2018 International Conference on Computing, Mathematics and Engineering Technologies – iCoMET 2018
Comparative Study Of Dry Cell And Wet
Cell For The Hho Gas Generation As A
Supplement Fuel For I.C. Engine
Shah, S. A. Q1 Ali, Z2
1
Department of Manufacturing Engineering, MUET, Jamshoro, Pakistan
2
Professor Head of Department Industrial Engineering & Management, DUET, Karachi, Pakistan
Correspondence: sayedaqs6514@gmail.com
Abstract—This study is based on the comparison of dry
cell and wet cell for the production of the HHO gas which
can be used as a duel fuel for internal combustion
engines. The physical and operational parameters for
both cells were compared and critically discussed. The
impact of heat generation on both cell and their relevant
safety issues were particularized. The HHO production
from both fuels was compared. It can be concluded now
that dry cell is far much better than the wet cell as it
produces more HHO gas as compared to wet cell for the
same input conditions. Its terms of working and
maintenance, the dry cell are more reliable and suitable
than the wet cell. The safety features of dry cell are more
promising than the wet cell.
Keywords—wet cell; dry cell; HHO generator; fuel
additives; I.C. engine.
I. INTRODUCTION
Water is the most plentiful compound and the major
source of life on this planet.The water molecule is
composed of two elements namely Hydrogen and
Oxygen. The chemical formula of the water molecule
is H2O and the chemical reaction to produce a water
molecule (combustion) and vice versa (electrolysis)is
as follows.
However, if this decomposition is taking place in a
controlled environment then the resulting product is the
HHO gas. It is a very well-known fact that fossil fuels
are used as the source of energy for the internal
combustion engines. However, due to their higher
depleting rates and increasing prices, a number of
researchers have dedicated their research work on
investigating alternative sources of energies for the
internal combustion engines. Some of the researchers
have focused on the methanol and organ metallic
(MnO2) fuels [1], vegetable oil [2], natural gas [3],
neem oil methyl ester [4], HHO gas [5, 6], etc. as
alternative fuels or additive fuels
Hydrogen is widely acknowledged as a non-
polluting, renewable, and recyclable fuel. The major
dissimilarity between hydrocarbon fuels and hydrogen
fuel is the absence of carbon. Moreover, as compared
to other hydrocarbon fuels, hydrogen has greater flame
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Larik, J1 Kaimkhani, A. A1
speed, faster burning velocity, and wider flammability
limits [7]. This helps the engine to complete the
combustion process and to run on very lean mixtures
which results in less unburnt fuels and reduced
pollutants in the emission. This research study focuses
on the hydrogen as a supplementary fuel. It is important
to mention here that the HHO gas is not used as an
alternative of the diesel or petrol because it will require
more battery power to generate adequate HHO for the
engine to run smoothly. Hydrogen is only used as an
additive in the existing vehicular fuels using the
electrical energy supplied by the alternator of the
vehicle which will not put extra burden on the engine.
Hydrogen can be used in cars as a fuel additive which
increases the combustion efficiency of the fuel-air
mixture. A small amount of hydrogen gas could also be
produced in a car by decomposing water by means of
electrolysis, using for this purpose the energy produced
by the car's electric power generator. The hydrogen and
oxygen (HHO) mixture obtained, which is also known
as Brown's gaseous mixture, is supplied to the engine's
intake manifold.
Hydrogen as a supplementary fuel for the internal
combustion engines has been the area of interest for
many researchers and the results of their research
outcomes are very promising[5-8]. In practice HHO
generator can be divided into two types based on their
construction i.e. wet cell and dry cell. The main
difference between HHO dry cell and wet cell is that in
a wet cell whole unit is immersed in water, while in dry
cell plates these are separated each other with rubber
seals. Plates and electrical connection are not in
electrolytic solution, these all remains dry so it is called
as a dry cell. The output gas is called HHO gas which
is the mixture of Hydrogen and Oxygen gases. Some of
the researchers are using wet cellfor the production of
the HHO gas while the others have opted for the dry
cell [9] for the production of HHO gas as a supplement
fuel for the IC engines. However, it is essential to
investigate thenature and the possible throughput (i.e.
HHO gas production) of each cell under the similar
input and load conditions at constant engine speeds.
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 2018 International Conference on Computing, Mathematics and Engineering Technologies – iCoMET 2018

To increase the conduction of electricity through
dry cellor wet cell a catalysts called potassium
hydroxide (KOH) is required to add in water to
diminish hydrogen and oxygen molecules.The
application of hydrogen generating cells is to use it as
a fuel supplement for internal combustion engines [10].
Both cells are individually connected with the battery
source of the vehicle to decompose water molecules
using electrolysis process to produce HHO gas. Both
cells will be tested under several similar conditions to
determine efficient design for HHO generator.There
are a number of factors associated with hydrogen gas
generation, which includes the amperage losses,
temperature losses during hydrogen generation,
amperage draw per unit of hydroxyl gas, and overall
efficiency of cells. These all factors are considered
while making a compact design of the most appropriate
cell to fit in the engine compartment. An efficient
system is one which uses the less power to produce
large volume of hydroxyl gas or brown’s gas. Core
intimation of this research study is to focus on the better
performance of both fuel cells and also consider the
design parameter for both cells basis on the engine’s
capacity for power.
and their capacity to generate hydrogen gas as a
supplement fuel for internal combustion engines, total
manufacturing cost for same capacity units, etc. Since
this hydrogen generation cell is mounted within the
engine compartment, therefore, it is also essential to
investigate the sustainability and health & safety issues
associated with this unit. In wet cells, the electrodes are
completely submerged all time in the water, whereas,
in the dry cell the electrodes are placed below the water
reservoir. This allows the water to circulate through the
HHO dry cell and back to the reservoir.
This block diagram shows the overall process of
HHO generator with internal combustion engine. It
consists a 12 volts battery connected to a 20 amperes
fuse. Electric current is supplied to the HHO generator
(dry cell or wet cell).The platesof dry cell and wet cell
are made of stainless steel 316L grade.When the
electrolysis process is started then the HHO gas flows
from cell to safety bubbler through ¼” inch gas hose
pipes in bubbler which shows the generation of HHO
gas. The HHO gas is further delivered to the engine
after air filter to the combustion chamber before it
reaches to intake manifold. Aflash back arrestor is used
for the safety purpose to avoid any spark from these
gases.The HHO gas is burnt with petroland air mixture
to produce power for the engine. Special feature of this
HHO dry cell is that it has same reservoir used as a
bubbler to prevent it from fire. The quantity of HHO
gas generation is measure in liters per minute.
Block Schematic Diagram of Hho Dry Cell Or Wet
Cell Integration With IC Engine

Fig. 1 Combustion and Electrolysis

II. THE RESEARCH AREA
This paper presents the comparative analysis of dry
cell and wet cell for the production of HHO gas also
known as brown gas. Both cells use battery power to
generate hydrogen gas, therefore, it is important to
investigate that which hydrogen generator is more
efficient. There are number of factors associated with
hydrogen gas generation which require detailed
investigation for both cells. These factors include the
total amperage draw per unit generation of hydrogen,
amperage losses, and temperature rise during hydrogen
generation, hydrogen production rate, and overall
efficiency of the cell. This detailed investigation will
ease the process of making a compact design of the
most appropriate cell to fit in the engine compartment.
This new emerging technology is capable enough in
reducing the fuel consumption and most importantly in
reducing the hazardous gases by excelling the
combustion process in the combustion chamber. One
of the important aspect of this study is to investigate the
cells’ configuration, e.g. size of electrodes, size of
plates, amount of electrolyte required, size of
containers for both cells, other accessories required,

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 2018 International Conference on Computing, Mathematics and Engineering Technologies – iCoMET 2018
Fig. 2. Block and schematic diagram of hho dry or
wet cell integration with IC engine.
III. PROBLEM STATEMENT
Since this study is mainly focused on the
comparative study of dry cell and wet cell for HHO gas
generation which is used as a supplement fuel in I.C
engine.One of the important aspect of this study is to
investigate the cells configuration, e.g. size of
electrodes, size of plates, amount of electrolyte
required, size of containers for both cells, other
accessories required, their capacity to generate HHO
gas as a supplementary fuel for internal combustion
engines, total manufacturing cost for same capacity
units, the electrolyte resistance to the flow of current
due the large distance between electrodes, etc. These
issues have been covered in the previous studies. It is
important to investigate the effects of these parameters
on the overall efficiency of the HHO generation.
Since these hydrogen generation cells are mounted
within the engine compartment, therefore, it is essential
to investigate the sustainability and health & safety
issues associated with this unit. Important safety point
in using HHO gas is that when engine starts it stars to
generate HHO gas that’s why it is called as HHO on
demand.HHO gas is not supposed to be stored for later
useand it is continuously produced and used.The major
issues are slow reaction due to inadequate current and
power supply. A detailed mathematical analysis is
mandatory for the appropriate solution. In order to
reduce the fuel consumption, it is essential to
investigate that how much fuel supply should be
reduced and how much HHO gas should be added to
get the same torque and speed ratio. When all factors
should be properly addressed so the proposed HHO
generator model can be utilized effectively and safely.
The comparison of both cell generators at the physical
level has not been covered in the previous studies.
Moreover, the sustainability and the required safety
measures for both cells will be thoroughly investigated
in this study.
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IV. AIMS AND OBJEVTIVES OF THE
RESEARCH STUDY
The aim of this research study is to compare the
HHO generation using dry cell and wet cell. It is
essential to figure out the influence of various physical
and operational parameters of both cells for the
optimum performance.
The measurableobjectives of this study include
1) To investigate the important physical and
operational parameters of dry cell and wet cell
which play significant role in the production
of HHO generation.
2) The comparison of these physical and
operational parameters will be then conducted
for the optimum HHO generation.
3) To analyze the influence of temperature
variation and the electrical power
requirements of both cells.
4) Investigate the sustainability and health &
safety issues associated with both cells.
V. METHODOLGY
The HHOcell is the heart of entireHHO generating
system.In this research study, a dry cell and a wet cell
of equal HHO production capacity will be first
finalized. It is important to mention here that selection
of the main components is also part of this study. The
main parts will include water reservoirs for both cells,
electric wires with their appropriate gauges, the amount
of catalyst, size of electrodes & plates for both plates,
water tubes for the circulation of water, the rubber seals
for the dry cell, etc. After this selection, each cell will
be connected to the battery power supply of the car
compartment. The HHO gas production of each cell
will be then calculated without any load and HHO gas
will be measured in liter per minutes. Health and safety
hazards will be investigated under these no-load
conditions. It is important to mention here that a very
precise calculation and selection of the components of
each cell is required to achieve the same HHO gas
production rate. This scenario will provide adequate
information for the performance analysis of both cells,
e.g. the amperage draw from the battery, temperature
rise inside each cell and in electric wires, the influence
of KOH on the production of HHO gas generation, etc.
This proposed research study is focusing on both
physical as well as operational parameters. The health
and safety hazards associated with both cells will be
investigated under these load conditions and the
respective hazard controls will be then recommended.
For the experimental purpose, the engine will be either
a 1000 cc petrol engine or an 800cc petrol engine or a
higher capacity diesel engine, depending upon the
availability of any one of them.
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 2018 International Conference on Computing, Mathematics and Engineering Technologies – iCoMET 2018

VI. ANALYSIS OF DRY AND WET CELLS 3. Spacing between the plates.
4. Cross-section area of the plates.
A. Physical and operational 5. Number of neutral plates.
parameters of both cells 6. Number of electrodes.
The dry cell and wet cell are both are connected 7. Type of electrolyte.
with the battery source of the vehicle to decompose 8. Amount of electrolyte.
water molecules using electrolysis process to produce 9. Quality of the electrical wiring, etc.
HHO gas. There are a number of physical and
operational parameters which play a significant role in It requires a great amount of research effort to
producing the HHO gas. The subsequent section will figure out the HHO gas production by varying all the
discuss about these parameters in detail. above physical parameters individually and keeping
the rests unchanged.
1. Dry Cell
A typical dry cell consists of a container, few plates
(neutral, positive, negative, and end plates), wires,
pipes, DC power supply, bubbler, flashback arrester,
rubber seals, fasteners, etc.as shown in Fig. 3.
The plates are separated by rubber seals to avoid the
leakage of water.
Dry cell is configured based on the number of plates
and their connection. For example, - n n n n n n + is
termed as 8 plates cell in series configuration with 7
water compartments. Whereas a series parallel cell can
be configuring as -n n n + n n n - which means two 5-
plates’ series cells in parallel configuration.
In this study, a 7-plates 6-water-compartment cell
is considered which has 5 neutral plates and two Fig. 4. Dry Cell Assembly [12]
positive and negative plates; all separated by rubber
seals to avoid the leakage of electrolyte solution. When 2. The Wet Cell
a 12 volts battery is connected then it will supply 2 A typical example to explain a wet cell is the
volts to each water compartment. It should be noted Lead -Acid battery. The active materials used in a lead-
that the spacing (defined by thickness of the rubber acid battery are lead (Pb, negative terminal) and lead
seal) between the two adjacent plates has a significant dioxide (PbO2, positive terminal) and a water solution
impact on the HHO production, therefor, precise of sulfuric acid (H2SO4). The load is connected to the
measure must be taken during the design and terminals which trigger the chemical reaction between
fabrication and assembly of the dry HHO generator. lead, lead oxide, and the electrolyte.
The salient physical parameters which are vital for
HHO gas production using wet cell are
1. Material of the electrodes.
2. Number of electrodes.
3. Spacing between the electrodes.
4. Number of electrodes.
5. Type of electrolyte.
6. Amount of electrolyte.
7. Quality of the electrical wiring, etc.

Fig. 3 Components of a Dry Cell

The salient physical parameters which are vital for
HHO gas production using dry cell are
1. Material of the plates.
2. Thickness of the plates.

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 2018 International Conference on Computing, Mathematics and Engineering Technologies – iCoMET 2018

loss of capacity, etc. Therefore, a temperature

controller must be added in the system for the
protection from overheating.

therefore, one has to be extra vigilant when using HHO
as a duel fuel for I.C. engines. The following are some
important recommendations regarding safety issues.
Fig. 5 Wet Cell Assembly [10]
B. Comparison of Dry and Wet Cells
a) The dry cell requires less amount of
electrolyte as compared to the wet cell.
Therefore, the weight and volume of the dry
cell is smaller than wet cell.
b) In the case of wet cell, the electrical
connections are under electrolytic water, thus,
the connections are corroded slowly.
Whereas, in dry cell the electrical connections
do not face such problems.
c) The heat generation in the wet batteries is
higher than the dry batteries.
d) Since the plate material in the wet cell erodes,
therefore, the size of the electrodes reduces
which results in killing out the battery power
and reduces the life of the battery.
e) For the same size of both cells, the HHO
output is higher in dry cell than wet cell and
offers coolest operation.
f) The dry cell batteries have longer working life
that wet batteries.
C. Influence of Temperature on both
cells
One of the most serious issues relevant to HHO
generator is the heat generation. High temperatures
have a dangerous impact on the HHO cell’s lifetime
and performance. Under hot conditions, the production
of HHO gas is seriously affected. Since the cell is
mounted in the engine compartment, therefore, the
HHO cell is exposed to the high temperature generated
by the heat of the engine. The cell is exposed to two
sources of heat; one from its own internal heat
generation due to excessive electron generation and the
other is the external heat of engine.Studies show that
foe each 80C rise in temperature reduces the cell’s life
by half. Once the cell is damaged by heart then its
capacity cannot be restored. If overcharged then the
cell generates excessive heat due to accumulation of
electrons which results in shedding of active material,
excessive gassing, rapid corrosion, plate deformation,
D. Safety issues
Since HHO gas is highly inflammable gas,
 Biggest and very important safety point in
using HHO is, it is only produced when
engine starts. So it is termed as HHO on
demand, its meaning is when the vehicle
engine starts to run, then and then cell starts
the electrolysis process of water.
 HHO is never stored. The HHO gas would be
aspirated directly to the engine intake process
while the engine is in operation, thereby
avoiding dangerous accumulations.
 A fuse should always be installed between
electrolysis cell and power source; a fuse will
protect form electrical shocks and possible
wires burning. A fuse will also protect the cell
from getting too hot from high amp usage.
 Bubbler tanks in between cell and air intake is
essential for neutralizing catalyst
contaminants. Also it will protect the cell
from flashbacks. It’s always easier to replace
a bubbler tank than a cell.
 For good HHO safety, it should never rely on
a check valve alone for flashback protection.
 Stainless steel of the highest quality (S.S 316
& 409) which can be affordable with all
hardware specifications are used in the
electrolysis process, so no degradation of
metals occur because electrolysis process
don’t able to degrade stainless steel.
 During usage, the electrolyte solution
produces some highly combustible gases so
one need to be careful during handling of the
battery when active. Check the battery for any
leakages regularly.
 Under any circumstances, avoid playing with
the wires when the batteries are charging.
 Sulfuric acid and lead are caustic which can
cause severe lead poisoning which may result
into skin burning.
 One should never experiment with seal.
 Always follow the security warning
instructions provided with the batteries.

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E. Calculations Calculations for only Petrol in the engine:

3. Engine Specifications B..P B.P
th    ( F .P  Cv  m fuel )
Table 1: Specifications of Suzuki Potohar F .P Cv  m fuel
F10A Engine used in this study B.P
Four-Stroke Cycle, Water  m fuel 
Type
cooled, OHC Cv th
Bore*Stroke 65.5*72
Piston
(Capacity)
Displacement
970cc 
Taking 25% thermal efficiency ( th ) we will have
Compression Ratio 8.8:1
33556.49
Lubrication System Wet Sump m fuel   3.195 10 3 Kg  3.195 g
Maximum Power (HP) 45 HP @5500rpm 42000000  0.25 sec sec
RPM 3000rpm
Air Pressure 0.35bar 
Taking 30% thermal efficiency ( th ) we will have
Temperature 38°C or 311K
Calorific Values 33556.49
For fuel 4200KJ/Kg m fuel   2.663 10 3 Kg  2.663 g
42000000  0..3 sec sec
for H2 120000KJ/Kg
 Fuel requirement for 25% to 30% thermal
Volume induced for the 4 stroke Engine:

efficiency ( th ) is 3.195 g/sec to 2.663 g/sec.
 RPM   3000 
   
0.00097   60 
 0.00097   60 
 0.02425 m
3

sec

At 25% ( th ):
2 2
From the General Gas Equation we have Replacing 10% petrol with H2

PV B.P
PV  mRT  m   th   B.P
RT ( F .P90% Petrol )  ( F .PH )
2

We are taking mass flow rate and volumetric flow   th  {( F .P90% Petrol )  ( F .PH )} 2

rate instead of mass and volume

So according to the ideal conditions the idea mass
F.P  Cv  m fuel
As we know that
flow rate of the air is
 B.P   th  {(Cv Petrol  mPetrol  0.9)  (Cv H  mH )}
 2 2


P V (0.35  10 )(0.02425)
5 
B.P  (Cv
m air( ideal)    m air( ideal)  0.009509 Kg  th Petrol
 mPetrol  0.9)
RT (287  311) sec
 mH  2
Cv H
Now for the actual air mass flow rate will be calculated 2

with the help of efficiency ratio mentioned above i.e. 33556.49  (42000000  3.195  10 3  0.9)
Efficiency Ratio = (actual mass/ideal mass)  0.25
120000000
So the actual mass flow rate of the air will be
 mH  1.1212  10 4 Kg  0.11212 g
 2 sec sec
m air( actual)  0.009509  0.4  0.003803 Kg
sec Now replacing 20% petrol with H2
Now mass flow rate for the fuel using air fuel ratio 
At 25% ( th ) we will have:
i.e. 14:1
We have B.P
 th   B.P
 0.0038036  ( F .P80% Petrol )  ( F .PH )
m fuel   m fuel  0.0002717 Kg  0.272 g 2

14 sec   th sec
 {( F .P80% Petrol )  ( F .PH )} 2

Calculations: (based on automobile principles)

F.P  Cv  m fuel
Taking thermal efficiency

( th ) in the range of
As we know that

25% to 30%.

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 2018 International Conference on Computing, Mathematics and Engineering Technologies – iCoMET 2018

So
 B.P   th  {(Cv Petrol  mPetrol  0.8)  (Cv H  mH )} Mass of H2 required vs % of petrol
2 2
0.001
B.P removed

mass of H2 required in kg
 th  (Cv Petrol  mPetrol  0.8)
 mH  2
Cv H 2
30% eff 25% eff 20% eff
33556.49  (42000000  3.195  10 3  0.8) 0
 0.25 0.5 0.7 0.9 1.1
120000000
 mH  2.239  10 4 Kg  0.224 g
2 sec sec -0.001
% of petrol removed

At 30% ( th ): VII. RESULTS AND DISCUSSION
Replacing 10% petrol with H2 For the electrolysis process to begin 30g of KOH
B.P was added in the water reservoir and a 12 volt battery
 th   B.P was connected to the HHO dry cell, the amount of
( F .P90% Petrol )  ( F .PH )
2 HHO gas produced was calculated by using the HHO
  th  {( F .P90% Petrol )  ( F .PH )}
2
meter as follows.

F.P  Cv  m fuel
As we know that HHO Amperage Voltage
drawn (A) supplied
So Production
 B.P   th  {(Cv Petrol  mPetrol  0.9)  (Cv H  mH )}
2 2
(liter/min) (V)
B.P For 1.5 14 12
 th  (Cv Petrol  mPetrol  0.9) Dry
 mH  2
Cv H 2
Cell
33556.49  (42000000  2.663  10 3  0.9)
 0.30
120000000 For 0.7 18 12
Wet
5 Kg
 mH  9.327  10  0.09327 g Cell
2 sec sec
Now replacing 20% petrol with H2


At 30% ( th ) we will have:
B.P
 th   B.P
( F .P80% Petrol )  ( F .PH )
2

  th  {( F .P80% Petrol )  ( F .PH )}

2

F .P  Cv  m fuel
As we know that
So
 B.P   th  {(Cv Petrol  mPetrol  0.8)  (Cv H  mH )}
2 2

B.P
 th  (Cv Petrol  mPetrol  0.8)
 mH  2
Cv H 2

33556.49  (42000000  2.663  10 3  0.8)

 0.30
120000000
 mH  1.8648  10 4 Kg  0.18648 g
2 sec sec

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 2018 International Conference on Computing, Mathematics and Engineering Technologies – iCoMET 2018

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can be as a supplementary fuel in the existing I.C. with HHO as a Fuel”, International Journal of Research
engines to reduce their dependency on the fossil fuels. Engineering and Technology, Vol. 04 (04), 2015.
The physical and operational parameters for both cells 12. [12] http://www.hhomaster.com/dry_hho.html
were compared and critically discussed. The impact of
heat generation on both cell and their relevant safety
issues were particularized. The HHO production from
both fuels was compared. It can be concluded now that
dry cell is far much better than the wet cell as it
produces more HHO gas as compared to wet cell for
the same input conditions. Its terms of working and
maintenance, the dry cell are more reliable and suitable
than the wet cell. The safety features of dry cell are
more promising than the wet cell.
ACKNOWLEDGEMENT
Authors would like to thanks Mehran University of
Engineering & Technology, Jamshoro and to all those
who provided the support during this research study.
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