SUMMARY LETTER REPORT ON WORK ORDER NO. 10 TASK ORDER NO. 30

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03624A000900070001-4
• Release Decision: RIPPUB
• Original Classification: C
• Document Page Count: 21
• Document Creation Date: December 27, 2016
• Document Release Date: June 24, 2013
• Sequence Number: 1
• Publication Date: June 20, 1964
• Content Type: REPORT

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SUMMARY- LETTER REPORT
on
WORK ORDER NO. 10
TASK ORDER NO. 30
June 20, 196+
OR Gs"; AL CL BY 7vZ6_ _
D IMCL C ?r O -f-1 l)
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EXT CYND 6 Y i!!2)
REASON
CONFIDENTIAL
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March 10, 1965
This letter represents the summary letter report on Work Order
No. 10, Task Order No. 30. The effort conducted under this program during
the period April 20 through June 20, 1964, is described in the "Summary
Letter Report on Work Order No. 1, Task Order No. 39", dated November 15,
1964.
On April 20, 1964, Work Order No. 10, Task Order No. 30, was
undertaken to perform a cursory investigation of the possibility of generating
300 cubic feet of hydrogen gas using Hydripills and water with a one-
package addition, and under other specialized conditions. The results of
this limited effort indicated that, as anticipated, the foaming experienced
under the specialized generating conditions was sufficient to necessitate
further experimental work to develop a suitable generation system. Effective
July 15, 1964, Work Order No. 1, Task Order No. 39, was set up to provide
for a more extensive effort on the development of a satisfactory generation
system. To make the discussion of the results of the two programs more
meaningful, the results were integrated and described together in the "Summary
Letter Report on Work Order No. 1, Task Order No. 39", dated November 15,
1964, in accord with the Sponsor's recommendation.
Sincerely,
ABW:mg.
In Triplicate
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NT AL
uIlk
SUMMARY LETTER REPORT
on
WORK ORDER NO. 1
TASK ORDER NO. 39
November 15, 196+
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March 10, 1965
This letter report summarizes the research conducted under Work
Order No. 1, Task Order No. 39, from July 15 through November 15, 1964;
and also, as a matter of coherence, the results of the effort performed
under Work Order No. 10, Task Order No. 30, from April 20 through June 20,
1964.
INTRODUCTION AND OBJECTIVES
During the past few years, several research efforts have been
conducted on the investigation and design of experimental hydrogen generators
to produce hydrogen gas on the basis of water and commercially available
Hydripills? (consisting of sodium borohydride and cobalt chloride). The
success of these efforts has led the Sponsor to consider a project directed
toward the development of a hydrogen-generating device with the following
characteristics:
(1) Generating capacity:
300 cubic feet of hydrogen
using Hydripillso and fresh
water at a temperature of
55 to 75 F
(2) Generating time: 15 minutes nominal, 25 minutes
maximum
(3) Generator:
Compact and lightweight, with
minimum volume in the folded
condition
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(4) Auxiliary Equipment: 2-foot-long gas exhaust hose
and, if practical, a hand pump
to facilitate filling the unit
(5) Operation:
Simple and straightforward,
with a one-package chemical
addition.
Based on these requirements and on past experimental work with
various types of hydrogen generators,, it appeared that a satisfactory device
might be about 3 feet in diameter', by 2 feet high, with a 6-inch-diameter
sealable opening for chemical and water addition and a 1-1/2 to 2-inch-
diameter opening for a gas outlet. It could probably be fabricated from
neoprene-impregnated nylon and use stays to rigidize the structure. The
generation would require about 9 pounds of chemical in about 45 gallons of
water. By the addition of all of the chemical to the water at one time in
a fairly exposed state, it was expected that the generation time would be
less than 15 minutes. However, the actual generation time at 55 to 75 F and
the resulting amount of foam formed at the top of the water bath could be
estimated only within wide limits. Accordingly, the Sponsor requested, be-
cause of the urgent need for such a device, that a cursory investigation
of the above-outlined general design be performed. This investigation was
to consist of preparing a design sketch, conducting one or possibly two
full-scale generations in a simulated generator, and modifying the design
sketch. It was hoped that generation in the simulated generator would be
sufficiently satisfactory that, a sketch of a suitable generator design could
be provided to the Sponsor within a relatively short period of time. This
cursory program was set up under Work Order No. 10, Task Order No. 30.'
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-3.
When the above-outlined activity was-performed, it was found that
primarily because of the foam problem, further experimental efforts were
needed in order to develop a generator which would satisfy the above-
listed requirements. A research program directed toward achieving this
goal was subsequently set up under Work Order No. 1, Task Order No. 39.
The research efforts performed on both of these programs are
summarized below in chronological order, to provide a coherent picture of
the entire development.
This development was conducted in two parts. The first was a cur=
sory investigation of the possibility of generating 300 cubic feet of
hydrogen gas using Hydripills? and water with a one-package chemical addition,
and was performed under Work Order No. 10, Task Order No. 30. The results
of this initial limited effort indicated that sufficient foaming was ex-
perienced to necessitate further experimental work to develop a generation
system.
The second phase consisted of a more extensive investigation of
K
the possibility of generating 300 cubic feet of hydrogen gas using HydripillsK
and water with a one-package chemical addition. This included the design
and construction of the generator proper, of the chemical-addition container,
and of related components, and was performed under Work Order N6. 1, Task
Order No. 39?
The ultimate objective of these efforts was achieved. A hydrogen
generator was developed that satisfied all of the stated requirements except
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one-the maximum allowable. generation time of 25 minutes was exceeded.
However, the Sponsor indicated that this maximum time specification can
readily be changed to 1I0-4+5 minutes without presenting any problems....
RESEARCH ACTIVITY
The research activity consisted of an initial cursory investiga-
tion of the design parameters of a proposed 300"cubic-foot generator; a
subsequent study of selected factors affecting the design and operation of
the proposed generator; and the preparation and evaluation of an experimental
generator. Following a successful demonstration, a final experimental
generator system, i.e., generator plus associated components, was prepared
incorporating selected modifications.
Simulated 300Cubic-Foot Generator
On the basis of the work conducted previously under Task Order
No. 15, it was estimated that approximately 9 pounds of chemical (HydripillEP)
added to about 45 gallons of water would satisfactorily generate 300 cubic
feet of hydrogen. Based on these figures, a simulated generator was
constructed from a modified 100-gallon metal tank for a cursory evaluation
of the previously estimated design parameters (Figure 1).
In addition to the simulated generator, a container for the
chemical was fabricated. This was made from woven glass cloth, such as used
for window screening, and was fashioned into a tubular configuration
6 inches in diameter and 20 inches long.
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20109
Figure 1. Simulated 300-Cubic-Foot Generator
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First Full-Scale Generation
On May 6, 1964, one generation test in the simulated generator
was conducted. Even with the use of a chemical-addition tube and.a baffle,
both of which have aided in controlling the foam in previously designed
generators, sufficient foaming was experienced to terminate the experiment
prematurely, i.e., after about two-thirds of the generation was completed.
Subsequent discussion indicated that because of the cost of the chemical and
the amount of chemical needed for each generation, methods for controlling
foam could probably be developed most satisfactorily by an empirical ap-
proach; and also that further experimental efforts were required to develop
a suitable generating system.
For subsequent experiments, the chemical container was.fabricated
from metal cans so that changes in design of the.container perforations
might be readily accomplished. It was known from previous similar efforts
that properly sized and located holes in the chemical container would
regulate the chemical reaction in the water, and that the appropriate size
and location of the holes could best be determined empirically.
As shown in Figure 2, an experimental metal chemical container was
fabricated for a second full-scale generation in the simulated generator.
The container consisted essentially of two 1-gallon cans soldered together
(with the bottom removed from the top can). The number, size, and location
of the drilled holes were selected arbitrarily; the single holes, one
located on the bottom of the container and one at the top edge, were to
assure the initial entry of water into the container and also the subsequent
complete filling of the container with water.
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?Figure.2. Two-Gallon Experimental Metal
Chemical Container (for Full-
Scale Test)
Two rows, each
having twelve
/ 316-inch-diameter
?
holes
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Second Full-Scale Generation
8.6 pounds of chemical was placed in this experimental chemical
container and about 45 gallons of 60 F water was poured into the simulated
generator. The chemical container was then inserted via the chemical.'
addition tube. The start of the resulting chemical reaction was almost im-
mediate. The generation rather quickly became so vigorous that the friction-
fitting lid which had been placed on the chemical-addition tube had to be
held in place. The vigorous reaction lasted for 6 minutes. The chemical-
addition-tube lid was removed, and the chemical container was jostled. The
vigorous reaction started again, and lasted for an additional 4 minutes.
Thus, a total time of 10 minutes was recorded for this generation. It ap-
peared that with such a vigorous generation reaction, a reduction of the
area of the holes in the chemical container was needed.
Experimental 300-Cubic-Foot Generator
In order to reduce the number of variables associated with the
subsequent generation experiments, it was decided that a fabric full-scale
generator would be fabricated such that the dimensions would more closely
resemble those of the ultimate design. Two units were constructed in the
course of the program. One reflected a preliminary design and was used to
grossly check out the design parameters. After the below-described genera-
tion tests were run in the preliminary unit and the unit was demonstrated
to the Sponsor, the final experimental unit was prepared, to reflect selected
modifications as outlined below.
The general dimensions of the final experimental generator were
24 inches square by 38 inches high. These dimensions provided a volume of
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about 12.7 cubic feet or about 95 gallons. When the necessary quantity of
water that had been established as 46 gallons was added, there was a free-
foam volume above the water surface that was about 20 inches high. As
seen in Figure 3, the experimental 300-cubic-foot generator resembled the
previously designed 28-cubic-foot unit. It consisted of a rectangular-
cross-sectioned unit fabricated from 16-ounce neoprene-coated nylon fabric
with cemented and sewn seams. Four vertical 3/8-inch-diameter aluminum
rods were used as supporting stays. An 8-inch-diameter neoprene-coated-
nylon fabric tube (chemical-addition tube) provided entry for the chemical
container. A polyethylene gas-outlet tube, 1-3/4+ inches in ID, was in-
corporated in the top of the generator. This provided a stub for the
attachment of the gas-outlet hose (automotive corrugated defroster hose) by
means of a metal hose clamp. In addition, a 1-3/4.inch-ID.polyethylene
tube was built in near the bottom of the generator, for attaching a drain
tube (2-inch=.ID neoprene-coated nylon fabric tube) by means of a metal
hose clamp. The 8-inch-diameter chemical-addition tube was designed to
facilitate insertion of the chemical container into the generator and also
to permit fast closing or opening of the tube.
In an operation, the drain tube is clamped off and water is added
to the generator through the chemical-addition tube. The gas-inlet tube
of the balloon is inserted over the generator gas-outlet hose, and taped
in place. ..Then the chemical container is introduced into the generator
through the "chemical-addition tube, and the chemical-addition tube is clamped
off. The chemical container floats partially under the water and releases
the hydrogen gas as the chemical reaction takes place.
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Figure 3. Final Experimental 300-Cubic-
Foot Generator -
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Following the construction of the 300-cubic-foot generator, one
half-scale and three full-scale generations were conducted. Some
experimentation with the design of the chemical container was performed
simultaneously.
Half-Scale Generation
The first generation in the fabric generator was a half-scale test.
The chemical container used (Figure 4) was of 1-gallon capacity and held
approximately 4.3 pounds of chemical; the number and size, and generally
the location of the holes were the same'as in the previously described full-
scale (2-gallon) container. In this test 23 gallons of 70 F water was
used. The generation was completed in 18 minutes, with a temperature rise
of 50 F to a maximum generation temperature of 120 F. There was no foam
apparent at the gas-outlet hose, and the generation was not overly vigorous.
This was considered an excellent generation.
Third Full-Scale Generation
A full-scale generation was conducted in the fabric generator.
The full-scale (2 gallon) metal container was filled with 8.6 pounds of
chemical and introduced into 46 gallons of 60 F water. The total generation
time was 15 minutes and the temperature rise was 50 F, to a maximum
generation temperature of 110 F.
This full-scale generation was satisfactory for the test conditions.
However, it was determined that, if the initial water temperature in the
generator was significantly-higher than 60 F, say, by 10 to 20 F, an
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One 3/16-inch-
diameter hole
Two rows, each having
twelve, 3/16-inch-
diameter holes
Figure i+. One-Gallon Experimental Metal
Chemical Container (for Half-
Scale Test)
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unsatisfactory or overly vigorous chemical reaction, i.e., an excessively
rapid reaction, could occur. Thus, it was decided that the area of the
water-inlet holes in the chemical container would be reduced by one-fourth.
This was accomplished by using 18 holes in two rows in the container
instead of the previous 24 holes. At that time, it was also decided to
make the chemical container from 16-ounce neoprene-coated nylon fabric; this
would reduce the packaging size of the chemical container in that it could
be folded and easily stored when not filled with the chemical. Thus, the
fabric chemical container was generally the same as the full-scale metal
container previously described, except that 18 holes, instead of 24 holes,
were approximately aligned in the two rows. To assure the complete reaction
of the chemical with the water when this chemical-addition bag was used,
a 2-pound weight was attached to the bottom of the bag, so that the bag
would submerge completely in the water near the end of the chemical, reaction.
The fourth full-scale generation was conducted with 8.6 pounds
of chemical added to 46 gallons of 64 F water using the chemical-addition
bag. The temperature rise of the water was 36 F, which gave a final water
temperature of 100 F. The generation was quite satisfactory, with a total
generation time of 37 minutes.
Subsequently, another full-scale test was conducted as a field
demonstration for the Sponsor. For this demonstration, a Sponsor-supplied
300-cubic-foot polyethylene balloon was used to receive the generated
hydrogen gas. As before, 8.6 pounds of chemical was added to 46 gallons
of, water using the bag. The initial water temperature was 77 F and the
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final water temperature 114 F. After a generation period of about 19 minutes,
the balloon was pulled loose from the generator gas-outlet hose by a
strong wind. The generation continued for an additional 4 minutes, making
a total generation time of 23 minutes.
It is estimated that the balloon was 2/3 to 3/4 full at the time
of detachment and contained 200 to 225 cubic feet of hydrogen gas. The
measured free lift of the balloon at that time was approximately 14 pounds.
The Sponsor judged the equipment and the operation to be quite satisfactory
for the intended use.
Following the field demonstration, several selected modifications
were suggested for the system. These were:
(1) Providing a two-clip close-off clamp for the
chemical-addition tube instead of a one-clip
clamp, as was used in the demonstration.
(2) Reducing the packaged length of the 3/8-inch-
diameter aluminum supporting stays by making
each stay in two halves.
(3) Providing a collapsible bucket (instead of a
hand pump) for filling the generator with water
in the field.
These modifications were subsequently incorporated into the final
generator system and one system was fabricated. The various components
were checked for dimensions and weight; the weights are as follows:
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Component Weight, pounds
Generator (complete with gas-outlet hose, 6.24
drain hose, and clamps, but without
aluminum supporting stays)
Chemical-addition bag (empty) 2.04
Aluminum supporting stays 0.94
Total net weight 9.22
Balloon weight 2.18
Chemical (addition for one generation) 8.60
Collapsible bucket 2.1
Total gross weight 22.10
The final generating system is shown in Figure 5.
Sketches showing the general construction of the generator
components were completed and the system was packaged for shipment. The
sketches and the complete system are to be shipped to the Sponsor.
FUTURE WORK
No future work is currently contemplated on the 300-cubic-foot
hydrogen generator.
We have enjoyed working on this development. If there are any
comments or questions regarding these efforts, we would be pleased to hear
about them.
Sincerely,
ABW:mg
In Triplicate
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Giomv-j r) r- U NTIAL
Figure 5. Experimental 300-Cubic-Foot Generating-
System Components. - -
(The fabric chemical bag is shown on
the left; the collapsible bucket on the
right)
JO -INNNTU\L
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