Internal combustion engine with hydrogen producing device having water and oil interface level control

A control system for maintaining a desired water level range from electrodes spaced thereabove in a layer of oil where alternating current discharge occurs from electrode down to and through water to another electrode, with the electrical discharge occurring between electrodes disposed at all times in the hydrocarbon oil layer. With the situs of reaction being confined to the oil and the interstitial boundry between the oil and water, dangerous conditions of hydrogen generation are generally obviated over most state-of-the-art methods of producing hydrogen with a highly efficient production process. Hydrocarbon gases and vapors are also produced from the oil with a cracking process occuring to some extent incumbant with the A C discharge from the electrodes through the oil to the water. This has also been found to gradually upgrade the quality of the oil remaining while some is at the same time consumed in the system. The hydrocarbon gases and vapors are also subject to hydrogen enrichment during the ongoing process. In a system with hydrogen produced being used along with hydrocarbon gases and vapors produced from the oil to run an internal combustion engine A C power developed by an A C generator driven by the engine flows through a current transformer to a step transformer increasing the A C voltage applied to the electrodes used in the process. A C current being sensed develops a D C signal, through a rectifier, proportional to the A C power current being fed to the electrodes. The D C signal is passed through control circuity to activate individual relay controls when the signal level falls below a desired level and rises above a desired level. This is effective to, at preset signal levels, activate a pump or open a drain cock for removing water from the tank or another pump (or reversal of a pump) to feed water back to the tank to maintain the water level in the tank within a desired range consistent with desired rates of hydrogen generation through the process.

This invention relates in general to the electrodecomposition of water and 
cracking of oil to produce gaseous hydrogen along with hydrocarbon gases 
and, more particularly, to production of hydrogen and hydrogen enriched 
hydrocarbon gases in a container holding oil and water and a closed space 
for gas above oil and water layers with AC discharge from electrodes in 
the oil layer down to and through the water from one electrode to another 
with a water level control activated for water removal or water addition 
by predetermined levels of AC power current flow. 
The process for producing hydrogen and other gases, such as set forth in 
U.S. Pat. No. 4,233,132 and entitled "Method and Apparatus for Producing 
Hydrogen", of which we are two of the co-inventors, produces hydrogen in 
varying amounts consistent with AC power supplied and the application. 
With AC electric power essential to the process, power control is required 
which, if the power is 60 cycle AC supplied by a power company, may be 
provided by standard controls. However, in adapting the process to fuel a 
conventional internal combustion engine there are various control and 
electric power supply considerations. In remote locations standard AC 
electric power may not be available, and in fueling an engine with 
hydrogen gas produced by the process precise process control is important. 
Standard controls have not been found that would yield the control 
accuracy required in the operating electromagnetic arc discharge state 
encountered in the process. The electromagnetic discharge arc voltage runs 
in the range of 1,000 to 2,000 volts with arc discharge initiating 
potential peaking as high as 8,000, even 10,000 volts- voltage variations 
and levels detrimental to many electronic controls. It is important that 
the water level control system be able to provide the close control 
required even though the AC power signal varies in frequency and that the 
control have high level and low level set points to operate relays and/or 
pumps or valves. A controlling factor in varying the AC current is the 
water level to electrode spacing that is varied through addition of water 
or removal of water. As crude oil is used in the process, water in the oil 
not used by the process may be removed to maintain the water level within 
the control limits required. Where herebefore electrodes were adjustable 
to compensate wear or water lever changes the improved water level control 
automatically compensates for electrode wear and eliminates the need for 
adjustable electrodes. 
It is, therefore, a principal object of this invention to provide wear and 
oil interface level spacing control from electrodes regardless of the 
state of electrode erosion in an electrodecomposition of water hydrogen 
production and hydrocarbon gas production oil cracking process. 
Another object is to ahcieve the desired water level control through sensed 
levels of AC power current flow. 
A further object is to provide such a water level control with an upper 
level control set point and a lower level control set point. 
Still another object is to provide such amperage current flow span between 
control upper level and lower level set points as to allow for small 
variations in AC power line current. 
Another object is to provide such a water level control not subject to pump 
water level control actuation by current surges of short duration through 
a built-in time delay in the control circuit. 
Features of the invention useful in accomplishing the above objects 
include, in a water and oil interface level to electrode end space control 
of a system for electrodecomposition of water to produce hydrogen along 
with hydrocarbon gas, produced with oil cracking, fueling an engine, an AC 
power current level sensed control for activating an upper water level 
control for removal of water and for activation of a lower water level 
control for adding of water. AC power developed by an AC generator driven 
by the engine flows through a current transformer to a step transformer 
increasing the AC voltage applied to the electrodes used in the process. 
The AC current being sensed develops a DC signal, through a rectifier, 
proportional to the AC power current being fed to the electrodes. This DC 
signal is applied through control circuitry to activate respective relay 
controls when the signal level rises above a desired level, and when the 
signal level falls below a desired level. This acts, at preset signal 
levels, to activate a pump or open a drain cock for removing water from 
the tank or another pump (or reversal of a pump) to feed water back to the 
tank to maintain the water level in the tank within a desired range 
consistent with desired rates of hydrogen generation through the process. 
A specific embodiment of the water and oil interface level to electrode 
spacing control in a hydrogen and hydrocarbon gas production process 
presently regarded as the best mode of carrying out the invention is 
illustrated in the accompanying drawing.

REFERRING TO THE DRAWING 
The hydrogen and hydrocarbon gas production unit 10 is shown in FIG. 1 to 
be connected for feeding gaseous fuel and hydrocarbon vapors to an engine 
11 useful to any number of purposes such as a stationary power plant for 
powering any number of things (detail not shown). A generator 12, driven 
by engine 11 in a conventional manner, develops AC power fed through lines 
13 and 14 to step up transformer 15 that has high voltage output 
connections through lines 16 and 17 to electrodes 18 and 19, respectively, 
the exposed portions of which, generally below the insulated feed mounts 
18' and 19', are in a layer of oil 20. The hydrogen gas production unit 10 
has a tank 21 containing a lower layer of water 22, the layer of oil 20 
above the water and a closed space 23 for gas above the layer of oil 20. 
The gap spacing between the bottom ends of electrodes 18 and 19 and the 
upper surface of the water layer 22 is important in the 
electrodecomposition of water to produce gaseous hydrogen where with AC 
power current flow decreasing with increased spacing between the 
electrodes 18 and 19 and the water layer 22. Obviously, the level of AC 
power flow in discharge through the oil 20 to the water layer 22 controls 
the degree of oil cracking and hydrocarbon gas production. 
The hydrogen and hydrocarbon gas production unit 10 is provided with an air 
inlet pipe 24 extending from an air cleaner 25 above the tank 21 to an 
outlet end 26 well within the layer of oil 20 to dispel inlet air into the 
oil layer 20. Air and gas fuel (mostly hydrogen along with hydrocarbon 
gas) is fed through pipe 27 from open end 28 within closed space 23 to 
valve and carburetor structure 29 on engine 11 through which additional 
air may be drawn from air filter 30 and delivered to inlet manifold 31 for 
engine 11. The AC power output of generator 12 is also connected through 
lines 13A and 14A to AC to DC rectifier 32 that rectifies the AC to 
provide 12-volt DC for charging 12-volt battery 33 through lines 34 and 35 
to battery terminals 36 and 37, respectively, with line 34 being the 
ground connection line for the system. The positive DC power line 35 is 
connected to control head 38 where subject to set level relay control 
power circuits are completed for power activation of high level pump 39 
and low level pump 40 through DC power lines 41 and 42, respectively, when 
a level limit is sensed. 
The current transformer 43 senses the AC power flow being delivered through 
line 14 to step up transformer 15 and develops a proportional low power AC 
signal fed through lines 44 and 45 to rectifier 46 (AC to DC inverter) 
supplying a like proportioned DC signal, low in the milliamp range, to 
control head 38 through DC lines 47 and 48. 
Referring also to the partial block schematic showing of FIG. 2, power line 
14 is shown to include a coil 49 wound around a ferrite circuit loop 50 of 
the current transformer 43. The DC leads 47 and 48 out of AC to DC 
converter 46 are shown to be series connected through current sensitive, 
adjustable, series connected coils 51 and 52 of relays 53 and 54 that 
have, respectively, a normally closed relay switch 55 and a normally open 
switch 56. The normally closed switch 55 of relay 53 is activated by the 
current flow at a preset current flow sensing level to open, and below 
that level to close, for the application of power through line 42 to low 
level pump 40 to pump water from water supply tank 57 through water pipe 
58 to the pump 40 and from the pump 40 through line 59 to the water layer 
22. This raises the upper surface of the water layer and decreases the gap 
between the low ends of electrodes 18 and 19 to thereby provide 
progressive increase in current flow to and through the electrodes 18 and 
19, hydrocarbon material of oil layer 20 and the intervening water layer 
22. A further increase in current flow through the series connected coils 
51 and 52 results in closing of switch 56 to apply positive DC power 
through line 41 to pump 39 in order to withdraw water from water level 22 
in tank 21 through pipe 59 and pipe 60 to the pump 39 and on through pipe 
61 back to water resevoir tank 57. 
These two lower level and upper level adjustable set points in activation 
of the switches of relays 53 and 54 allow the system to be operated at a 
predetermined current level range spanning several amps that may be 
adjusted for specific applications with typically, in one instance, a 
10-amp span being provided between the two respective relay actuation 
points to allow for small variations in line current. An inherent or 
built-in time delay in the control circuitry allows for current surges of 
short duration without activation of either pump. As the AC power current 
level rises above the set point power is supplied to the high pump 39 for 
removal of water from the hydrogen and hydrocarbon gas generation process 
tank 21. When the AC power current falls below the low set point the 
normally closed switch 55 of relay 53 closes to power pump 40 in order to 
add water to the water layer 22 in tank 21. Obviously this operates at a 
very effective water level to electrode gap control to thereby maintain 
proper power flow through the system in developing gas for fueling the 
engine 11 in system operation. This control of water level eliminates any 
need for adjusting of electrodes since it is a self-adjusting water level 
control to maintain water to electrode spacing within the desired range 
provided in the span associated with the sensed level operation of the two 
relays 53 and 54 in series or parallel. 
It should be noted that pumps 39 and 40, either one or both, could in some 
installations be valves that permit exhaust flow to a lower water level 
outlet and that the other pump could be a valve that opens to admit water 
under pressure from a water pressure source to the water level 22 in tank 
21. 
It should also be noted that the pump drives of pumps 39 and 40 could be AC 
power drives instead of the DC power drive system shown by circuitry and 
motor equipment known to those skilled in the art. Furthermore, the 
frequency of AC developed by generator 12 can vary through a considerable 
range without having an adverse effect on the hydrogen and hydrocarbon gas 
process and control therefor provided herein. 
Oil from oil supply tank 62 is used to supply oil to the layer of oil 20 as 
oil is consumed in the gas generating process as demand is indicated by 
float 53 and float control 64 that is connected in a conventional manner 
(indicated by dashed line 65) to oil supply pump 66. A pipe line 67 
connection from the bottom of oil supply tank 62 to pump 66 and pipe line 
68 to valve 69 and pipe line 70 feed make up oil to the layer of oil 20 at 
the electrode end of tank 21 when pump 66 is activated to pump oil. An oil 
withdrawal pipe line 71 extends from the opposite end of tank 21 from the 
electrode end to an oil circulation pump 72 from which outlet pipe line 73 
connects to valve 69 for circulation of oil on through pipe line 70 back 
to the electrode end of tank 21. Temperature sensor 74 that may be located 
in either the oil or water near water oil surface in tank 21 and connected 
for activating the circulation pump 72 in a conventional manner manner as 
through a connection indicated by a dashed line 74A when the temperature 
sensed reaches a predetermined level. The circulation pump is also 
equipped with a pipe flow line 75 connection to the oil supply tank 62 to, 
as controlled by temperature control valve 76, divert some of the oil 
pumped by pump 72 to supply tank 62. It is of interest to note, 
particularly where crude oil is used in the process, the cracking action 
with the arc discharge of the process upgrades the oil to a more valuable 
higher price oil so, even though some oil is consumed in the overall 
system with hydrocarbon gases and vapors being used to help run a motor 
along with hydrogen generated the improvement in the otherwise crude oil 
so processed can go toward covering the cost of oil consumption. An air 
vent valve 77 in the top 78 of oil storage or supply tank 62 prevents 
pressure differential damage to the tank 62 as oil is drawn from the tank 
or pumped into the tank. The temperature control valve 76 is generally set 
to divert oil back to the supply tank 62 only when the temperature of oil 
being recirculation pumped by pump 72 is above a predetermined level in 
order that oil circulated through the oil layer 20 in tank 21 be readily 
maintained at a desired process temperature level without having to heat 
massive supplies of oil in a storage and supply tank 62. The valve 69 is a 
self adjusting valve permitting flow of oil from oil feed pump 66 or from 
circulation pump 72 or balance of oil flow from both pumps when they are 
simultaneously pumping. 
Since the process produces more fuel in gas and vapor form at higher 
temperature a heat exchanger engine exhaust pipe line 79 is passed through 
the water layer 22 portion of process tank 21. The temperature sensor 74 
is connected through a conventional connection as indicated by dash line 
80 for varying valve 81 in balanced controlled diversion of hot exhaust 
gases from the engine exhaust manifold 82 between direct exhaust pipe 83 
and the pipe line 79 extended through tank 21. This helps, for example, in 
countering disassociation cooling of the water as hydrogen is released 
from oxygen in the electro-disassociation process. 
Testing of the system was conducted using a 534 cubic Ford engine running 
at 1,750 r.p.m. pulling a 70 horse power load with the process adding 
approximately an additional 15 horse power to the engine load. Oil 
consumption was, with proper controls, lowered into approximately the 2.5 
to 4 gallon per hour consumption rate at approximately 50 hours into a 
run. Further, starting with 39 gravity oil with recycling of oil passed 
through the process tank 21 returned to large tank storage gravity of the 
stored oil was lowered beneficially to 36 gravity in approximately 90 
hours of running. 
Whereas the invention is herein described with respect to a preferred 
embodiment thereof, it should be realized that various changes may be made 
without departing from the essential contribution made by the teachings 
hereof.