WARNING!
It’s important to note that mixing water, electricity, and lye (sodium hydroxide) can be dangerous and should only be performed by trained professionals or under close supervision. Lye is a highly caustic substance that can cause severe chemical burns and is toxic if ingested. Additionally, the electrolysis process generates hydrogen gas, which is highly flammable and can pose an explosion risk if not handled properly.
When working with lye and electricity, it’s important to wear protective gear such as gloves, eye protection, and clothing that covers your skin. You should also make sure to work in a well-ventilated area and follow all relevant safety guidelines and regulations. If you have any concerns or uncertainties about the process, it’s best to seek the assistance of a qualified professional.
Inspiration
Several year ago, and friend and I got curious about hydrogen generators and what they could be used for. This ultimately lead to this project, but first it is important to note there are two types of wet cell hydrogen generators, batch cell and flow cell.
The process where the electrodes are submersed in an electrolyte solution is commonly referred to as batch electrolysis. In batch electrolysis, the electrodes are placed in a container filled with the electrolyte solution and a voltage is applied to initiate the electrolysis reaction. Once the reaction has proceeded for a certain amount of time, the solution is drained and the hydrogen and oxygen gases are collected.
In flow electrolysis, the electrolyte solution is continuously circulated past the electrodes rather than being stored in a stagnant container. This approach allows for more efficient use of the electrodes and can help to overcome some of the limitations of conventional wet cell electrolysis, such as the accumulation of waste products and the buildup of electrical resistance.
The generator described here is a flow cell.
Step #1
Cut T-Slot Framing to the lengths listed
- 7 – 14″
- 2 – 16″
- 2- 20″
Step #2
Align the 20″ vertical piece to the 16″ horizontal part as shown. Use a 1′ 45 degree corner and 1 gusset to make the connection. Insert a gusset into the 45 degree for later use. The upright piece should be 3″ from the left side.
Step #3
Prepare 2 rubber feet, found on amazon, with 1/4″ T-Slot nuts and install them onto the bottom of the side. Now duplicate steps 1 and 2 to make the other side.
Step #4
The next several steps will have a lot of T-Nuts / components inserted in to framing that may not make sense now but will not be accessible later. The first section has 2 t-nuts with 1/4″ washers and 2 gussets. Assemble as shown.
Step #5
Repeat step #4 exactly and install as shown. There should be a 1-3/4″ gap between the two.
Step #6
A PWM Controller is useful for adjusting the output of the generator. This part was purchased on Amazon and had the mounting holes modified since they would not accept a 1/4″ screw. The PWM controller can be mounted as shown. Its exact position is not important.
Step #7.1
This frame piece has 4 gussets, 4 zip tie mounts, and 4 t-nuts. Install as shown.
Step #7.2
Install the frame exactly 3.5″ off the ground.
Step #8.1
Assemble 2 zip tie mounts, 2 gussets, 4 t-nuts, and 1 3D printed bracket as shown.
Step #8.2
Attach to the 45 degree supports prepare earlier. Ensure it sits square and is 3.5″ off the ground.
Step #9
Cut 2 – 7.75″ lengths of T-Slot Framing and tap one of the ends for a zip tie mount. Attach to the frame as shown. If done correctly, the ends should line up perfectly. The position of the two lengths are not important right now as they will be adjusted later.
Step #10
Assemble 2 gussets, 4 t-nuts, and 1 zip tie mount. Attach to frame 10″ off the ground as shown.
Step #11
Assemble 2 gussets, 5 t-nuts, and 1 zip tie mount as shown. Attach 16″ off the ground.
Step #12
Assemble 2 gussets, and 1 t-nut as shown. Attach to the top of the frame.
Step #13
The reservoir tank was also bought off Amazon. Attach it to the frame using to screws and 1 t-nut. Use the right most t-nut currently installed in the frame for the left side of the tank.
Step #14
This generator uses a 120vac to 12vdc power supply. To mount it, gather some appropriate screws and washers and mount four gussets to the side. There will be movement but that is ok, it will make things easier to adjust later while still providing a firm connection. Mount the assembly to the back side of the frame using the 4 previously installed t-nuts.
Step #15
The part that makes this whole generator work, at it core was bought off Amazon, however this one is modified. A new base was designed just for it and the inlet and outlet was changed to stainless steel. A drain valve was also added for ease of cleaning. Make some adjustment to the cell platform so everything sits comfortably. Attach with 4 t-nuts and screws.
IMPORTANT!
Do not install a drain unless proper precautions are taken when using the device. Accidently bumping the drain will result in a very caustic solution spilling out. It will dissolve flesh if not properly handled!
Step #16
Cut 2 lengths of 3/8″ poly and connect as shown. Secure with 4 hose clamps.
Step #17
To monitor the system voltage, current, and flow rate, I created this panel. The meters were purchased and the panel is cut on the laser cutter. Assemble the panel as shown and attach to the frame using the 4 previously installed t-nuts.
Step #18
This next part simply makes attaching a hose for the gas output a bit easier and nicer. Attach the 3D printed part as shown using 2 t-nuts and 3 screws using 1 previously install t-nut.
Step #19
Time to finish the poly work. Cut a length of 3/8″ and 1/4″ poly. You will also need a 1/4″ gas quick connect and 2 hose clamps. Connect the output of the tank to the input of the flow meter. Connect the output of the flow meter to the quick disconnect.
Step #20
Time to prepare for the wiring harness. Gather 12 zip tie mounts and attach in the places shown. Exact placement is not a requirement, it simply makes the wiring neater.
Step #21
Using lots of wire, zip ties, and various connectors. Assemble the wiring harness as shown. It is easier to do this gradually on the frame itself to get the lengths correct.
Completion!
This particular generator produces roughly 1 liter of gas per minute. Be very careful as hydrogen gas when mixed with oxygen gas at the same time is very dangerous and detonating the gas may not be legal in your area.