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Fox Valley Technical College Dynamometer Test Analysis

 

          On July 8, 2008 a Model 40SS hydrogen generator was temporarily installed onto the Caterpillar C15 turbo-diesel engine attached to a Taylor engine dynamometer in the diesel lab.  A fresh baseline test was performed, followed by turning on the hydrogen generator and doing the same test procedure again with hydrogen gas production at 40-50 amps supplied by the alternator of the dynamometer engine.

          At each of the following load % and RPM settings, data were recorded.  25%, 50%, 75%, and 100% load, 1200, 1400, 1600, and 1800 RPM.  Data recorded included horsepower, torque, hydrogen gas production rate, and the weight of the fuel tank at the beginning and end of each 5 and/or 10 minute test period beginning after the dynamometer was set for load % and RPM.  For the 25% load tests a 10 minute period was used for better accuracy, given the low fuel consumption.  During the test with Hydrogen Boost the 10 minute period was also used for the first few settings at 50% load, because the results were slightly better than expected and confirmation was desire by extending the test to 10 minutes to get double data.  The data was indeed confirmed with the extended period so after the first few extensions the 5 minute test period was resumed for the remainder of the tests. 

 

          The charts below represent the data and calculations after anomalies and miscalculations were corrected, including work achieved per unit of fuel consumed (HP hr/lb) and % improvements caused by the Hydrogen Boost.

 

           

 

 

Baseline run 7-8-8 without Hydrogen

 

RPM

Load %

lbs fuel/hr

HP

Torque

Amps H2

HP hr/lb

1200

25

40.8

90

395

0

2.206

1400

25

58.8

107

402

0

1.82

1600

25

54.6

85

277

0

1.557

1800

25

61.8

91

281

0

1.472

 

 

 

 

 

 

 

1200

50

67.2

158

692

0

2.351

1400

50

102

180

670

0

1.765

1600

50

115.2

171

562

0

1.484

1800

50

108

178

520

0

1.648

 

 

 

 

 

 

 

1200

75

93.6

231

1008

0

2.468

1400

75

117.6

266

1000

0

2.262

1600

75

126.

278

908

0

2.206

1800

75

146.4

288

832

0

1.967

 

 

 

 

 

 

 

1200

100

105.6

259

1133

0

2.453

1400

100

159.6

355

1330

0

2.224

1600

100

156

383

1250

0

2.455

1800

100

174

400

1165

0

2.299

 

 

 

 

 

 

 

 

 

1687.2

3520

12425

0

2.0398

 

Notice on this second chart an extra column is added to show the increase in HP hr/lb (horsepower hour per pound of fuel) expressed as a percent increase compared to the baseline figure for each data point.

 

 

 

With Hydrogen Boost

 

 

 

RPM

Load %

lbs fuel/hr

HP

Torque

Amps H2

HP hr/lb

% increase

1200

25

45

90

395

25

2

-9

1400

25

48

105

388

37

2.187

20

1600

25

45

83

270

44

1.845

18.5

1800

25

45

93

270

46

2.067

40.8

 

 

 

 

 

 

 

 

1200

50

63

156

680

48

2.476

5.3

1400

50

78

174

651

48

2.231

26.4

1600

50

78

168

552

49

2.154

45.1

1800

50

90

175

510

50

1.944

11.9

 

 

 

 

 

 

 

 

1200

75

78

228

995

49

2.923

18.4

1400

75

90

265

1000

48

2.945

30.5

1600

75

114

279

906

48.5

2.447

10.9

1800

75

132

291

846

48

2.205

12.1

 

 

 

 

 

 

 

 

1200

100

96

259

1133

42

2.698

10

1400

100

138

354

1320

43

2.565

15.3

1600

100

138

380

1250

43

2.754

12.2

1800

100

150

394

1136

45

2.627

14.3

 

 

 

 

 

 

 

 

 

 

1428

3494

12302

 

2.37925

16.64%

 

          These results were quite consistent with tests that were done over a year ago by Purdue University students and reported on in the May 2007 and September 2007 newsletter pages at www.hydrogen-boost.com Internet web site.  Noticed on both sets of results are areas in the operating envelope that showed major improvements and similar areas on both tests that showed only minor improvements.  Most notable was the mid RPM range of the 75% load data that had similar minor improvements.  This point may be when the unequipped diesel engine performs under optimum conditions and hence may confirm the theory that Hydrogen Boost gives the greatest benefit under “stressed combustion” as defined at http://www.hydrogen-boost.com/August%202007.html .

 

          Overall the Hydrogen Boost showed an average improvement in work done per unit of fuel burned of 16.4% over the operating range tested, but that should not be used to develop an expectation of 16% increase in mileage for a tractor trailer equipped with this common engine, especially if the majority of driving happens to be done at the lowest improvement data point (75% engine load and 1400 RPM) where only a 8.2% improvement was noticed.  However it should be noticed that a conservative adjustment in driving speed that brings the engine load closer to the 50% range and slightly lower RPM, would achieve the benefits of the Hydrogen Boost shown in that section of the chart above (50% engine load and 1300-1400 RPM), an improvement of 20-26%.  This would increase mileage due to reduced speed and wind resistance, but it would also take the best benefit of the Hydrogen Boost in relieving any stressed combustion caused by operating outside the sweet spot of the engine’s operation envelope.       

          It should also be noted that the benefits of the hydrogen injection are not usually evident in fuel mileage increase alone.  When a typical driver finds greater torque available it will be used in getting up the hills faster and therefore shorter trip times.  The ECM report analyses done on numerous fleet vehicles have shown notable increases in fuel mileage but also notable increases in average speed, top gear distance, top gear time, and idle time per gallon of fuel. 

 

          Notice the results reported below that were achieved with our hydrogen boost system installed on a tractor trailer owned by Titletown.

 

Parameter             Baseline    with Hydrogen 2nd trip         3rd trip         difference

                                                                                           

Drive fuel economy 5.59 mpg     5.92 mpg      5.83 mpg      5.957mpg   up 6.56%

Average speed       54.4 mph      54.67 mph    54.4 mph      56.62mph   up 4.1%

Idle time per gallon 1.411 hr/gal 1.585 hr/gal  1.596 hr/gal  1.646hr/gal up 16.7 %

Top gear distance  71.5 %          78.4 %          78.1%           75.15%       up 5.1%

Top gear time        58 %             65.3 %          59.83%          64.16%       up10.6%

 

Mpg x mph             304.09          323.65          317.15          337.29       up 10.9%

 

This last parameter is a good overall calculation introduced by Hydrogen Boost in our August 2001 newsletter.  It takes into account both fuel mileage and average speed.

 

Watch WBAY-TV News story about Hydrogen Boost by clicking here or on video below.

 

 

 

 

 

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