Estimation
ESTIMATION OF HHO GENERATOR
The HHO generator system ( Oxygenarator) electrolyzer that splits water into hydrogen + oxygen require small amount of live on demand (No storage) HHO gas can use as co-fuel needed for different applications like a boiler, furnace, or petrol/diesel engine.Target fuel replacement ratio of HHO generator usually supplements 5–30% of fuel, not full replacement. so, its more safe ratherthen ising 100% liquid hydrogen.The requirment and capacity size an HHO system depends on Fuel consumption rate how much diesel, petrol, coal, or gas your system uses per hour.
Fuel Replacement by Application:
- Boiler/Furnace rating in kW, HP, or tons of steam per hour.
- Engine displacement & load for machine, gensets or vehicles.
Example:
A 10 HP diesel engine burns roughly 2–2.5 liters diesel per hour. If we want to replace ~20% energy with HHO, we calculate how much HHO gas equals that energy.
Similarly, for a 1 ton steam boiler, we check fuel use (like 70–80 liters furnace oil per hour), then figure out what % HHO can supplement.
First Principle of Energy Equivalence:
- 1 liter of diesel ≈ 36 MJ energy
- 1 m³ HHO gas ≈ 3.7 MJ energy
- 1 liter diesel ≈ 10 m³ HHO (approx.)
That means if we want to replace 10% of diesel, we need about 1 m³ HHO per liter of diesel burned. Same different ratio may works for petrol, furnace oil,coal pr gas (pl. adjust as per fuel energy value)
Requirements:
[1] Boiler Requirement :
Boilers are usually rated by steam output (tons/hr) or heat duty (kcal/hr).
Example:
1 TPH boiler (1 ton steam/hour) uses ~65–70 liters of furnace oil/hr.
70 liters × 10 m³ HHO/liter = 700 m³ HHO/hr (for full replacement).
But since HHO is mostly a supplement, not full replacement:
For 10–20% savings → need 70–140 m³/hr HHO.
[2] Furnace Requirement :
For a heating furnace say for metal or ceramic
Fuel oil consumption: ~50 liters/hr.
50 × 10 = 500 m³/hr HHO (full replacement).
If targeting 15% replacement → 75 m³/hr HHO.
HHO is often injected with main burner fuel to stabilize flame, reduce carbon, and improve combustion efficiency.
[3] Petrol/Diesel Engine Requirement:
Let’s use a diesel genset as an example:
10 HP engine burns ~2 liters diesel/hr.
2 × 10 = 20 m³/hr HHO (full replacement).
If aiming for 20% → 4 m³/hr HHO.
[4] For Truck and cars:
A 1500 cc diesel car at cruise (2 liters/hr) → same 20 m³/hr full, 4 m³/hr supplement.
A 100 cc motorbike at 0.3 liters/hr petrol → 3 m³/hr full, ~0.5 m³/hr supplement.
System Design Considerations:
Electrolyzer Power Need
To make 1 m³ HHO, you need ~4.5 kWh electricity. So, if you need 10 m³/hr → about 45 kWh of power supply (huge load).
HHO Efficiency Reality:
Since power to make HHO often costs more energy than it saves, HHO is used mostly as a combustion enhancer, not full replacement.
Safety:
HHO system producing live hydrogen you cannot be stored in large tanks → must be produced on demand so its more safe and easy to produceeeasy to mantain also.
