Introduction
This comprehensive guide explains how to construct a homemade 19-plate HHO dry cell generator, harnessing the process of electrolysis to split water into its constituent gases—hydrogen and oxygen. Water, composed of hydrogen and oxygen atoms, can be decomposed into these gases by applying electrical energy. Since pure water is a poor conductor of electricity, an electrolyte such as sodium hydroxide or potassium hydroxide is added to enhance conductivity. The HHO generator operates on this principle, providing a clean, efficient, and environmentally friendly energy source suitable for powering various devices and appliances.
STEP 1 : MATERIALS REQUIRED
To assemble the electrolyzer, you’ll need essential components including electrode plates, neutral plates, gaskets, and front and back plates reinforced with metal. Typically, the electrode and neutral plates are fabricated from 304 stainless steel sheets. Neoprene rubber sheets, approximately 1/8-inch thick, serve as gaskets to create airtight seals between plates. The neutral plates are placed alternately with the electrode plates during assembly, ensuring even voltage distribution and optimal gas production. Water enters the cell via an input tube positioned at the top, contacting the charged electrode plates, causing a chemical reaction that splits water molecules into hydrogen and oxygen gases. These gases are directed out through an output tube located at the bottom of the cell. When electrical current flows through the electrodes, bubbles form at each plate—hydrogen bubbles at the cathode and oxygen bubbles at the anode. The process is driven by a power source such as a battery or solar panel, with the neutral plates playing a vital role in dividing voltage evenly, preventing uneven gas generation and enhancing efficiency.
STEP 2 : ASSEMBLING THE PLATES
Constructing the plates involves using 12 x 12 inch, 24-gauge 304 stainless steel sheets. These sheets are cut into four 6-inch segments using tin snips or a similar cutting tool, creating the electrode and neutral plates essential for the cell. Proper orientation is crucial; neutral plates are marked by cutting both corners, while electrode plates have only one corner cut. This distinction helps during assembly, ensuring correct placement and electrical connections. The neutral plates are situated between the positive and negative electrode plates to facilitate uniform voltage distribution. The plates are stacked onto a sturdy base, such as a cutting board with metal support frames at each end, holding everything securely in place. Holes are drilled at the top and bottom of the assembly for gas and water flow. To maintain structural integrity and proper spacing, neutral plates are separated by neoprene gaskets, acting as spacers. The entire stack is enclosed with bolts at four corners, sealing the assembly tightly to prevent leaks and ensuring efficient electrolysis.
STEP 3 : ADDING A WATER RESERVOIR AND A POWER SUPPLY
The next phase involves setting up a water reservoir, which holds the electrolyte solution—distilled water mixed with sodium hydroxide. The amount of sodium hydroxide depends on the size of your cell and the desired gas output; typically, a small quantity suffices for larger volumes of distilled water. The reservoir can be a simple container, such as a plastic bottle, with two connecting tubes: one for electrolyte input and another for gas output. These tubes are typically three-eighths of an inch in diameter. The electrolyte solution is poured into the reservoir, which is then connected to the cell to facilitate water flow. To power the electrolysis process, a 12V, 30-amp power supply is recommended. Suitable options include a car battery with a trickle charger, an old UPS unit, or a dedicated 12V solar battery. Proper wiring and connectors are essential for safe and reliable operation. For portability, the entire setup—including the electrode cell, power source, and water reservoir—can be mounted onto a wooden frame, making transportation and setup more convenient.
STEP 4 : DIFFUSION USING A BUBBLER
Post-gas generation, it’s important to filter and purify the HHO mixture before its application. A bubbler acts as a vital component in this process, diffusing the gas into water to trap impurities and remove residual sodium or potassium hydroxide vapors. The bubbler consists of a column filled with water, into which the gas enters at the bottom and bubbles upward. The small bubbles increase contact with water, effectively filtering out contaminants. To enhance safety, a pressure relief feature can be added: drill a hole in the top of the bubbler, covering it with a plastic foil membrane that acts as a pressure relief valve. This prevents dangerous pressure buildup inside the bubbler, especially in case of a flashback or increased internal pressure, ensuring safe operation at all times.