one of which is simply increasing the current applied to the electrodes. Another approach is to align electrodes
in series such that their polarities are like so: [+n-n+n-n+…] where n represents an electrode with no charge
(neutral). Neutral plates divide the total available voltage applied to the system and help to decrease the
amount of heat created in the system. The number of neutral plates is based on the overall voltage applied to
the system; one neutral plate per 2.3V. A system using 2.3V would not need any neutral plates. These two
approaches can be combined to achieve optimum performance.
From an efficiency standpoint, it is desired that the system provide as little electrical resistance as
possible. The reason for this can be illustrated using the equation 𝑉 = 𝐼𝑅, where V is voltage, 𝐼 is current and 𝑅
is resistance. Current is a set constant based on the desired hydrogen output and resistance is another constant
governed by the architecture of the system. That means that voltage has to yield to the product 𝐼𝑅 and will
increase with the increase of 𝐼 and/or 𝑅. The desire for a low voltage may be demonstrated using another
equation 𝑃 = 𝑉𝐼, where 𝑃 is power and 𝑉 and 𝐼 are as previously noted. In short, decreasing the resistance will
decrease the overall power needed to run the system while maintaining the same hydrogen output.
Modern water electrolysis for use in PHI systems employs the use of corrosion resistant electrode
materials. Stainless steel is a common material used in less expensive systems, but has a few drawbacks. Over
time, the corrosion of the electrodes leads to high concentrations of hexavalent chromium in the
water/electrolyte solution, an extremely toxic carcinogen (http://www.hhogenerator.com, 2009). To avoid this,
some manufacturers have moved to using titanium electrodes. However, some research shows that the
hexavalent chromium only leeches out of the surface of stainless steel electrodes for a short time. Leeching
stops after a period of use known as the conditioning period and may take up to a week of continuous operation
to complete. We will be using 316L or 320L stainless steel in our cell, as cost is a concern.
In general, it is desired to use a non-caustic electrolyte. Caustic electrolytes can end up in the engine
and cause premature wearing of engine components. The byproduct of the chemical reaction is also a concern.
There are many things that can increase the conductivity of water, but will produce other pollutants during the
electrolysis process. Much of our research will focus on determining which solution is appropriate. We’re not
just trying to make the ICE more efficient, we’re trying to do it without introducing other toxins to the
atmosphere.
The Need
Today’s consumers are being met with an increased need to concern themselves with fuel efficiency
from an economic stand point. Solutions to this problem can include driving less, using public transportation or
even purchasing a more fuel efficient vehicle. For some, these are not practical solutions. They need their
current vehicle to be more fuel efficient.
In recent years, there has been a growing interest in using hydrogen gas to increase fuel efficiency. The
general understanding is that when hydrogen is introduces fed into the air intake of an internal combustion
engine it helps to burn more of the fuel that is injected into the cylinders. The end result is a cleaner burn
(reduced emissions) and a higher power output.
The Objective
The driving force behind this project is our desire to investigate how mixing hydrogen with the fuel in an
internal combustion engine will effect the performance.
The Work Plan (Methods and Evaluation)
The project will begin with researching of the current technology. This should take about 4 weeks and
most of this research will be based on the electrodes and electrolyte solution, as they are the backbone of the
system. Once we’ve gained a strong understanding of the existing systems, we will spend a two weeks
brainstorming and designing our own system. Following this will be the experiment design and testing of the
system. The remaining time will be spent analyzing the data, writing the report, and preparing the final
presentation. A Gantt chart is provided in Appendix B to help display the work flow.
The Risk
The analysis of this system will involve the production of hydrogen gas and handling gasoline. The
hydrogen will be produced and injected into the air intake at atmospheric pressure. The only time hydrogen is
compressed will during the compression stroke of the engine. The ignition of the hydrogen will be in a
controlled environment (the piston) where the energy from the expanding gasses can be converted directly into
kinetic energy.
Hydrogen production of 1 lpm at atmospheric pressure poses almost no hazard, as any hydrogen
released to the atmosphere will quickly rise and dissipate into the air. This rapid dissipation will result in
concentrations well below 4% hydrogen.1
Gasoline vapors have a higher density than air and will fall to the ground where they collect if the area is
not properly ventilated. In the presence of an ignition source, dense gasoline vapors can ignite and present
hazards. In an effort to eliminate the collection of these vapors, experiments will be conducted in a way that
ensures that all vessels containing gasoline are sealed. In the event of a gasoline spill, the experiment will be
aborted and attention will be turned to cleaning and ventilating the contaminated area.
Potassium hydroxide and sodium hydroxide are two very possible candidates for electrolyte. Both of
these strong alkaline bases and can burn the skin or make one blind at high enough concentrations. Any
handling of the electrolyte solution will be conducted wearing appropriate eye and skin protection.
Our electrodes will be made of either 316L or 320L stainless steel. To address the concern of hexavalent
chromium leeching into the electrolyte solution, all waste electrolyte solution will be bottled, labeled, and
disposed of according to OSHA regulations.
1
Hydrogen is only combustible at concentrations from 4% to 74.2% by volume.
Team Qualifications
See Appendix A for resumes.
Justin Bruyn
- Manufacturing Industry (1 year)
o Created detailed AutoCAD diagrams of machines and machine setups.
o Recorded and analyzed tested data for new machine setups.
o Designed one off machine modifications to improve production quality.
- Skilled Mechanic
o 2 years of training at Newburgh Free Academy High School (Newburgh, NY)
o 1 year of experience in industry
Andrew Cammorata
- AUV Industry (1 year)
o Solidworks: Designed AUV parts and systems.
o Assembled AUV's and troubleshouted design flaws with a design/build team.
o Tested AuV's in the ocean.
- Mechanic
o Self taught and apprentice at Norm's Automotive Service (Hanover, MA)
o Custom Car Design and Maintenance, specializing in Hot Rods.
Myles Moore
- Proton Exchange Membrane Hydrogen Fuel Cells (1 year)
o Performed various material property/behavior investigations on internal fuel cell components
- Building Automation Industry (1 year)
o Commissioned building control systems
o Troubleshot system errors
o Designed computer interface used for communicating with the control systems
- Skilled Machinist
o 4 years of training at Old Colony Regional Vocational Technical High School (Rochester, MA)
o 1 year of experience in industry
Chris Sandini
- LED Industry
o Solidworks: Designed custom LED signs for customers.
o Designed an automated soldering machine.
o Surface soldering, PCB desgin and troubleshooting.
- Computer Technician
o Built custom computers, advanced skill level in overlocking/tweaking computers
o EASYtech at Staples ~2 years.
- Web and Multimedia Designer
o Highly Experienced in Flash, Dreamweaver, and Photoshop.
Project Budget
The project budget is not expected to exceed $200. The group already had possession of most of the
materials. A few thermocouples, pressure gages, hoses, and gradated cylinders will need to be purchased.
Project Future (What do you see happening with this?)
Partial hydrogen injection (PHI) is something that has been on the back burner of the alternative energy
field since before the 1970’s. There have been many attempts to couple on-board steam reformers with
combustion engines, but “the major drawback of this process is its complexity. The operation of the steam
reformer at a specified temperature, followed by shift conversion at a specified lower temperature, followed by
water separation presents temperature and flow control problems that were considered to be too complex for
an automotive application.” (Cerini, 1974) As a result, much attention has been turned to water electrolysis for
hydrogen production.
Having the hydrogen mixed with the fuel causes almost 100% of the fuel injected into the cylinder to be
burned. These systems could eliminate the need for a catalytic converter while increasing fuel efficiency at the
same time. PHI is a truly remarkable way to use our petroleum resources more responsibly.
If our discoveries regarding PHI lead to something that we can see being a viable fuel supplement, this
project could be carried over into the senior design project for further investigation.
Bibliography
Cerini, J. H. (1974). On-Board Hydrogen Generator for a Partial Hydrogen Injection Internal Combustion Engine.
New York, New York: Society of Automotive Engineers, Inc.
http://www.hhogenerator.com. (2009, Dec. 28). Retrieved from http://www.hhogenerator.com:
http://www.hhogenerator.com/hho-and-the-energy-market-olympic-hydrogen-ti-hho-generators/
Appendix A
(845) 464-0180
222 Fostertown Road
Newburgh, NY 12550
Justin Bruyn
Bruynj@wit.edu
EDUCATION
Wentworth Institute of Technology, Boston, MA
Bachelor in Mechanical Engineering Technology, Aug 2010 exp.
COURSEWORK
Statics
Thermodynamics I
Strength of Materials
Manufacturing Processes
Intro to HVAC
Mechanical CAD
Applications
Mechanical Graphics
Calculus I, II & III
College Physics I & II
Machine Design
Fluid Mechanics
TECHNICAL COMPETENCIES
Engineering: Arc Welding, Tig Welding, Oxy-acetylene Welding, Casting,
Flow Meters, Material Testing.
Milling Machine, Lathe, Drill Press
Devices:
AutoCAD, SolidWorks, Microsoft Office, Excel, PowerPoint, Word
Software:
LAB WORK
Velocity Measurements, Flow meters, Viscosity, Vapor Compression RefrigerationSystem, Heat Pump Performance, Tensile Test, Shear Test, Torsion Test, Specific Heat
Capacity, Engine Timing.
PROFESSIONAL EXPERIENCE
Mar. 2009 – May 2009
Madico Inc, Woburn, MA
Mechanical Engineer Co-op
 Designed and managed multiple projects to increase production quality and
efficiency.
 Created detailed AutoCAD drawings of machines and machine set ups.
 Responsible for installation and testing of machine modifications.
Sep. 2004 - Aug. 2005
Toyota of Newburgh, Newburgh, NY
Mechanic
 Communicated with manager and staff to replace drive belts, brake rotors and
pads, replacing transmissions, etc.
 Completed car evaluation forms and troubleshoot problems with vehicles.
June 2004 - Aug. 2006
Poughkeepsie Seamless Gutters, Newburgh, NY
Technician
 Maintained and operated gutter machine.
 Prepared and installed gutters by utilizing recorded measurements.
 Trained and evaluated new employee on preparation and installation skills.
INERESTS
Dirt-Bike racing, Automobiles, Re-building engines, Golf, and Traveling
Andrew P. Cammorata
108 Fair Acres Dr., Hanover, MA 02339
(781) 956-3938, cammorataa@wit.edu
EDUCATION
Wentworth Institute of Technology, Boston, MA
Bachelor of Science in Mechanical Engineering Technology
August, 2010 exp.
COURSEWORK
Fluid Mechanics
Strength of Materials
Dynamics
Kinematics
Thermodynamics
CAM (computer-aided manufacturing)
Mechanical CAD Applications 1
Manufacturing Processes 1
Mechanical Graphics
TECHNICAL COMPETENCIES
Design:
Fabrication:
Software:
Solidworks, unigraphics, hand sketching and drafting
Experience in sand casting, metal hand lathe, hand milling machines, gas and arc welding, and CAM
(computer-aided manufacturing) machines such as CNC lathes and milling machines
Microsoft Office; Word, Excel, Power Point, FrontPage, Solid Works, AutoCAD, and Unigraphics
LAB EXPERIENCE
Manufacturing Processes 1




Made the Wentworth Wobbler, an air powered engine
Turned and milled Wobbler parts using a South Bend lathe and Bridgeport milling machines
Casted remaining Wobbler parts using sand casting methods where we constructed the molds
Tested the Wobbler to see maximum rpm
ENGINEERING WORK EXPERIENCE
Hydroid Inc., Pocasset, MA
January, 2008 to September, 2008
Co-op Student
 Designed AUV parts and modifications using Solidworks
 Worked on an assembly team for R6000 AUV’s
 Procured machined AUV parts and aided in hands on quality control
WORK EXPERIENCE
J. Bonome & Sons, Inc., Hanover, MA
June, 2005 to Present
Laborer
 Transport vehicles & heavy equipment to construction site
 Perform site maintenance tasks to keep site clean and orderly
 Clean & maintain company trucks & equipment
A & J Landscaping, Hanover, MA
May, 2003 to Present
Owner/Operator – Part time
 Lawn & landscape maintenance; Solicit jobs & provide estimates
 Maintain lawn equipment; Maintain accounts
DESIGN PROJECT


Fully restored a 1972 Chevelle to be a daily driver
Refurbished power train, drive train and safety controls
AFFILIATIONS
Boy Scouts of America, Eagle Scout
Wentworth Lacrosse
INTERESTS
Motocross, auto mechanics, wrestling, weight lifting and physical training
September, 2005
September, 2005 to May, 2006
Myles Moore
22 County Street, Lakeville, MA 02347
MrMylesMoore@gmail.com 774-406-1202(c)
___________________________________________________________________________________________________________
EDUCATION
Wentworth Institute of Technology, Boston, MA
August 2010 exp.
Bachelor of Science in Mechanical Engineering Technology
Dean’s List – ’07, ’08, ‘09
GPA 3.46/4.00
PROFESSIONAL EXPERIENCE
Nuvera Fuel Cells, Billerica, MA
Jan. 2009 – Jan. 2010
Position: Engineering Intern

Identified and studied trends relating the effects of material properties to fuel cell stack performance using in-situ and
ex-situ test data.

Designed and executed ex-situ tests that mimic fuel cell stack operation using a uniaxial tensile testing machine.

Tested fuel cell components to characterize mechanical properties and material reliability.

Investigated component failures in fuel cell stacks and hydrogen storage systems.

Developed computer software program for faster test data analysis.

Determined range of operating conditions for stack components through statistical analysis of test measurements.
Siemens Building Technologies, Canton, MA
May 2008 – Jan. 2009
Position: Engineering Intern

Programmed and troubleshot equipment control systems.

Designed and constructed computer interfaces for HVAC control systems.

Assisted engineering department in the design of HVAC systems by generating AutoCad drawings.

Extracted and utilized information from data reports to determine system performance.

Prepared project submittals.
TECHNICAL PROFICIENCIES
Fabrication:
Four years of machine shop experience using a lathe, horizontal and vertical milling machine, grinders,
press breaks, etc.
Software:
Microsoft Excel, Microsoft Word, Microsoft Visual Basic, Bluehill 2, Mini-Tab, SolidWorks,
COSMOSWorks , AutoCAD, LabVIEW, eDrawings, Microsoft Project, Microsoft PowerPoint, Engineering
Equation Solver (EES), Working Model
COURSEWORK
 Thermodynamics 2
 Heat Transfer
 Instrumentation &
Controls




Fluid Mechanics
Calculus 3
Differential Equations
Physics 2
ACHIEVEMENTS AND CERTIFICATIONS
 Massachusetts Notary Public
 Kenpo Karate Black Belt




SolidWorks
Strength of Materials
Material Science
Statics



Machine Design
Electronics
Dynamics
Christopher Sandini
1 S Point Drive
Dorchester, MA 02125
sandinic@wit.edu
(508) 320-4896
EDUCATION
Wentworth Institute of Technology, Boston, MA
Bachelor of Science, Mechanical Engineering Technology, August 2010
COURSEWORK
Fluid Mechanics
Manufacturing Processes
Differential Equations
Calculus III
Thermodynamics
Mechanical CAD Applications
Mechanical Graphics
Statics
LABWORK
Fluid Mechanics:
-
Manufacturing Design:
-
Thermodynamics:
-
Calculated water flow rates through pipes of different sizes with
different degree elbows
Fabricated an air propelled motor complete with piston and
flywheel
Calibrated a diesel engine’s timing and made water boil at
various pressures.
TECHNICAL COMPETENCIES
Engineering:
Devices:
Software:
- Welding, Strength Testing, Casting, Soldering, Strain Gauges
- Drill Press, CNC, Lathe, Milling Machine, Hydrometer, Hand tools
- Solidworks, AutoCAD, Adobe Photoshop, Flash, Illustrator, Microsoft Word, Excel,
PowerPoint, MatLab, Microsoft Visual Studio
WORK EXPERIENCE
Sunrise Systems, Pembroke, MA
August 2009 – January 2010
Mechanical Engineering Intern

Designed custom LED signs through Solidworks.

Made 3D models and detailed drawings.

Talked to manufacturers and sent out drawings for quote.

Made part orders weekly.
Fire & Ice, Natick, MA
November 2008 - Present
Jewelry - Sales Supervisor

Assisted customers by informing them about the products.

Opened and closed the store as a key holder and made daily deposits.

Organized incoming and outgoing shipments to customers and sister stores.

Became lead seller per hour.
LEADERSHIP EXPERIENCE
Wentworth Institute of Technology
Boston, MA
Captain and Team MVP of Baseball Team
May 2009 – Present
Led a group of twenty-two baseball players through a rigorous forty game schedule to
the playoffs for the third year in a row. The captain is used as a focal point of majority of communication
between coach and team involving scheduling, team organization, daily workouts, and group meetings.
Took lead in fundraising for team involving concessions at Boston College Football games and
Wentworth Men’s and Women’s basketball games.
Appendix B
H₂ + 0₂ TO AIR
INTAKE OF ENGINE
NEGATIVE ELECTRODE
ELECTROLYTE SOLUTION
POSITIVE ELECTRODE
Figure 1: Electrolyzer
Figure 2: Gantt chart list