Moffat Research describes their patent-pending Mark VIII Module for hydrogen generation. The Module uses electrolysis with a non-reactive metal electrode and potassium hydroxide solution to produce hydrogen and oxygen through a gravity-assisted separation technique. It has a simple and inexpensive design using off-the-shelf components, with a projected 20-year lifespan. Modules can be combined into groups and scaled up as needed for hydrogen production rates. The Module has strengths like low cost and maintenance requirements compared to proton exchange membrane electrolyzers, though it requires higher power input and produces lower pressure hydrogen.

1. Moffat Research, LLC
The Moffat Hydrogen Generator
Overview
The Moffat hydrogen generation and separation technique is based on a patent-pending hydrogen
generation unit, the Mark VIII Module. The module is designed to be powered by any DC
electrical source capable of producing the requisite amperage, (see below). The Mark VIII
Module has several unique features that, we believe, make it ideal for large scale hydrogen
production. Like any device, it has inherent strengths and weaknesses when compared to others
on the market. These strengths and weaknesses are detailed below.
The Module
The Mark VIII Module uses the electrolysis method, with potassium hydroxide as the conductive
solute. The electrodes are made of a relatively cheap, non-reactive metal in a patent-pending
design that ensures a large electrode surface area in a compact space. Unlike other electrolysis
based methods, the module achieves hydrogen and oxygen separation via a patent-pending
geometric, gravity assisted technique that eliminates the need for proton exchange membranes.
Water consumed in the conversion process is replaced by a patent-pending method that maintains
the potassium hydroxide solution at a constant concentration.
The Mark VIII is constructed almost entirely with ‘off the shelf’ hardware. Its projected
operational life expectancy is about 20 years. Modules can be combined into groups, and groups
of groups, depending on needed hydrogen production rates. The modular system can be adjusted
to collect either hydrogen alone, or separately collect both hydrogen and oxygen. A patent-
pending modular combination and placement method gives the entire system the capability to
function outdoors, in climates ranging from arctic to tropical. The only limiting factors for
function are the availability of power and a renewable water supply.
The Mark VIII is roughly 9"x10"x6" in its largest dimensions, and is designed to fit comfortably
into a 16" diameter reactor containing the potassium hydroxide solution. The containment reactor
is built with ‘off the shelf’ materials, and is sized to allow optional monitoring features, as well
as projected future retrofit modifications. Optimal operating parameters are 1.5 volts at 50 amps,
giving a predicted output of 1.96 moles molecular hydrogen per hour per module. Inevitable
waste heat production is addressed with a heat sink created by the placement method.
Our patent-pending multi-module designs are based on unit groups that can be linked into 'super
groups' of sizes dictated by location, water supply, and power output of the DC source. Our basic
design, based on placement requirements available in most locations in the United States, has
predicted outputs of about 800 grams molecular hydrogen per hour per group, and 800 kilograms
per hour per super group. Hydrogen gas pressures with this design are about 26 PSI. Water
consumption at the super group peak production rate is approximately 14,000 liters per hour.

2. Strengths and Weaknesses of the Module
In comparison with proton exchange membrane (PEM) hydrogen generation systems, the Moffat
Mark VIII Module requires higher amperages and produces lower hydrogen pressures. Both of
these features translate into lower efficiency per kilowatt hour of input power in order to achieve
comparable molar quantities at comparable pressures. The PEM generator is far more compact
compared to module group sizes required to produce similar hourly rates. The Moffat Module
requires a high flow water source, especially in its super group configuration. However, despite
these differences, we believe our approach has multiple advantages.
The simple, elegant design of the Mark VIII, and its use of largely off the shelf components,
make it inexpensive and easy to construct. The module has no moving parts, and neither the
electrolyte nor the electrodes are consumed in the hydrolytic reaction. These features, along with
the long life of the other module components, translate into very low maintenance and further
cost savings. A single Mark VIII Module will produce at 80% of the output of a standard
commercial PEM unit, but the module cost is less than 1% of the PEM unit cost. Moreover, a
super group configuration for PEM units is impracticable. The Mark VIII is the only hydrogen
generator designed to be used outdoors and in all climates. It is ideal for use in combination with
renewable power sources, especially solar. Its modular design allows it to be tailored to the
supply of power and water available in any given locale.
The Future of Hydrogen?
We believe hydrogen generation has a bright future as one viable means of energy storage. We
further believe that the Moffat Module technique, especially in combination with solar, wind, or
wave power generation, can produce quantities of storable energy that allow markedly reduced
dependence on fossil fuels. (One scenario, grand but not unobtainable, would be the construction
of a vast series of super groups, powered by solar cells, in the border strips along our system of
federal highways. One super group, occupying 2 acres, and requiring 111 acres of solar cells
performing at 16% conversion efficiency, will produce about 1.1 million kilograms of hydrogen
each year, based on an average of only four hours of sunlight per day.) While the national
savings in terms of decreased carbon dioxide emissions and decreased foreign spending are
obvious, we would also call attention to the potentially huge job market that would open if a
major move were made toward a hydrogen augmented energy economy.