Portable hydrogen generation using metal emulsions

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US 2004/0025808 A1 Feb. 12, 2004

PORTABLE HYDROGEN GENERATION USING which may result in resistance to water diffusion and an METAL EMULSIONS incomplete conversion of rather expensive materials. There is thus a need for complete conversion of metal to hydrogen.

CROSS-REFERENCE Another example of the in-situ-hydrogen-generation for 0001. This application is a continuation-in-part applica internal combustion engines ShowS hydrogen generated by tion of and claims the benefit of non-provisional patent the reaction of non-compressed packed-iron-powder with application Ser. No. 09/923,887 filed on Aug. 7, 2001, and alkaline hydroxide as a catalyst at temperatures lower than is hereby incorporated by reference in its entirety. 250 degrees C. However, the quantity of iron or aluminum in emulsion form being precisely metered into the reactor

FIELD OF INVENTION and completely reacted according to the demand of the internal combustion engine, has not been observed.

0002 The present invention pertains to a portable hydro 0006 Others suggest that any active material, such as gen generation System and method which can power internal Sodium, may be coated with an impervious material, Such as combustion engines on-board vehicles Such as automobiles. plastics or aluminum film. The pellet coating can be broken Furthermore, this hydrogen generation System can Supply by an electrical current or a mechanical means, Such as a hydrogen to feed fuel cells. The fuel Supplied to the portable knife, and then the Sodium is exposed to water to generate hydrogen generation System comes in the form of an emul hydrogen on-board of a motor vehicle. However, Such sion that consists of metal powder pre-mixed with oil. The inventions can only Supply the fuel in large increments, due metal emulsion can be precisely injected into the hydrogen to the size of the pellets, but not continuously. In particular, generation System based on demand. The hydrogen is gen Some have shown reacting iron with water in the presence of erated from the reactions between an alkaline metal, Such as an alkali hydroxide as a catalyst to generate hydrogen, then, Sodium and water, or the reaction between alkaline hydrox using it to feed a fuel cell. The electricity produced is ide Solution and a metal Such as iron or aluminum.

utilized to run an electric car. However, Such an invention

BACKGROUND OF THE INVENTION does not have the benefits of Simplicity of a mechanical arrangement and the precision and continuity of metering 0003. It is well known that hydrogen can be used to fuel the fuel according to the demand of the engine. In addition, internal combustion engines or to feed fuel cells, and it has neither is there a high rate of hydrogen production nor the been commercially produced as a byproduct from chlorine desired lowered temperature for reactions to take place alkali electrolysis or through large-scale production through between metal emulsions and water Seen in Such inventions. a steam-carbon reaction. However, hydrogen is bulky and a real challenge to Store. Such an obstacle can be overcome by SUMMARY OF THE INVENTION hydrogen generation on-situ and by on demand delivery. 0007. The principal object of the present invention is to Some processes have been disclosed as producing hydrogen provide a fuel for an in-situ-hydrogen-generation System from the reaction between an alkali metal and water. How ever, Such disclosure fails to show that metal in emulsion can using a metal emulsion that can be continuously metered and facilitate metering-on-demand and precise injection into an precisely fed into a reactor, in which the metal is rapidly and internal combustion engine. The on demand hydrogen gen completely reacted with water or hydroxide solution. The eration systems have been exemplified by others but show hydrogen generated is used to operate an internal combus Systems which do not use a metal emulsion. For instance, tion engine or to fuel a fuel cell. The electricity generated from the fuel cell can be used to drive an electric car or other one particular System utilizes a membrane to Separate a electrical devices.

water container from a metal hydride or alkali metal with water slowly diffusing through the membrane to achieve a 0008 Another object of the present invention is to pre chemical reaction. However, the System is unreliable. In the pare the metal fuel (finely divided iron or aluminum or alkali case of membrane rupture, all alkali metal or metal hydride metals) in paste form to prevent pre-usage contamination of would be instantly be exposed to water and result in an the metal by water vapor or oxygen in the air. The Said paste uncontrollable generation of the hydrogen. This is totally (or emulsion) has a certain consistency to allow it to be fed unsuitable for use in automobiles and motor vehicles. or injected Smoothly, precisely, and continuously. The metal Another drawback of the membrane is the possibility of fuel emulsion may be contained in cartridges. membrane clog after prolonged use. 0009 Still another object of the present invention is to 0004. The use of hydrogen as fuel for internal combus provide for the Said hydrogen generation System, a micro tion engines or for fuel cells to run an electric car has also processor controlled System to orchestrate the Smooth opera been disclosed. However, there is still no teaching of the use tions of the metal to hydrogen conversion. The micropro of metal emulsions which can be metered and fed precisely ceSSor timely opens and closes the delivery valves of on demand to the hydrogen generator and at the same time emulsion cartridges according to the operating conditions of have low temperature reactions with a high rate of hydrogen the internal combustion engine which the hydrogen genera generation. Some others have used hydrochloric acid to tion System serves. It also controls the Supply of water (or react with a pure metal to generate hydrogen. There, again hydroxide Solution) to the reactor and the discharging of the no metal emulsion is involved. waste reaction products.

0005. In other teachings, activated iron is reacted with 0010 Still another object of the present invention is to heated water for hydrogen generation. However, again there provide a stirrer for the reacting tank to promote a complete is no use of metal emulsion. OtherS Seek to generate hydro reaction between the metal powder granules and water (or gen from metal hydrides and water. The diffusion of water hydroxide Solution). Thus, the rapid reaction and the com into metal hydride granules results in hydroxide or oxide plete conversion of the metal to hydrogen are assured.

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0.011 Yet, another object of the present invention is to 0019. The method of operation of an embodiment of the provide for instant pure hydrogen generation using reactions system is described by the following. When the engine is at low temperatures, for instance water at or near room Starting or running, a Suction is building up in the hydrogen temperature, to react with metal fuel So as to result in a delivering line 15, and the pressure in the reactor tank 2, is higher rate of hydrogen generation than currently observed, lowered. This is So, Since the pressure above the metal-oil making it highly desirable for use with automobiles. The emulsion cartridge in use is in equilibrium with that in the pure hydrogen is also preferably generated at or near room compressed air reservoir 8, which is kept constant with a temperature. pressure controller (not shown). The pressurized air is 0012 Further, it is another embodiment of the present Supplied by compressor 7. Before entering the cartridge, the invention that the reaction tank of the System is kept at a preSSurized air is dried by passing through a desiccator 9. constant and desirable temperature through the use of a The flow rate of metal-oil emulsion from the cartridge into variable speed blower to remove exceSS heat generated by the reactor is proportional to the pressure difference between the reaction tank. the cartridge in use and the reactor. This preSSure difference varies proportionally with the engine's Starting, idling and 0013 These and other embodiments of the present inven acceleration. For example, when the engine is running from tion are further made apparent, in the remainder of the idling to acceleration, the hydrogen pressure in the reactor is present document, to those of ordinary skill in the art. progressively decreased, and the rate of flow of metal-oil emulsion is proportionally increased.

BRIEF DESCRIPTION OF THE DRAWING

0020. The stirrer 3 in the reactor tank 2 provides a 0.014. In order to more fully describe objects, features and Vigorous mixing effect to break up the metal-oil emulsion advantages of the present invention, reference is made to the and to promote complete rapid reaction between the fuel accompanying drawing. This drawing is not to be considered metal and water or hydroxide Solution. Thus, the complete limitations in the Scope of the invention, but is merely utilization of the fuel metal is insured. illustrative.

0021. The microprocessor 5 continuously keeps track of 0.015 FIG. 1 illustrates the flow diagram of the in-situ the metal-emulsion content (through level measurement) of hydrogen-generation System according to an embodiment of the cartridge in use. When the cartridge in use is exhausted, the present invention. it closes the delivery valve 13 of the cartridge in use, at the Same time, it opens the delivering valve 13 of the next

DETAILED DESCRIPTION OF SPECIFIC unused cartridge in sequence until the cartridge bank is used EMBODIMENTS up. The microprocessor 5 also sends the Status information 0016 References will now be made in detail to the about the metal-emulsion content to the LCD display Screen preferred embodiment of the method of the present inven 6. It also issues a warning Signal and/or emits an audible tion. The following discussion describes in detail one warning Sound to alert the automobile driver or the engine embodiment of the invention and several variations of that operator to prepare for a refill. The cartridge bank is built as embodiment. This discussion should not be construed, how one unit, which can be easily disconnected from and reat ever, as limiting the invention to those particular embodi tached to the System. The System can be installed on board ments. PractitionerS Skilled in the art will recognize numer an automobile or motor vehicle having a hydrogen powered ous other embodiments as well. For a definition of the internal combustion engine.

complete Scope of the invention, the reader is directed to the 0022. The metal emulsion supplied to the cartridges is appended claims. comprised of metal fuel and oil. The metal fuel is preferably 0.017. As shown in FIG. 1, a set of metal emulsion in the form of a powder of finely divided iron, aluminum or cartridges 1 Surround and connect to a reactor tank 2, alkali metals. Such metals may include finely divided through solenoid delivering valves 13. The set of cartridges Sodium, potassium, magnesium or zinc. The size of the 1 may be in a group of about 6 to 12 cartridges. All metal fuel powder may range from 25 to 500 microns. The metal-emulsion cartridges 1 are connected to the com oil comprises a high boiling point hydrocarbon or a Veg pressed air reservoir 8 through a desiccator 9. The pressur etable oil. The preferred embodiment uses a hydrocarbon oil ized air is Supplied by a compressor 7. The reactor tank 2 is with a boiling point above 300 degrees F. Such a hydrocar also connected to a fresh water tank 14 and a waste Sepa bon oil provides for stability and long shelf life. The ration tank 10 in which the waste Stream is separated into combined metal-oil emulsion may contain from about 25% two layers. The upper layer bleeds into the waste oil Storage to 75% of metal by weight. The preparation of the metal 12 and aqueous products discharge into an aqueous waste powder occurs immediately before its combination with oil Storage tank 11. to produce to the emulsion So as to minimize the possible contamination of the metal by air and water vapor. Once 0.018. The whole hydrogen generating system is managed combined, the emulsion may resemble a paste-like consis by a microprocessor 5. The operating Status and conditions tency. The metal emulsion is Stored in a bank of cartridges are indicated on a liquid crystal display (LCD) 6. The comprising about 6 to 12 cartridges to Surround the reactor compressed air reservoir 8 and each of the cartridges 1 has tank2. The metal-oil emulsion is Supplied to the reactor tank a pressure Sensor. Each of the metal-oil emulsion cartridges 2 in combination with water or alkali hydroxide solutions. 1 has a level Sensor. The microprocessor 5 collects and For instance, Sodium, potassium, Zinc or magnesium based processes the Signals from all pressure Sensors and then metal emulsions are reacted with water, whereas aluminum issues commands to all parts of the System, as shown or iron based emulsions are reacted with an alkali hydroxide through the dotted lines. Solution.

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0023 The reaction temperatures for reacting potassium f. controlling the System with a microprocessor, which and Sodium for example with water ranges between the controls timely opening and closing of the delivering freezing point and the boiling point of the water. AS for Valves in each of the cartridges in a Sequence and aluminum and an alkali Solution, the reaction temperatures continuously tracks metal-oil emulsion content and can range between the melting point and the boiling point of Supply, the alkali Solution. The melting and boiling points of Such a wherein oily waste is continuously separated from the Solution are increased proportionately with the increase of aqueous waste and bled into the waste oil tank from the the concentrations of the Solution. The reaction of aluminum or iron with an alkali Solution is normally a slow reaction, reacting Step, and pure hydrogen is generated at or near room temperature.

therefore an electric heater may be used to Speed up the 2. The method according to claim 1, wherein the metal-oil hydrogen generation for Such reactions. The electric heater emulsion consists of a metallic powder comprising: can be used to bring about the reaction at a predetermined and desirable rate to Sustain the power generation in a fuel finely divided Sodium, potassium, magnesium or Zinc, cell or hydrogen burning internal combustion engine. Dur when reacted with water or ing reaction, the reaction tank temperature and thus the aluminum powder or iron powder, when reacted with generated hydrogen may be controlled at a constant tem alkali hydroxide Solution and perature by providing a variable Speed blower to remove exceSS heat generated by the reaction tank. The reaction tank wherein the Size of the metallic powder ranges from about may be installed with cooling fins to radiate off the exceSS 25 to about 500 microns.

heat. The speed of the blower may be controlled by micro 3. The method according to claim 2, wherein the emulsion processor as described above. The resulting pure hydrogen comprises between 25% to 75% of metal by weight. is generated at a high rate at or near room temperature. 4. The method according to claim 1, wherein a metallic Although preferred at or near room temperature, the gen powder in the Said metal emulsions is prepared just before eration of the pure hydrogen need not occur at Such a the making of the metal-oil emulsion to minimize possible temperature. The resulting method and System generates contamination by air and water vapor. pure hydrogen without generation of any Secondary gaseous 5. The method according to claim 1, wherein the oil in the products. metal-oil emulsion is a high boiling point hydrocarbon oil 0024. Throughout the description and drawings, example (above 300 degrees F) or a vegetable oil. embodiments are given with reference to specific configu 6. The method according to claim 1, further comprising rations. It will be appreciated by those of ordinary skill in the Stirring within the reaction tank with a Stirrer to promote a art that the present invention can be embodied in other rapid and complete reaction between the metal and water or specific forms. Those of ordinary skill in the art would be between the metal and alkali hydroxide solution. able to practice Such other embodiments without undue 7. The method according to claim 1, wherein the emulsion experimentation. The Scope of the present invention, for the has a consistency comparable to that of a paste. purpose of the present patent document, is not limited 8. The method according to claim 1, further comprising: merely to the Specific example embodiments of the forego Supplying a Smooth and Steady flow of the metal emulsion ing description, but rather is indicated by the appended into the reaction tank, claims. All changes that come within the meaning and range regulating the flow by the pressure difference between a of equivalents within the claims are intended to be consid cartridge in use and the reaction tank, ered as being embraced within the Spirit and Scope of the claims. controlling the pressure in the cartridge by a pressure controller attached to a compressed air reservoir Sup plied by a compressor,

What is claimed is:

1. A method for generating portable hydrogen fuel on wherein when the engine is Stopping, the pressure of demand for a hydrogen powered internal combustion engine hydrogen in the reaction tank builds up to equal that of comprising: the metal emulsion cartridge, resulting in no flow of metal emulsion;

a. reacting water or alkali hydroxide Solution with a metal wherein when the engine is running from idle to accel in a reaction tank, the metal being in the form of a eration, the hydrogen preSSure in the reaction tank metal-oil emulsion; progressively reduces, and the rate of flow of metal b. Storing the metal-oil emulsion in a Set of cartridges emulsion is proportionally increased. connected to and around the reaction tank, each car 9. The method according to claim 1, further comprising tridge having a Solenoid delivering valve to deliver a Sending information to a liquid crystal display. flow of emulsion into the reaction tank, 10. The method according to claim 1, further comprising c. Supplying compressed air to the System through a collecting information of pressures in the System and compressor to control pressure in the Set of cartridges, levels of metal-oil emulsion remaining in cartridges through a set of preSSure and level Sensors, and d. drying the compressed air through a dessicator;

managing Such information by a Software program, e. collecting an oil and aqueous waste into a waste wherein the microprocessor facilitates collecting and Separating tank from the reacting Step, whereby aque managing the information.

ous waste is collected in an aqueous waste tank and oil 11. The method according to claim 1, further comprising waste is collected in a waste oil tank, and heating the reaction tank with an electric heater in the case

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where the metal used is aluminum or iron wherein the 17. The system according to claim 15, wherein a metallic temperature of the reaction tank is controlled by the micro powder in the Said metal emulsions is prepared just before processor to maintain an optimal Setting between room the making of the metal-oil emulsion to minimize possible temperature and 250 degrees C. contamination by air and water vapor. 12. The method according to claim 1, further comprising 18. The System according to claim 15, further comprising removing exceSS heat generated by the reaction tank by a a stirrer for Stirring within the reaction tank to promote a variable Speed blower to keep the temperature of the reac rapid and complete reaction between the metal and water or tion tank constant, and the Speed of the blower is controlled between the metal and alkali hydroxide solution. by the microprocessor.

13. The method according to claim 12, wherein removing 19. The System according to claim 15, further comprising exceSS heat from the reaction tank is further facilitated by a pressure controller attached to a compressed air reser installing cooling fins to the reaction tank. Voir Supplied by a compressor to control the pressure in 14. The method according to claim 1, wherein the System is installed on board an automobile or motor vehicle having a cartridge in use wherein a Smooth and Steady Supply a hydrogen powered internal combustion engine. of the metal emulsion flow enters the reactor tank, 15. A portable hydrogen-on-demand-generating System regulated by the pressure difference between a cartridge for a hydrogen powered internal combustion engine com in use and the reaction tank, prising: wherein when the engine is Stopping, the pressure of a. a reaction tank for reacting water or alkali hydroxide hydrogen in the reactor tank builds up to equal that of Solution with a metal, the metal being in the form of a the metal emulsion cartridge, resulting in no flow of metal-oil emulsion; metal emulsion;

b. a set of cartridges connected to and around the reaction wherein when the engine is running from idle to accel tank for Storing the metal-oil emulsion, each cartridge eration, the hydrogen pressure in the reactor tank having a solenoid delivering valve to deliver a flow of progressively reduces, and the rate of flow of metal emulsion into the reaction tank; emulsion is proportionally increased. c. a compressor to control pressure in the Set of cartridges 20. The System according to claim 15, further comprising and for Supplying compressed air to the System;

a set of pressure and level Sensors for providing pressure d. a dessicator to dry the compressed air before entering and metal-oil emulsion level information to the micro the cartridges; processor e. a waste Separating tank for collecting an oil and a set of pressure and level Sensors for providing pressure aqueous waste resulting from the reacting Step, further and metal-oil emulsion level information to the micro having an aqueous waste tank for collecting aqueous proceSSOr, waste and a waste oil tank for collecting oil waste; and f. a microprocessor for controlling and managing the a Software program to manage Such information; and System, the microprocessor controls timely opening a liquid crystal display for providing Such information to and closing of the delivering valves in each of the an end-user.

cartridges in a Sequence and continuously tracks metal 21. The System according to claim 15, further comprising oil emulsion content and Supply; an electric heater for heating the reaction tank in the case wherein oily waste is continuously Separated from the where the metal used is aluminum or iron wherein the aqueous waste and bled into the waste oil tank from the temperature of the reaction tank is controlled by the micro reacting Step, and pure hydrogen is generated at or near processor to maintain an optimal Setting between room room temperature. temperature and 250 degrees C.

16. The System according to claim 15, wherein the metal 22. The System according to claim 15, further comprising oil emulsion consists of a metallic powder comprising a variable Speed blower for removing exceSS heat generated finely divided Sodium, potassium, magnesium or Zinc, by the reaction tank, to keep the temperature of the reaction when reacted with water or tank constant, and wherein the Speed of the blower is controlled by the microprocessor.

aluminum powder or iron powder, when reacted with 23. The System according to claim 22, further comprising alkali hydroxide Solution and cooling fins attached to the reaction tank for facilitating wherein the Size of the metallic powder ranges from about removal of exceSS heat from the reaction tank. 25 to about 500 microns and wherein the emulsion comprises between 25% to 75% of metal by weight.