Fuel Cell Nation

Electrolysis Explosions in California

By LA Fire Department Photo

On August 9, 2011, an apparent hydrogen/oxygen explosion occurred at the alternative energy firm Rainbow of Hope in the Sylmar section of Los Angeles. Timothy A. Larson, 42, an L.A. firefighter who was on disability leave due to an existing injury, was one of the two inventors critically injured in the blast, as they were thrown into an alley by the force of the explosion. Larson apparently lost an arm an a leg in the blast. In the hospital, William A. Stehl, 68, was induced into a coma with extensive shrapnel wounds in his face.

This latest accident occurred 14 months after Larson's brother (28-year-old Tyson Larson) was killed in a June, 2010 explosion at Realm Industries, in Simi Valley, their father's predecessor alternative fuel business. In 2008, there was an explosion at Realm Industries when it was located in a different building. The 2008 blast was smaller, and there were no serious injuries.

The father, Timothy A. Larson, was among the numerous investors in a New York company formed in 2001 by Stehl, (photo at left by the Adirondack Daily Enterprise) who was indicted in 2010 in New York on charges of bilking more than 300 investors out of $7 million. Stehl claimed he developed an economical process to create energy from water, and allegedly promised his investors guaranteed returns. When the business, BGX Technologies (formerly known as Rainbow Technologies), went under, Timothy A. Larson bought its equipment and had it shipped to California so he could set up Realm Industries with his sons.

Somehow Stehl (and Tyson Larson) got a patent issued for this "technology":

U.S. Patent 7,793,621, Alternative Fuel Engine.

Neither this patent, nor the predecessor patent application, mentions "Brown's Gas" (or "HHO Gas"), which is actually what they were producing. In brief, Brown's gas is produced by simultaneously capturing the two product gases of water electrolysis, hydrogen and oxygen, in a single, unstable product stream. They instead claim they were "modifying the bond angles of water." The slightest spark (or an errant piece of catalyst) will cause an explosion in the product gas mixture, as the hydrogen and oxygen violently recombine back into water. I have no idea why anybody would willingly produce such an unstable gas mixture, and especially why they might try to store it. It seems that Cal/OSHA believes that Stehl and the Larsons were trying to compress and store their hydrogen/oxygen gas mixture at pressure in a pair of 8-foot diameter pressure vessels! Of course, a pressurized hydrogen/oxygen mixture has even more explosive energy than an atmospheric pressure hydrogen/oxygen gas mixture.

One final note: notice how the name of one of Stehl's companies, "BGX", seems to be an acronym for "Brown's Gas"?

DOE 2011 Hydrogen and Fuel Cells Meeting (Part 1)

I'm just back from the 2011 US DOE Hydrogen and Vehicle Technologies Program Annual Merit Review and Peer Evaluation Meeting in Crystal City, across the river from Washington DC. It was well attended; I heard there were 1,700 people at the two hotels where it was held.

My favorite presentation was by Avālence LLC CTO Paul Dunn, presenting his project "High-Capacity, High Pressure Electrolysis System with Renewable Power Sources." He mentioned how they had a problem in the lab last year with 6,500 psig alkaline electrolysis of hydrogen and oxygen: they produced oxygen gas with only a 96% purity (or 4% H₂ in O₂.) There's a big problem with operating this way: the lower flammability limit of hydrogen in air, or oxygen, is 4%! It's a wonder that they didn't blow themselves up!

The best part is where he described their plan to reduce the hydrogen content of the oxygen by recirculating their electrolyte on both the anode and cathode sides of the electrolyzer. Guess what - he told us they used a thermosiphon to recirculate electrolyte without a pump, and it reduced their oxygen to 0.3% hydrogen! Guess what my Giner Electrochemical Systems poster presentation discussed last year? A proton exchange membrane (PEM) electrolyzer using a thermosiphon to recirculate the catholyte! Just a coincidence? Who knows! I'm just glad I helped minimize his chances of blowing up!!

Hamilton Sundstrand's ILPE - Oops!

U.S. Navy nuclear submarines can travel around the world under water, generating a supply of breathing oxygen as required. Virginia-Class subs generate oxygen utilizing what is called the   Integrated Low Pressure Electrolyzer (ILPE), an electrolytic system made by Hamilton Sundstrand (a unit of United Technologies Corp. (UTX)).The heart of the ILPE involves proton exchange membrane (PEM) electrolyzer technology (right), which uses electricity and distilled water as inputs to create high purity breathing oxygen (and byproduct hydrogen).  In 2009, Proton Energy Systems announced it would provide electrolyzer stacks to Hamilton Sundstrand for the ILPE.

 When the electrolyzers have been integrated into complete ILPE systems, they look like an arrangement of individual tan cabinets that have been bolted together (left). This is because the sections must be transported in pieces through the narrow passageways on a sub, until the ILPE undergoes final assembly in place.

On March 19, 2011, the USS New Hampshire (below), a Virginia-class attack boat that entered service in 2008, was on ICEX 2011 arctic maneuvers. While approaching the Applied Physics Laboratory Ice Station, a floating ice station north of Prudhoe Bay, Alaska, its ILPE oxygen generator failed. According to NAVSEA, the sub switched to its backup oxygen system — using sodium chlorate “candles” — and continued normal operations.

   
Navy Photograph

According to a 3/21/2011 Reuters article:

"Daniel Coulom, a spokesman for Hamilton Sundstrand, confirmed late Monday that company staff would travel to the ship to help repair the oxygen generator, but said it was too early to speculate on what caused the problem."

A 3/28/2011 article in the NavyTimes states:

"The technicians arrived at Prudhoe Bay late March 24, according to Kevin Copeland, spokesman for Submarine Force Atlantic. They flew to the ICEX base March 25 and were to be taken by helicopter to the sub March 26."

No word on if any repairs were conducted, or even if the mode of failure has been discerned.