US20110203918A1

US20110203918A1 - Apparatus and method for generating hydrogen from water

Info

Publication number: US20110203918A1
Application number: US13/099,125
Authority: US
Inventors: Sanford Brown; John D. Parkyn
Original assignee: Hydrox Energy Corp LLC
Current assignee: Hydrox Energy Corp LLC
Priority date: 2006-01-13
Filing date: 2011-05-02
Publication date: 2011-08-25
Also published as: US20070163877A1; US20130175163A1

Abstract

Described herein is an apparatus is capable of generating hydrogen and oxygen gases from water containing little or no electrolyte. The apparatus includes a container and at least one electrolysis assembly comprising one or more permanent magnets which are covered with at least one pair of porous conductive electrodes separated by a non conductive insulator. The assembly is connected to the leads of a direct current power supply. After the container is filled with water to cover the electrodes, application of voltage from the power supply results in the generation of hydrogen and oxygen gases. This apparatus and method provides a means of producing and distributing hydrogen on-site, simply and inexpensively, since it uses very little energy and liquefaction, transportation, and delivery costs can be avoided.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/507,400, filed Aug. 21, 2006 and also claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 60/758,700, filed Jan. 13, 2006, the disclosures of which are hereby incorporated by reference in their entireties.

BACKGROUND OF THE INVENTION

1. Field of the Invention
This invention relates to an apparatus and method for performing electrolysis of water to form hydrogen and oxygen.
2. Description of the Related Art
The combustion of hydrogen and oxygen yields energy and water. No pollutants or chemicals are released that are toxic or damaging to the environment; a claim that no other chemical fuel is able to make. Hydrogen is also highly efficient. Accordingly, hydrogen is a highly desirable fuel source.
Conventional methods of generating hydrogen have been problematic because they defeat one or more of the purposes for using hydrogen as a fuel. Billions of tons of carbon dioxide are expelled into the atmosphere every year from facilities that produce hydrogen through the burning of fossil fuels, such as coal, oil, or natural gas. One conventional method commonly used for producing hydrogen is by steam reforming of natural gas, which produces carbon dioxide and other gases. The technology for conversion of coal to hydrogen is also presently available and among the least expensive methods in current practice. However, the carbon dioxide produced from making hydrogen from coal is greater than from any other production technology. Thus, although hydrogen seems to be produced cheaply, if one includes the hidden costs from carbon dioxide production and other pollutants on our environment, the cost of making hydrogen from coal is much higher than it first appears. Other technologies using fossil fuels listed also suffer these same inadequacies. Additionally, these methods usually provide for the hydrogen to be manufactured remotely from its ultimate place of use, requiring additional energy use for transportation of the fuel, further defeating efficiency and cost savings.
Roughly four percent of the hydrogen produced in the U.S. is from the conventional electrolysis of water or burning of hydrocarbon products such as oil and gas, which, in its current state, produces hydrogen at an energy cost greater than the amount of energy it produces from its combustion with oxygen. If one could lower this cost significantly and also make hydrogen simply and easily, the hydrogen economy that people have dreamed about would be closer to becoming reality.

SUMMARY OF THE INVENTION

In one embodiment, there is provided an apparatus for performing electrolysis of water. The apparatus comprises a container containing water, an electrode assembly comprising upper and lower substantially planar electrodes having an insulator therebetween, and a permanent magnet having an upper and lower surface and oriented substantially parallel to the lower electrode. In a preferred embodiment, the lower electrode lies within 0.1 inches of the upper surface of the magnet.
In one embodiment, there is provided an apparatus for performing electrolysis of water. The apparatus comprises a container containing an electrolysis assembly immersed in water, wherein the electrolysis assembly comprises a stack comprising an upper electrode having upper and lower surfaces, a lower electrode having upper and lower surfaces, an insulator between the upper surface of the lower electrode and the lower surface of the upper electrode, and a permanent magnet below and substantially parallel to the lower surface of the lower electrode. In one embodiment, the angle formed between the surface of the water and the surface of the upper electrode is less than 90 degrees.
Certain preferred embodiments comprise one or more of the following: the angle formed between the upper surface of the upper electrode and the surface of the water is less than about 30 degrees, including less than about 5 degrees; the upper surface of the magnet is less than about 0.06 inch from the lower electrode, including where the lower electrode and magnet touch; the magnet is made from a material comprising a rare earth element, for example, Neodymium Iron Boron or Samarium Cobalt; the magnet has a pull of about 100-350 pounds; the magnet has a residual induction or flux density of about 10,000 to 14,000 gauss; the electrodes comprise palladium, platinum, and/or gold; the electrodes include a plurality of openings, holes or pores; and the electrodes comprise a wire mesh.
In some embodiments, the apparatus further comprises a gas handling unit comprising a gas separator operable to separate hydrogen gas. In one embodiment, the gas separator includes a membrane that selectively permits or excludes the passage of hydrogen gas and/or means to remove water and/or water vapor from the gas.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional schematic view of an electrolysis device according to one embodiment.

FIG. 2 is an enlargement of the region indicated by the number 2 in FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Disclosed herein is an apparatus capable of generating hydrogen and oxygen gases from water, including water in which no foreign material, such as salt or electrolyte, has been added. In a preferred embodiment, the process uses magnetic electrons and Coulomb forces to produce and/or enhance electrolysis and generate hydrogen and oxygen gases.
FIG. 1 illustrates one embodiment of electrolysis apparatus in a cross-sectional view vertically through the apparatus. The illustration is largely schematic, such that the shape, relative size and orientation of the components as illustrated should not be taken as limiting the scope of this disclosure and the attached claims.
The housing or container 10 holds the gas generating equipment and water from which the gases are generated. The container may be of any shape, including, but not limited to a cylinder, sphere, cube, cuboid, prism, and the like. The container 10 may also be of any size. The container may be made of any suitable material or combination of materials (e.g. plastic-coated glass, glass-lined metal, plastic-lined metal, etc.). Suitable materials include, but are not limited to, Pyrex glass, high density polyethylene, graphite, PVC, PVDF, and non-magnetic metals. The interior surface in contact with the water is preferably formed of glass and/or plastic. The container 10 is preferably heat resistant, and able to resist deformation and/or degradation when heated and exposed to the reactants, products, current, and magnetic field. The walls of the container 10 should be of sufficient thickness to contain the equipment and reactants and withstand any pressure that develops within the container 10 during use. The container 10 may be a single piece or it may be multi-piece, comprising two or more pieces that are fitted and sealed together. In multi-piece containers, the seal is preferably substantially air- and water-tight, and the seal may be removable, permanent or semi-permanent. Gaskets, o-rings, clamps, and the like are utilized in some embodiments of multi-piece containers.
The container is equipped with one or more openings of any size or shape, at least one of which provides passage for associated equipment such as electrical leads and gas handling unit to attach to the container 10. In the illustrated embodiment, there are four openings (12, 14, 16, 18), one each for the two electrical leads (20, 22) the gas handling unit 24, and the water inlet 26. Numerous different configurations besides that illustrated are possible, including, but not limited to those having one, two, three, five or more openings, having openings in different locations, and/or having additional equipment associated with one or more openings. For example, in other non-illustrated embodiments, the leads pass through a single opening, one or more of the leads pass through the same opening as the gas handling unit or the water inlet, one or more openings are sealed with a plug or stopper, and/or an opening is fitted with additional equipment as discussed in greater detail below. In preferred embodiments, the openings include a grommet, gasket, or o-ring to form a seal (preferably air- and water-tight) between the container and the item passing through or connected to the opening to substantially prevent undesired escape of water and/or gas to the outside.
In a preferred embodiment, a gas handling unit 24 is located in an opening 14 at or near the top of the container. Although this location is preferred, other locations may be used in lieu of this location and/or one or more additional units may be used in one or more other locations on the container. The top opening 14 provides a passage through which the hydrogen and oxygen gases leave the container and travel into the gas handling unit. In its simplest form, the gas handling unit comprises a passageway connecting the container to a location such as a vessel, preferably a pressurized vessel, for storing one or both of the gases or a combustion chamber or other place where one or both gases are directly used.
In a preferred embodiment, the gas handling unit further comprises a gas separator to separate the hydrogen and oxygen gases that are produced. Any separation technology and equipment may be used in connection with this system. One preferred means of separation involves the use of one or more membranes that selectively allow the passage of a particular gas or selectively exclude a particular gas. One suitable type of membrane is a membrane selective for hydrogen gas. Such membranes are known from several sources, including RTI International (palladium-silver alloy/ceramic composite membrane) (Research Triangle Park, North Carolina) and Media and Process Technology, Inc. (ceramic membranes) (Schenley, Pa.) and are also described in the technical literature. Preferred membranes have high selectivity for hydrogen gas and high flow rates. Membrane technology is a preferred method in part because no energy is required to separate the hydrogen and oxygen gases.
In the illustrated embodiment of FIG. 1, the gas bubbles containing both hydrogen and oxygen rise from the water and pass through the opening 14 into the gas handling unit. There the gas encounters a hydrogen selective membrane 28 which allows the hydrogen to pass through the membrane 28 and through the outlet 30. The oxygen does not pass through the membrane and remains behind and passes out of the unit through outlet 32 where it may be collected, such as in a pressurized vessel, used directly, or vented to the surroundings. To assist in collection of the hydrogen gas, a slight negative pressure or a vacuum may be placed on the outlet 30 or the outlet-side of the membrane to urge flow of hydrogen through the membrane and reduce loss of hydrogen through the outlet 32. The hydrogen that passes through the outlet 30 may be burned or used directly as it is produced, or it may be stored. Storage of hydrogen gas is preferably in a pressurized vessel. The storage vessel may be of any type. One preferred storage vessel is a pressurized tank that both stores the gas and dispenses the gas, such as to a smaller vessel or a combustion chamber. This can be analogized to the types of propane tanks that are known to consumers. A large tank can directly feed one or more energy consuming units (such as appliances, motors, generators, and the like) at a location such as a home or business. Alternatively, a large tank may be at a location where consumers can purchase gas to fill and refill smaller, preferably portable tanks, and/or a tank in an automobile or other vehicle.
The gas handling unit may also comprise means to remove water and/or water vapor from the gas. Suitable means include, but are not limited to, chemical drying agents, adsorbent or absorbent material, cold condensers, and the like.
An electrolysis assembly 34 comprises one or more magnets associated with at least one pair of electrodes. The embodiment illustrated in FIG. 1 shows one magnet associated with a single pair of electrodes. In other embodiments, two or more magnets may be associated with one or more pairs of electrodes, and/or one magnet may be associated with two or more pairs of electrodes. The electrolysis assembly 34 is submerged in the water 40 inside the container 10. It may sit on the bottom of the container, as illustrated, or it may rest upon a platform or shelf such that it lies at least in part above the bottom of the container.
The magnet component of the electrolysis assembly may comprise any kind of magnet. In preferred embodiments, the magnet component comprises a permanent magnet. In especially preferred embodiments, the magnet component consists of one or more permanent magnets.
The magnet component is central to the system, in that it supplies the electrons to complete the electrical current for the DC voltage, which in turn provides the flow of current for the electrolysis, as discussed in greater detail below. Permanent magnets differ from electromagnets in that they do not require any electrical stimulant to generate their magnetic field. A preferred magnet is highly resistant to demagnetization and has a very high magnetic energy for its size. A magnet of any size or shape may be used. In a preferred embodiment, the magnet has the shape of a cylinder, cuboid, or prism, and has a relatively uniform thickness underneath the entire surface area of the electrode pair with which it is associated. The lower electrode of the electrode pair preferably rests directly upon the associated magnet(s) or is within a very short distance thereof, including less than about 0.25 inches, less than about 0.1 inch, less than 0.06 inch, less than 0.04 inch, and less than 0.02 inch.
The magnet and electrode portions of the electrolysis assemblies are oriented such that the field of the magnet extends first through one electrode and then into the other, in a line, therefore allowing the magnetic field to act as a medium like an electrolyte. In a preferred embodiment, the electrodes are positioned so that the north-south axis of the magnet is perpendicular or substantially perpendicular, preferably about 75° to about 105° to the plane of the electrodes. In one embodiment, the plane of the electrodes or electrode assembly is about 0° to about 30°, including substantially parallel (e.g. about 0° to about 15°) or parallel (e.g. about 0° to about 5°), to one of the two opposing, large, faces of a magnet, such as a magnet having a cylindrical or prismatic shape.
Preferred permanent magnets used in the electrolysis assembly are those having a high flux density or residual induction for their size. Preferred magnets include, but are not limited to, rare earth magnets, including those made of alloys of Neodymium or Samarium, such as Neodymium Iron Boron (NdFeB) or Samarium Cobalt (SmCo). In one embodiment, the Neodymium alloy magnet is coated with a metal such as nickel or a non-magnetic substance such as phenolic resin or epoxy resin to extend its useable life. Examples of suitable permanent magnet are Neodymium alloy magnets and Samarium alloy magnets from Magnetic Component Engineering (Torrance, Calif.). In one embodiment, a cylindrical magnet having a diameter of about 4.5 inches and a thickness of about ½ inch has one or more of the following characteristics: a pull of about 100-350 pounds, including about 150 to about 250 pounds, about 180 to about 220 pounds, and about 200 pounds; and a residual induction (Br, also called flux density) of about 10,000 to 14,000 gauss, including about 11,000 to 13,000 gauss, about 11,500 to 12,500 gauss, about 12,000-12,500 gauss, about 12,100 gauss, about 12,200 gauss, about 12,300 gauss, and about 12,400 gauss. Magnets having one or more characteristics falling outside of these ranges can also be used.
Because some magnets, such as rare earth magnets, can be brittle, if a brittle magnet is used, one or more sides of the magnet may be all or partially covered or encased in a protective tray or sheath. The protective covering is preferably not, however, disposed between the magnet and the electrode assembly. The protective covering may be made of any suitable material, including corrosion-resistant, low-conductivity metals, graphite, and plastic.
In preferred embodiments, one or more electrolysis assemblies cover as much of the bottom surface of the container as possible, including most of the bottom surface, substantially the entire bottom surface, about 75% of the bottom surface, about 80% of the bottom surface, about 85% of the bottom surface, about 90% of the bottom surface, and about 95% of the bottom surface. If more than one magnet is used, the magnets are preferably separated from each other by a shielding material to reduce repulsion and interference between the fields of the magnets. Although a single layer of electrolysis assemblies is preferred, more than one layer electrolysis assemblies is possible, including where there is overlap of one assembly with another.
The orientation of the electrolysis assemblies with regard to the container can vary. In preferred embodiments, the magnet is not positioned between the surface of the water and the electrode pair. In a preferred embodiment using a substantially planar electrode, the plane of the electrode is substantially parallel to the surface of the water in the container. The electrolysis assembly may also be at an angle with respect to the water, with that angle preferably being less than about 90 degrees, less than about 75 degrees, less than about 60 degrees, less than about 45 degrees, less than about 30 degrees, less than about 15 degrees and less than about 5 degrees, where the angle measured is the angle formed between the surface of the water and the side of the electrode plane in closest proximity to the surface of the water, with the parallel configuration being 0 degrees.
The electrode assembly comprises two electrodes separated by an insulator. In a preferred embodiment, the electrodes are on either side of a generally flat insulator in a stack or sandwich-type configuration where each electrode preferably touches the insulator. One preferred embodiment of electrode assembly 38 is illustrated in FIG. 2, where the electrodes 50 lie on either side of the insulator 52 and the lower or bottom electrode is very close to or rests directly upon the upper surface of a magnet 36 which, in the illustrated embodiment, rests on the bottom of the container 10. In a preferred embodiment, the plane of the lower electrode is above, in contact with, or otherwise associated with one or more magnets for at least 85% of its planar area or “footprint”, including at least 90%, and at least 95%. In other words, in a system having one electrode assembly and one magnet, the footprint of an electrode assembly is preferably very similar or identical to the footprint of the magnet, the surface of the magnet to which it is closest or contacts. In preferred embodiments, the footprints are similar in both area and shape. In systems having one or more electrode assemblies and one or more magnets, the total footprints of each are preferably similar or identical. All things being equal, the more of the footprint of an electrode assembly that is associated with the footprint of a magnet, the greater the efficiency of the system.
The electrodes comprise a conductive material, preferably a conductive metal or alloy, and may be of any shape, such as round, oval, circular, polygonal (with rounded and/or sharp corners), and are, in preferred embodiments, generally flat or planar.
In a preferred embodiment, the electrodes are also corrosion resistant and/or formed from high-purity materials. The electrodes may be made of a single metal or alloy, or they may be a combination of one or more metals and/or alloys in mixtures or in layers, such as a metal-plated material, including materials plated with gold, palladium or platinum. In certain preferred embodiments, the electrodes comprise palladium, platinum, and/or gold.
The insulator comprises a dielectric or non-conductive material in one or more layers. The insulation can be any electrical insulating material, which preferably does not interfere with the electron flow or the ability of the gases to pass through the assembly and rise to the top of the container. Preferred insulators include, but are not limited to natural rubber, synthetic rubber, silicon dioxide, glass, quartz, porcelain, ceramic, non-conductive plastics, such as Teflon and polyethylene, and combinations thereof. In a preferred embodiment, the insulator is less than about 0.3 inches thick, including about 0.01 to 0.3 inches, about 0.05 to 0.25 inches, and 0.1 to 0.2 inches thick. Insulators having thicknesses outside of these ranges can also be used.
Each of the electrodes and insulator preferably include a plurality of openings, holes or pores to allow the gases to pass through the electrode assembly as they are formed from the water. The plurality of openings increases the surface area of the electrodes and therefore increases the rate of gas generation. Preferred electrodes include, but are not limited to metal plate or sheet with holes punched or drilled therethrough, wire mesh, and porous sintered metals. In choosing a material for the electrodes, one of skill in the art will understand how to strike a balance between having high surface area to speed up gas generation and void space to allow for easy passage of gases to achieve a desired rate of gas collection for a given application. Insulators may be in the form of a mesh, sintered material, perforated material, woven material, or any other suitable form that provides a plurality of openings to allow substances to pass therethrough.
In a preferred embodiment, electrodes are made from wire mesh in which the wires have a thickness (diameter) of about 0.001 to about 0.03 inches, including about 0.001 to about 0.006 inches, about 0.004 to about 0.01 inches, about 0.002 to about 0.004 inches, about 0.005 inches to about 0.03 inches, about 0.005 to about 0.02 inches, and about 0.01 inches to about 0.03 inches. Wires having diameters outside of these preferred ranges can also be used. The wires can be stacked, woven, or welded (with or without weaving) to form a mesh. Preferred mesh sizes (openings per linear inch) include, but are not limited to, about 8 mesh to 50 mesh, about 8 mesh to about 16 mesh, about 18 mesh to about 24 mesh, about 24 mesh to about 48 mesh, about 28 mesh to about 36 mesh, and about 34 mesh to about 50 mesh.
The electrodes are connected to a power supply supplying direct current, preferably using wire 20, 22 such as insulated electrical wire, which pass through one or more openings in the container. Selection of a suitable wire is within the abilities of one skilled in the art, taking into consideration one or more factors including operating conditions, apparatus configuration, power supply chosen, and materials used. In the illustrated embodiment of FIG. 1, wire 20 connect to the output and wire 22 connects to the input of the DC power supply (not illustrated), and then pass through openings 12 and 16, respectively, into the container where each wire connects with one electrode of the electrode assembly 38. A wire may be permanently connected to an electrode, such as by welding, or it may be removably connected such as by using clips.
The electrode assembly is connected, through the wires, to a power supply. In one embodiment, the power supply comprises a source of power, such as a generator, battery, wall outlet or other feed from a local power grid. In some embodiments, the power source further comprises a variable autotransformer or other apparatus to allow user control of the applied voltage and/or current. For example, in North America, the variable autotransformer may be connected to a common wall outlet at 120 volts and 60 cycles/second. The power feeds the variable autotransformer, which is may be monitored by separate voltage and amperage meters. The variable autotransformer connects to an electrical input and output of the apparatus. Where the power source is AC, the output from the autotransformer feeds a direct current converter prior to connecting to an input and output. In one embodiment, the negative connection is to the upper electrode of the assembly and the positive connection is to the to the bottom electrode of the assembly. Selection of a suitable DC power supply is within the abilities of one skilled in the art, taking into consideration one or more factors including, but not limited to, magnet size and power, desired voltage, desired current, container size, wire used, size of electrode, type of electrode, insulator, desired rate of gas generation, and the like.
The voltage and current from the power supply are adjusted to regulate the production of hydrogen and oxygen from the apparatus. Although both voltage and current affect production, hydrogen production appears to be proportional to the applied voltage. In one embodiment using a 4.5 inch cylindrical magnet having a residual induction of 12,300 gauss and two circular zinc steel wire mesh electrodes having a diameter of about 4.5 inches (as discussed below in Example 1) the voltage is preferably about 10V to about 200V, including about 20V to 150V, and about 50V to 100V, and the current is about 1 amp to about 5 amps, including about 2 amps to about 3 amps. In one embodiment, the system functions at 100 volts direct current at 3 amps input. In view of the disclosure herein with regard to test cells and preferred values, selection of suitable voltage and current for operation is within the abilities of one skilled in the art, taking into consideration one or more factors including, but not limited to, magnet strength, electrode material, electrode configuration, wires, power supply, and the like.
The container holds the water which is the reactant and source of the hydrogen and oxygen. Water may be added to the container in any manner. In one embodiment, as illustrated in FIG. 1, a hose or tube 26 conveys water through opening 18 and into the container. The opening or water inlet may be above or below the level of the water in the container. In certain embodiments, the hose or tube 26 is connected to a water supply having a valve and/or pump that is controlled manually or by machine. In preferred embodiments, the water flow control is machine-operated and/or controlled by a computer or other device such that it may run automatically. Such automatic means of water level adjustment include, but are not limited to use of a timer which permits flow of water at set intervals, use of a float which opens and close a valve connected thereto when the water reaches certain levels, or electronically in connection with a sensor or depth gauge in the container that provides feedback allowing a given depth or range of depths to be maintained. In a preferred embodiment, the water level in the container is 0.1 to 1 inch above the uppermost electrode, including 0.2 to 0.8 inch, and 0.25 to 0.5 inch. In preferred embodiments, such maintenance is carried out automatically using means discussed above. In certain embodiments, the configuration, water level, and size of the container is selected to maintain the headspace above the level of the water at a volume equivalent to about 0.5 to 3 times the volume of the water, which in one embodiment is about 1 to 6 inches, including about 2 to 4 inches.
The water used in the apparatus and method may be any kind of water, including, but not limited to purified water, distilled water, tap water, and reclaimed water. The water may contain one or more solutes. It should be noted, however, that the electrons and field provided by the magnet serve the same purpose as an electrolyte such that an electrolyte is not needed to operate the apparatus as described herein. Accordingly, in certain embodiments, the water does not include any added electrolyte, the water meets US EPA or US FDA standards for drinking water, and/or the amount of solutes in the water does not exceed about 5% by weight, including about 0.5% to about 5%, about 1% to 4%, about 1% to 3%, and about 2% to 4%.
The water used in the apparatus may be treated prior to use. For example, the water may be exposed to a vacuum, treated with sonic energy, and/or sparged with a gas, to remove dissolved gases and/or replace undesired dissolved gases with more desired ones. The water may be filtered to remove particulate matter that could deposit on the electrodes. The water may be treated to remove dissolved metals, chlorine, or other chemicals that could cause degradation, corrosion or otherwise possibly interfere with the functioning or useful lifetime of the apparatus and/or its components. Suitable filters include those that are commercially available for the purification of drinking water to remove particles, pathogens, and/or chemicals. In embodiments where water is added to the apparatus automatically, any such treatment is preferably done prior to adding the water to the apparatus or to a reservoir from which the water for the apparatus is drawn.
Operation of the apparatus without circulating the water over an extended period of time may result in the eventual buildup of undesired contaminants present in the water, even if they are present at very small concentrations. Therefore, the water in the apparatus can be periodically changed, in all or in part, to keep the water in the container at the chosen level of purity and/or cleanliness.
The temperature of the water in the apparatus during use is preferably greater than 0° C. and less than 100° C. so that it remains liquid. In a preferred embodiment, the temperature of the water is about 15° C. to 50° C. In one embodiment, lower temperatures are preferred to minimize the water vapor in the headspace and thus reduce the need for drying the gas(es) collected.
Although not illustrated in FIG. 1, additional equipment may be included in the electrolysis apparatus. One type of equipment is that which allows for monitoring and/or controlling of one or more conditions. For example, a thermocouple or temperature probe may be used to monitor the temperature of the water and/or provide temperature data as an input to a temperature control unit or a controller which operates a heating and/or cooling unit, to allow for heating and/or cooling of the chamber and/or feed water added to the unit to maintain a given temperature or temperature range. A float or circuit may be included to monitor the level of the water in the apparatus and/or provide data on water level to a water pump or valve, or an electronic controller thereof, that can allow more water to flow into the container to maintain a desired water level. A camera may be included to allow the operation of the apparatus to be observed and monitored. Other sensors may be included to monitor conditions and/or provide alarms should one or more conditions fall outside of desired or safe ranges.
The apparatus is operated by passing electrical current through the electrodes 50. Hydrogen and oxygen gases are produced at the electrodes, forming bubbles which grow and eventually rise to the surface of the water 40 and release the gas into the headspace 42 above the water. Once in the headspace 42, the gas rises, through the action of density, bulk flow or at the urging of a reduced (or negative) pressure at one or more of the outlets 30, 32 or collection vessels attached thereto, and passes through the opening 14 into the gas handling unit 24. There the gases may be separated and/or treated such as by drying, before flowing through an outlet to be collected, discharged, or vented, as desired.
In one embodiment, the apparatus is purged of some or all of any air contained within the headspace 42 and/or gas handling unit 24 prior to operation. This may be done by any suitable method, including evacuation and/or purging with a gas. Preferred purge gases include hydrogen, helium, and argon.
Preferred embodiments of apparatus and method described herein operate with little or no electrolyte in the water. An electrolyte is used in conventional electrolysis because it provides charged particles that conduct a current. One important advantage of the apparatus and method disclosed herein in preferred embodiments is that permanent magnets are used essentially as a substitute for some or all of the electrolyte normally used to achieve electrolysis in that the electron force of the permanent magnet creates a current through which electrons are transferred in the pure water. Permanent magnets are now available in strengths to provide sufficient current conducting capability to achieve commercially useful production rates of hydrogen. These permanent magnets are highly desirable because they do not require any energy input for their operation.
Reduction or elimination of electrolyte is also desirable because one need not worry about having to maintain the concentration of electrolyte within a desired range in a process where the solute (water) in the electrolyte solution is constantly being eliminated through conversion to hydrogen and oxygen. Furthermore, many conventional electrolytes are dangerous or harmful materials, such as sulfuric acid such that their elimination or reduction increases safety and increases the cost efficiency of the process by eliminating or reducing costs associated with the purchase and handling of electrolyte materials.
Industrial electrolysis of water is typically run at high current density, due to the high over-potential at the electrodes. In preferred embodiments, over-potential is minimized in one or both of two ways: the conductive metal assembly increases the number of sites (surface area) where reduction and oxidation of the water take place compared to a typical electrolysis apparatus; and/or the magnetic field of the magnet pushes the bubbles of gas toward the surface freeing sites on the metal assembly where further reduction and oxidation can take place.
One can appreciate this from certain electromagnetic interactions. For instance, a current-carrying wire always produces a magnetic field. There is only one type of electron so the electrons moving in the permanent magnets are the same as those in the electrolysis. All electrons are the same (Chapter 17—Section Titled “Electric Charge, College Physics, by Franklin Miller, Jr. (1959), pages 297-325). This magnetic field can be demonstrated by arranging magnetic compasses around the wire through which the current travels. The compasses line up with the magnetic field produced, which is dependent on the direction of the moving charges (current). Since a current implies a magnetic field, a magnetic field implies a current. Conduction occurs through the current of the magnetic field. Thus one may think of the magnetic field as substituting for electrolyte in this invention.

Example 1

A cell was made using a one liter Pyrex vessel (7 inch diameter) as the container. The electrolysis assembly included a single magnet having a single electrode pair placed directly on one broad face of the magnet, while the other broad face of the magnet rested in an aluminum tray to protect the magnet material from physical damage. The magnet was a 4.5 inch (diameter) by ½ inch (height) cylindrical NdFeB magnet with a residual induction (Br) of 12,300 gauss and an approximate 200 pound pull. The electrodes were 4.5 inch diameter sheets of galvanized steel or iron wire mesh in which the wires of the mesh had a diameter of 0.075 inch, and the wires in the mesh were positioned to create square openings 0.2 inch on each side. An insulator was positioned between the electrodes, wherein the insulator was a 0.075 inch thick 4.5 inch diameter piece of plastic mesh having square openings in the mesh that were 1 inch on each side. Each of the two electrodes had a piece of mesh about 5 mm wide and 10 mm long extending out therefrom to which the wires were soldered. The wires were connected to the power supply. The container was filled with approximately 500 ml of distilled water to a level approximately 0.5 inches above the surface of the upper electrode. A Pyrex lid having two openings was placed on top of the container. One opening was fitted with a glass stopper to keep it closed and the other opening had a tube connected thereto to allow the collection and sampling of the gas produced in the cell. Further details about the test equipment, conditions, and results are as follows:


Voltage line	15A, 110 VAC line
Voltage control	Variac variable autotransformer model
	3PN 1010, 1.4 KVA
DC supply	KBU 1003 bridge with 2 1000 μF
	200 V capacitors in series
Volt/amp/thermometer	Fluke, Model 179
Sampling cans	Restek, T.O-Can, Model 24153
Voltage across cell	30 VDC
Average current	2 amp
Power consumption	60 watts
Gas collection time	2.5 hours
Energy consumed	0.150 kWh
Energy cost at $0.098/kWh	$0.015
Gas collection volume	6 liters
Hydrogen collected	0.12 grams
Cost of hydrogen at STP	$0.0104/liter

The cell was connected to the DC power supply, and voltage and current were determined using the Fluke multimeter. Evacuated gas collection bottles were plumbed to the output of the cell with a vacuum gauge between the cell and the needle valve. The needle valve was opened very slightly to maintain a slight vacuum in the system in an effort to collect the gas at the rate that it was being produced. The valve required continuous monitoring and adjustment to maintain the slight vacuum. An inline dryer was used between the cell and the collection bottle to reduce the amount of water vapor collected. The gas collected was analyzed in accordance with ASTM D-1946. Moisture was analyzed in accordance with ASTM D-4888.
The various methods and techniques described above provide a number of ways to carry out preferred methods and make preferred apparatus. Of course, it is to be understood that not necessarily all objectives or advantages described may be achieved in accordance with any particular embodiment described herein. Thus, for example, those skilled in the art will recognize that the methods may be performed and apparatus made in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other objectives or advantages as may be taught or suggested herein.
Furthermore, the skilled artisan will recognize the interchangeability of various features from different embodiments. Similarly, the various features and method steps discussed above, as well as other known equivalents for each such feature or step, can be mixed and matched by one of ordinary skill in this art to perform methods and make apparatuses in accordance with principles described herein.
Although the invention has been disclosed in the context of certain embodiments and examples, it will be understood by those skilled in the art that the invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof. Accordingly, the invention is not intended to be limited by the specific disclosures of preferred embodiments herein, but instead by reference to claims attached hereto.

Claims

1. An apparatus for performing electrolysis of water, comprising: a container containing

water;

an electrode assembly comprising upper and lower substantially planar electrodes having an insulator therebetween; and

a permanent magnet having an upper and lower surface and oriented substantially parallel to the lower electrode;

wherein the lower electrode lies within 0.1 inches of the upper surface of the magnet.

2. The apparatus of claim 1, wherein the angle formed between the upper surface of the upper electrode and the surface of the water is less than about 30 degrees.

3. The apparatus of claim 1, wherein the angle is less than about 5 degrees.

4. The apparatus of claim 1, further comprising a gas handling unit comprising a gas separator operable to separate hydrogen gas.

5. The apparatus of claim 4, wherein the gas separator includes a membrane that selectively permits or excludes the passage of hydrogen gas

6. The apparatus of claim 4, wherein the gas handling further comprises means to remove water and/or water vapor from the gas.

7. The apparatus of claim 1, wherein the upper surface of the magnet is less than about 0.06 inch from the lower electrode.

8. The apparatus of claim 7, wherein at least a portion of the lower electrode rests directly upon the magnet.

9. The apparatus of claim 1, wherein the electrode assembly meets the magnet at an angle of about 0° to about 5°.

10. The apparatus of claim 1, wherein the magnet comprises a rare earth element.

11. The apparatus of claim 10, wherein the magnet comprises Neodymium Iron Boron or Samarium Cobalt.

12. The apparatus of claim 10, wherein the magnet has a pull of about 100-350 pounds.

13. The apparatus of claim 10, wherein the magnet has a residual induction or flux density of about 10,000 to 14,000 gauss

14. The apparatus of claim 13, wherein the magnet has a residual induction or flux density of about 11,500 to 12,500 gauss.

15. The apparatus of claim 1, wherein the electrodes comprise a corrosion resistant conductive metal or alloy

16. The apparatus of claim 15, wherein the electrodes comprise palladium, platinum, and/or gold.

17. The apparatus of claim 1, wherein the electrodes include a plurality of openings, holes or pores.

18. The apparatus of claim 17, wherein the electrodes comprise a wire mesh.

19. The apparatus of claim 18, wherein the wire mesh has a mesh size of about 16 mesh to about 48 mesh.

20. The apparatus of claim 1, wherein the insulator comprises one or more dielectric or non-conductive materials selected from the group consisting of natural rubber, synthetic rubber, silicon dioxide, glass, quartz, porcelain, ceramic, and plastic.

21. The apparatus of claim 1, wherein the electrodes are connected to a power supply providing about 50V to 150V direct current at about 1 amp to about 5 amps.

22. The apparatus of claim 1, wherein the water level is 0.1 to 1 inch above the upper surface of the upper electrode.

23. The apparatus of claim 1, wherein the water used comprises purified water, distilled water, tap water, and/or reclaimed water.

24. The apparatus of claim 1, wherein the temperature of the water is about 15° C. to 50° C.

25. An apparatus for performing electrolysis of water, comprising

a container containing an electrolysis assembly immersed in water, wherein

the electrolysis assembly comprises a stack comprising an upper electrode having upper and lower surfaces, a lower electrode having upper and lower surfaces, an insulator between the upper surface of the lower electrode and the lower surface of the upper electrode, and a permanent magnet below and substantially parallel to the lower surface of the lower electrode, and

the angle formed between the surface of the water and the surface of the upper electrode is less than 90 degrees.

26. The apparatus of claim 25, wherein the angle formed between the upper surface of the upper electrode and the surface of the water is less than about 30 degrees.

27. The apparatus of claim 25, wherein the angle is less than about 5 degrees.

28. The apparatus of claim 25, further comprising a gas handling unit comprising a gas separator operable to separate hydrogen gas.

29. The apparatus of claim 28, wherein the gas separator includes a membrane that selectively permits or excludes the passage of hydrogen gas

30. The apparatus of claim 28, wherein the gas handling further comprises means to remove water and/or water vapor from the gas.

31. The apparatus of claim 25, wherein the magnet is less than 0.25 inches from the lower electrode.

32. The apparatus of claim 31, wherein the magnet is less than about 0.06 inch from the lower electrode.

33. The apparatus of claim 31, wherein at least a portion of the lower electrode rests directly upon the magnet.

34. The apparatus of claim 25, wherein the electrode assembly meets the magnet at an angle of about 0° to about 5°.

35. The apparatus of claim 25, wherein the magnet comprises a rare earth element.

36. The apparatus of claim 35, wherein the magnet comprises Neodymium Iron Boron or Samarium Cobalt.

37. The apparatus of claim 35, wherein the magnet has a pull of about 100-350 pounds.

38. The apparatus of claim 35, wherein the magnet has a residual induction or flux density of about 10,000 to 14,000 gauss

39. The apparatus of claim 38, wherein the magnet has a residual induction or flux density of about 11,500 to 12,500 gauss.

40. The apparatus of claim 25, wherein the electrodes comprise a corrosion resistant conductive metal or alloy.

41. The apparatus of claim 40, wherein the electrodes comprise palladium, platinum, and/or gold.

42. The apparatus of claim 40, wherein the electrodes include a plurality of openings, holes or pores.

43. The apparatus of claim 42, wherein the electrodes comprise a wire mesh.

44. The apparatus of claim 43, wherein the wire mesh has a mesh size of about 16 mesh to about 48 mesh.

45. The apparatus of claim 25, wherein the insulator comprises one or more dielectric or non-conductive materials selected from the group consisting of natural rubber, synthetic rubber, silicon dioxide, glass, quartz, porcelain, ceramic, and plastic.

46. The apparatus of claim 25, wherein the electrodes are connected to a power supply providing about 50V to 150V direct current at about 1 amp to about 5 amps.

47. The apparatus of claim 25, wherein the water level is 0.1 to 1 inch above the upper surface of the upper electrode.

48. The apparatus of claim 25, wherein the water used comprises purified water, distilled water, tap water, and/or reclaimed water.

49. The apparatus of claim 25, wherein the temperature of the water is about 15° C. to 50° C.