Hydrogen Fuel Systems Pty Ltd Producing hydrogen gas May 24 2026

 

Electrolysis works by passing a DC current through water containing an electrolyte. At the cathode, water gains electrons and forms hydrogen gas. At the anode, water loses electrons and forms oxygen gas. The overall reaction is:

How the process works (step‑by‑step)

1. Water alone doesn’t conduct well

Pure water is a poor conductor, so electrolysis usually requires:

• An electrolyte (KOH, NaOH in alkaline systems)
• Or a proton‑conducting membrane (PEM systems)

This allows current to flow.

 

 

 

2. Apply DC voltage

A DC power supply is connected to two electrodes:

• Cathode (–) → where hydrogen is produced –  a Reduction reaction where hydrogen ions absorb electrons
• Anode (+) → where oxygen is produced-  an oxidation reaction where the hydroxide ions give up electrons

The minimum theoretical voltage is 1.23 V, but real systems need 1.6–2.2 V due to losses of internal to internal resistance / reactance of the water

 

 

 

⚗️ 3. Chemical reactions at each electrode

At the cathode (negative electrode)

Water molecules gain electrons:— an reduction  reaction

This produces hydrogen gas.

 

 

At the anode (positive electrode)

Water molecules lose electrons: – a oxidation  reaction

This produces oxygen gas.

 

 

 

🌬️ 4. Gas collection

Because hydrogen and oxygen form at different electrodes, they can be collected separately:   this is theoretical production as in a science laboratory . 

In a vehicle this is not practical without complex separation techniques. 

In a vehicle , generator or generator assembly a mixture of both gases are collected ( not stored ) and used immediately by the IC to perform fuel saving and emissions,

• Hydrogen bubbles off the cathode
• Oxygen bubbles off the anode

In PEM systems, the membrane keeps the gases separated with very high purity.

 

 

 

📊 Gas ratio

Electrolysis always produces gases in a 2:1 ratio:

• 2 parts hydrogen
• 1 part oxygen

This matches the molecular structure of water (H₂O).

 

 

 

⚡ Efficiency and energy use

Typical efficiencies:

• Alkaline electrolysis: 55–70%
• PEM electrolysis: 60–80%
• Solid oxide electrolysis: up to 90% (high temperature)

Higher efficiency = less electrical energy needed per kg of hydrogen.

 

🧪 Types of electrolysis systems

System	Electrolyte	Pros	Cons
Alkaline (KOH/NaOH)	Liquid alkaline solution	Cheap, durable Electrodes are protected from electrolysis in an alkaline solution	Lower purity, slower response
PEM (Proton Exchange Membrane)	Solid polymer membrane	High purity H₂, compact, fast Expensive to produce and maintain	Expensive catalysts
HHO / Dry cell	KOH/NaOH	Simple, DIY-friendly but problems with electrode stability / corrosion	Low efficiency, mixed gas output

🔥 Why this matters for hydrogen fuel systems

For your hydrogen‑assist kits:

• HHO cells produce a mixed gas (H₂ + O₂ together).  And a large amount of water vapour / steam—because the HHO systems have too many cells , not enough applied voltage and no way of circulating and cooling  the liquid other than convection within the cell  – which has zero  cooling effect.   Basically the Typical HHO cell designed  by  “backyard Mechanics” is a faulty system that heats water  to boiling point
• PEM systems produce pure hydrogen, which is safer and more efficient for controlled injection.— but impractical because of the very high cost of setting up the systems
• PEM also avoids electrolyte contamination and corrosion.

 

 

Why PEM produces more usable hydrogen per watt compared to typical HHO cells,

The short answer: PEM produces more usable hydrogen per watt because almost all of the electrical energy goes into splitting water — not fighting heat, resistance, or side‑reactions like in HHO cells.

 

 

 

Here’s the deeper, engineering‑level breakdown tailored to the systems you work with.

⚡ 1. Internal resistance: PEM is extremely low, HHO cells are high

A PEM membrane is a solid polymer proton conductor with very low ionic resistance. An HHO cell uses liquid electrolyte + metal plates, which introduces:

• Ohmic losses in the electrolyte
• Bubble‑induced resistance  as the effective plate area is reduced and a greater percentage of the  current is working through a reduced electrode area
• Plate surface resistance – again related to the smaller effective  area of electrodes by bubbles clinging  to plates…. Hydrogen fuel systems Pty Ltd  have addressed this problem by using a pumping system that displaces bubbles and increases the diffusion coefficient of the electrolysis system, reduces laminar flow over the plates  making more gas.  Turbulent flow is ideal but we don’t waste too much electricity producing turbulent flow  as this means we are sacrificing  gas production
• Heat buildup increasing resistance further

Every extra ohm wastes watts as heat instead of hydrogen.

Result: PEM converts more of each watt into actual electrochemical work.

 

 

 

⚡ 2. PEM runs at high current density without overheating

PEM stacks are designed to operate at 1–3 A/cm² efficiently. HHO cells typically struggle above 0.2–0.4 A/cm² before:

• Heat skyrockets
• Efficiency collapses
• Electrolyte boils
• Plates warp or delaminate

So even if both systems draw the same amps, the PEM stack stays in its efficient zone while HHO cells fall off a cliff.

 

 

 

⚡ 3. No mixed gases → no recombination losses

HHO cells produce mixed steam,  H₂ + O₂ in the same chamber. This causes:

• Micro‑recombination at the plate surface  –    which generates heat
• Energy lost as heat
• Lower net hydrogen output

PEM separates gases by design:

• Hydrogen at the cathode
• Oxygen at the anode
• No recombination
• No cross‑contamination

This alone increases usable hydrogen per watt.

 

⚡ 4. PEM has catalytic electrodes, HHO plates do not

PEM uses platinum‑group catalysts that dramatically reduce activation energy.

HHO cells rely on:

• Stainless steel
• Nickel
• Sometimes titanium  ( very expensive to manufacture , cut , shape and in many if not most cases are simply false)

These are not catalytic, so more voltage is wasted overcoming activation losses.

PEM typically operates at 1.6–2.0 V per cell. HHO cells often require 2.2–2.8 V per cell once heated.

My HFS systems are operating at levels close to that of a PEM systems .   WE have developed a new patented alloy anode together with the stainless steel 316L cathode that operates at a reduced Eo value to have a lowetr operating voltage per cell and waste less energy as heat.  This innovation is patented  / patent pending and will be released for commercial applications as soon as the patent is granted.

Lower voltage per cell = more hydrogen per watt.

 

 

⚡ 5. PEM has no electrolyte contamination or parasitic reactions

HHO cells suffer from:

• Electrolyte breakdown
• Chromium/nickel leaching…. Toxic chemical
• Side reactions forming oxides
• Electrolyte heating changing conductivity
• Bubble adhesion reducing active surface area

PEM uses pure water, so:

• No side reactions
• No contamination
• No changing electrolyte concentration
• Stable performance over time

This stability increases watt‑to‑hydrogen efficiency.

 

⚡ 6. PEM produces usable hydrogen, HHO produces a diluted gas

This is the part most people miss.

HHO gas is:

• Mixed
• Moist
• Contains steam  – in many  cases 70 % or more
• Contains trace contaminants
• Lower energy density
• Not compressible safely  – compressing Hydrogen and oxygen can be explosive …. For trucks that use airbrakes the air intake should never be taken from the intake used to power the engine if a Hydrogen system is being used by the truck….
• The airbrake air intake must be from a separate air intake airfilter  so as not to compress hydrogen / oxygen in the compression tanks

PEM produces:

• 99.999% pure hydrogen
• Dry
• Compressible
• Usable for fuel cells or injection

So even if the raw volume per amp is similar, the usable hydrogen from PEM is far higher.

 

🎯 Bottom line

PEM wins because it wastes far less energy.

Factor	PEM	HHO Cell
Internal resistance	Very low	High
Heat losses	Low	High
Gas purity	99.999% H₂	Mixed HHO
Voltage per cell	1.6–2.0 V	2.2–2.8 V
Current density	High	Low
Side reactions	None	Many
Efficiency	60–70%	20–40%

So per watt, PEM gives you more hydrogen, cleaner hydrogen, and more usable hydrogen.

 

 

 

Hydrogen generating Knox Scientific Hydrogen fuel systems

have developed 4 models  of Hydrogen system for engines of 

1. Capacity up to 4.5 liter – Gen 10 System

   

2. Capacity up to 10 litre – Gen 15 System

   

    
3. Capacity up to 16 liter …. Gen 20 System

   

   

   

   

4. Capacity greater than 16 liter ….. Gen 20 system

The Hydrogen gas produced by these systems is collected  in the recycling water tanks and then passed into the engine air-intake ahead of the turbo charger

The Gas simply increases the efficiency of the combustion process by burning all the fuel injected at close to TDC.

Wasting up to half the fuel at the lower part of the power stroke and wasting it out the exhaust is of no use to the engine … the Power of combustion cant be used to power the engine to reach its required speed when burnt at the bottom of the engine stroke.

Hydrogen massively speeds combustion so less throttle is used, less fuel is injected, required power is produced and gas emissions are reduced.

These systems are being used internationally through my JV partners  ( Singapore and India) FOR cars , trucks, generators, farming, marine applications etc

Water Resin Filter. Produce laboratory grade Pure water

Water resin filter produces Pure water out of polluted ground water  — lasts 5000 liters before needing to replace the cartridge … Purifies 5 liters per hour

Gen 15 hydrogen system on campervan

Photos ABOVE show a 16 litre volvo of Ian uses twin Gen 20 systems and a modified tank system to store his electrolyte

25 to 30% savings

J#### – a farmer in SW Wa has a gen 15 system on his Nissen  mounted into a steel box hinged under his Nissen tray

K##### a Keen surfer having spent his lige working his farm in N qld … divorce and now lives week to week surfing around Australia…. Promoting my systems and getting commissions for sales…a bit lonely but living the Dream he says

Work Vehicle in Perth Gen 15 system fitted out by C##### ….  Attempted to copy and to BREACH My PATENT… Illegal –  legal action  will follow

 

Photos of connection of HFS systems

Basic structure fo connecti0ons  – wiring and tubing for the hydrogen fuel system

the system recycles the electrolyte —– each liter of water produced 1440 litres of hydrogen gas over a 6 hour period

The tank size can be changed to sut your needs and how the gas production can be increased by altering the control dial on the power supply , to suit your needs

L#### is a keen WA gold prospector and with the Hydrogen system can travel further between refills …. Which is crucial in outback West Australia where stations can be many hundreds of miles apart

 

My last Photo of this presentation is that of my second youngest daughter — my princess…..The Most important reason I invented my hydrogen fuel system is to give my daughter and the  rest of the world a chance to live in a world where global warming is not what they have to try and live under

A few years ago (17 now ) and my increased sales internationally shows my systems are being used by governments like India …. We have hope

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Sunday, May 24, 2026