SUMMARY REPORT ON TASK ORDER NO. 13

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03624A000900070002-3
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 41
• Document Creation Date: December 27, 2016
• Document Release Date: June 24, 2013
• Sequence Number: 2
• Publication Date: May 21, 1962
• Content Type: REPORT

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E MEANING OF THE ESPiONAGE LAWS.
.S.C.,SECTION 793 AND 94. AS AMENDED.
MISSION OR THE REVELATION OF ITS CON-
ANY MANNER TO AN UNAUTHORIZED
S PROHIBITED BY LAW.
SUMMARY REPORT
ON
TASK ORDER NO. 13 10
May 21, 1962
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CONFIDENIK
TABLE OF CONTENTS
Page
INTRODUCTION 1
OBJECTIVE 2
SUMMARY 3
RESEARCH ACTIVITY 4
Preparation of Generator 4
Generator Repair and Modification 5
Conversion to Water4.PUrification Unit 9
Hydrogen.-Generation Experiments
Small-Scale Experiments
Half., and Fullq.Scale Experiments
12
13
16
Chemical Packaging and Handling
19
Operating Procedure
20
Water*Purification Set Up
24
WateroiPUrity Test Procedure
25
Hydrogen*Generation Set Up
27
FUTURE WORK
35
APPENDIX 1 Drawing of Final Design of 750acuftft Generator
?
?
?
?
36
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Figure
Figure
Figure
Figure
LIST OF FIGURES
1 Original Experimental 1/5*Scale Hydrogen Generator
Developed Previously Under Task Order No. C
2 Modified Generator Filled With 112 Gallons of
Water
3, Water0sPump Assembly Being Placed in the Generator ? . .
OD
4 Plastic Bags.Containing Hydripills and the Containers
Used to Provide Camouflage
Figure 5
Figure 6
Figure
Figure
Figure
Components Needed for Operation of the Generator as a
WatermPurification and ..Storage Unit and. Also as a>
HydrogenGeneration Unit
T?0Adapter Support With Elbows Attached to Two
Aluminum Stays Near Generator Gas Outlet
7 Installation of the ToiAdapter on.the.Generator.
8 Removal of T?Adapter Lid
9: Cutting of Sealed End of Plastic.Bag.Containing
Pellets
Pellets Being Dropped Into the Generator
Figure 10
TABLE
TABLE
LIST OF TABLES
.. ..
1 RESULTS OF DIFFERENT.HYDROGEN.GENERATION.EXPERIMENTS. .
2 CHRONOLOGY OF FULL*SCALE, FIELD,-HYDROGEN-GENERATION.
TEST
TABLE 3 COMPONENTS, ETC., NEEDED FOR OPERATION OF THE GENERATOR
AS A WATERftPURIFICATION AND 0STORAGE UNIT AND ALSO AS A
HYDROGEN-GENERATION UNIT
ECRET
Page
7
11
21
23
26
29
30
32
33
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L. 10
SUMMARY REPORT
ON
TASK ORDER NO. 13
...
May 21, 1962
INTRODUCTION
Your technical representatives had an urgent need-for a unit which
could be used at night to generate enough hydrogen to provide about 45 lb
of lift at sea level; this corresponded, in round numbers, to about 750 cu
ft of dry hydrogen. An acceptable total generation time was thought to fall
within the range of 15 to 4o minutes. A desirable total operating time,
from the time that the operator-started-to set up-the-generating unit until
the generation MRS concluded, was 2 to 3 hours. The generating-unit was to
be operated on dry land. Also, it was to be capable of operating with as
small a volume of water as was practicable, with the temperature of the water
available ranging from 70 to 80 F. The procedure to be followed in operating
,
the unit was to be simple, so that a nontechnical operator, with no previous
operating experience, could-successfully perform the generation-on the basis
of oral and written instructions. Also, it vas essential that the entire
generation operation be such that it could beperformed-at as-law.a-noise
level as possible. Further, the unit and the necessary materials and
accessory equipment were to be as small as possible in size and weight.
E REY
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During previous research under Task Order No. CI a detailed investi*,
gation had been made of the aqueous sodium borohydrideo.cobalt chloride reaction
for generating hydrogen, and a generator had been developed that utilized
this reaction to provide 3,500 cu ft of hydrogen. In the course of that
effort, an experimental "1/5 scale" unit had been designed and prepared, and
generation tests had been performed in that unit. On the basis of the back.*
ground of knowledge and experience with the abovementioned chemical reaction
and the "1/5 scale" unit, it was considered likely that, with minor
modifications of that unit and of the operating procedure, experiments could
be performed to demonstrate the applicability of the unit to the problem of
interest.
To provide for this research, Work Order No. 3 under Task Order
No. 9 was set up for the period February 7 through May 6, 1962, and subse-
quently Task Order No. 13 was set up for the period February 20 through
May 21, 1962. Also, the Sponsor furnished us the 3,500cu.-ft and the
experimental "1/5 scale" (700+ cu ft) hydrogen generators prepared previously
under Task Order No. C. As a matter of convenience, this report summarizes
the results of the overall development effort performed under the two agree-,
ments.
OBJECTIVE
The objective of this effort was to investigate the feasibility of
utilizing a previously developed experimental hydrogen generator (the "1/5
scale" unit from Task Order No. C) for a particular specialized application,
as generally outlined above.
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SUMMARY
The "1/5 scale" generator from Task Order No. C was repaired and
modified, and then adapted to operate and to look like a water.-purification
and ...storage unit. Leaks were patched and wooden stays were replaced with
aluminum stays. The air mat, which had been used to float the original unit
in water, was removed. Because the generator resembled typical portable
water-purification and *storage containers, the disguise of the generator
as an operating water purifier was completed rather simply by the provision
of a hand pump to be inserted in the gas outlet of the generator. It was
envisioned that stencilled lettering would be applied to the generator to
label it as a Government..issue water*purification unit.
Prior to the beginning of
borohydride and cobalt chloride for
market in pelletized form under the
this program, a combination of sodium
producing hydrogen had appeared on the
label of Hydripills . Small-scale and
half-scale experiments were conducted to determine the amount of these chemical
pellets and the time required to generate 750 cu ft of hydrogen. It was
determined that 22 pounds of Hydripills would satisfactorily produce 750
cu ft of hydrogen in the modified "1/5 scale" generator with the pellets
added in 3..pound batches; and that a batch of Hydripills could be
satisfactorily added to the generator from a polyethylene bag, which also
served as a good packaging container. Bags containing 3 pounds of Hydripills
were then prepared and inserted in the cartons of various commercial food.
staff and detergent packages. These packages were used to provide camouflage
for the chemical pellets under anticipated service conditions.
A satisfactory operating procedure was developed. This consisted
generally of adding water to the generator, attaching the balloon to the
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generator, and then introducing the Hydripills into the generator. The
equipment and the operation were demonstrated successfully at our facilities
and subsequently at a field site provided by the Sponsor.
RESEARCH ACTIVITY
The hydrogen! generation reaction used in the program was the
catalyzed hydrolysis of sodium borohydride (NaBH4), with cobalt chloride
used to provide the catalyst. The information and experience underlying
our exploitation of this reaction stemmed from previously performed research,
described in three reports: (1) "Summary Report on Task Order No. C" dated
January 28, 1957, (2) "Summary Report on Task Order No. C (Phase li)', dated
December 31, 1958 and (3) "Summary Report on Task Order No. C (Phase II]',
dated August 31 1959.
The research effort performed consisted of the following three
types of activities: . (1) the modification and conversion of the "1/5 scale"
generator fabricated previously under Task Order No. C, (2) the hydrogen'
generation experimentation with Hydripills , and (3) the packaging and deo..
velopment of a technique for handling the Hydripills?. Also an operating
procedure was formulated to cover all of the steps involved in using this
generator to obtain 750 cu ft of hydrogen under the anticipated service
conditions.
Preparation of Generator
?The experimental 1/5.0sca1e hydrogen generator which Shad been
developed during the Phase II study of Task Order No. C (and is shown in
*Commercially available pills which consisted of sodium borohydride and cobalt
chloride; additional detail on these pills is given later.
err,Pfn
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Figure 1) was ideally suited to the requirements of the urgent application of
interest. The original generator was a cylindrical, neoprene.coated nylon
unit 33 inches high by 43 inches in diameter. An inflatable rubber mat
approximately 3 inches in annular thickness and 15 inches high was cemented
to the periphery at the upper part of the generator. When the generator was
placed in water (the expected procedure for the original application), the
inflated mat served to support the generator and to stabilize it in a cylindrical
configuration. Wooden stays attached to the lower sides of the generator
served to keep the sides essentially vertical. The generator was equipped
with a 4.inch.diameter, neoprene" coated nylon water-inlet tube located at one
point on the cylindrical surface close to the bottom. Also, there was a gas
outlet consisting basically of a reinforced tube.shaped component with a
brass ring at the top; this was attached at the top surface of the generator,
along with another 4.inch.diameter tube with a larger bag attached to it.
In order to use this unit for the application of interest, two
types of activities had to be performed: (1) the generator had to be repaired
and modified to satisfy certain new requirements; and (2) it had to be modified
and disguised so that it would look like, and could be used as, a wateria
purification unit. (This latter requirement was imposed after the effort was
started and is described in more detail below.) The remodelled generator
is shown in Figure 2. The drawing for the final design evolved is included
in Appendix 1.
Generator Repair and Modification
Two types of repairs had to be made on the experimental 1/5-scale
generator. The wooden stays had either broken or become warped from
moisture. These were replaced with aluminum.rod stays (1/2 inch in diameter
err_PFT
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N49968
Figure 1. Original Experimental 1/5AScale Hydrogen
Generator Developed Previously Under
Task Order No. C
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N87936
Figure 2. Modified Generator Filled With
112 Gallons of Water
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SVAL
8,
by 30 inches long). During the handling of the generator for the experimental
work under Task Order No. C, holes and tears had developed in the bottom and
lower sides of the generator. These were repaired as described below.
The formerly used repair method was improved by adopting a recently
developed adhesive. This adhesive is used extensively in the manufacture of
neoprenei.rubber skinwdiving gear and is available under the trade name of
"Black Magic". It is a foam neoprene cement which is manufactured by the
Lebec Chemical Corporation, Paramont, California.
To effect a repair, the damaged area was cleaned with coarse sand.,
paper and denatured alcohol. A repair patch was cut from the same neoprene..
coated nylon fabric used to fabricate the generator. The repair patch and
the area to be repaired were each coated with the special adhesive. The
patch was then placed over the defect and pressure was applied to the patch
with a rolling pin. Satisfactory repair was thus accomplished.
Under the requirements of the current application of interest, the
generator was to be used on land instead of in water. In this situation, the
air mat would not be needed to float the generator. Furthermore, with the
air net attached, the volume and weight of the generator in the packaged
condition were approximately doubled. However, it was not evident that the
generator would function properly on land without the air mat to help keep
the generator sides in a cylindrical shape.
Tests were made in which the generator with the air mat attached
but not inflated was filled with the required amount of water (112 gallons).
It appeared that the generator could support the water and still remain sub.,
stantially cylindrical in shape; the water tended to push the aluminum stays
into a vertical position. The air mat was removed as shown in Figure 2, and
SEC ET
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'
the generator generator functioned satisfactorily. It was subsequently found that
preparatory to adding water to the generator, it was particularly convenient
to place the bottom of the generator flat on the ground and to arrange the
aluminum stays in "teepee" fashion; as water was added, the aluminum stays
assumed an upright position.
. For the application of interest, there was no need.for 40,inche,'
diameter tube and bag assembly attached to the top of the generator. This
assembly was cut off leaving a stub, which was sealed.
Conversion to Water...Purification Unit
After the effort described herein was initiated, the Sponsor
presented information which made it necessary, and convenient, to convert the
generator into a unit which, prior to being used to generate hydrogen, would
serve as a normal...looking water.,!Turification and storage unit.
It was expected that the generator would be used in an area where
water was relatively scarce. The climate would be hot and dry, such that
the presence of a water-purification and ?storage unit would not be conspicuous.
Because it would not be possible for much advance notice to be given relative
to the specific time for the generation to be performed and because 112
gallons of water could not be easily obtained once the operator had learned
the time for the generation, it appeared prudent for the generator to be
disguised as a water-purification unit, and .also to be usable as such.
The conversion of the generator to a water.purification unit was
rather straightforward. The black neoprene?coated nylon material from which
the generator was fabricated was similar to that. often used for portable
water-purification units and containers. The application of a stenciled
'ECRU'
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,4 tat twil
label on the side of the generator, to call out selected identification
words such as are frequently found on Government.-issued items, would, it
was believed, help convince indigenous observers that the unit was indeed a
water-purification and storage unit. It was decided that this would be
done ultimately by the Sponsor's associates.
It was necessary to add a pump which would permit water to be-drawn
from the unit for drinking purposes. A satisfactory pump assembly, shown
in Figure 3 (and later in Figure 5), consisted of an inexpensive, hand...
operated bilge pump fitted with an adapter that permitted the pump to be
attached to the generator by insertion into the gas outlet. The pump
adapter was machined from black plastic pipe and sheet,, and was assembled
with an adhesive. The outside diameter was such that this adapter slipped
into the gas outlet without too much difficulty, but the fit was tight enough
to permit the pump to operate effectively. The pump itself was fitted-through
the center of this adapter. As a result of judicious selection of dimensions,
it was also possible for the pump assembly to be fitted into a plastic T.,
adapter (Figure 5) which was fabricated for use in generating hydrogen and
filling the balloon, although this combination was not considered necessary
by the Sponsor.
The generator T-.adapter was also prepared from black plastic pipe
and consisted of several components glued together. The inside of the
vertical part of the-T was lined with rubber so as to minimize the noise
generated by the chemical pellets as they were dropped into the generator
through the T..adapter. In the area corresponding to the cross section of the
horizontal or gas...outlet portion of the T...adapter, holes were cut in the
rubber lining to permit flow of the hydrogen generated from the reaction
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Sto Vti"
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N87930
Figure 3. Waten.Pump Assembly Being
Placed in the Generator
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bath into the balloon (Figure 5). Also, the Nadapter was provided with a
?
black plastic lid equipped with a handle on top; the lid fitted snugly into
the top of the vertical portion of the T.adapter.
(These accessory components are described in detail in the report
summarizing the effort under Work Order No. 2, Task Order No. 21.)
A purification chemical was needed that would make the indigenous
water safe for drinking and at the same time would not interfere with the
reaction of the chemicals in the generation of hydrogen. As described in the
next section, chlorine in the form of Na0C1 (Clorox) was finally selected as
the watertTurification chemical.
Hydrogenl.Generation Experiments
Under Task Order No. C, considerable work had been done with the
aqueous sodium borohydride.,cobalt chloride reaction for generating hydrogen.
Work with the 1/5?.scale generator had shown that 750 cu ft of hydrogen could
be generated from 20 lb of sodium borohydride and an appropriate amount of
cobalt chloride. The rate of hydrogen generation was a function of the
amount and temperature of the water, and the amount of catalyst (cobaltous
chloride, C0C12). Under Task Order No. CI the use of 112 gallons of water
in the 1/5-scale generator (corresponding to a water height of 18 inches)
generally resulted in satisfactory generation conditions of foam level and
elapsed time.
Subsequent to the completion of our Task Order No. C effort,
OD
Metal Hydrides, Incorporated, placed Hydripills on the market. Hydripills
are cylindrical pellets normally containing 92.5 weight per cent of Nal3H4
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and 7.5 weight per cent of C0C12 (anhydrous). ?The pellets are available in
two sizes, 10/3200 and 3/404inch diameter. ?By special order, pellets with
different percentages of the chemicals can be obtained. For the available
pellets, assuming 98 per cent purity for the Hydripillg', it was calculated
that about 22 lb of Hydripills would be needed to generate 750 cu ft of
hydrogen.
ID
Because we had not previously worked with Hydripills , and because
our previous experience indicated that too rapid a reaction can produce
excessive foaming and gas pressures, it was decided that three series of
experiments should be run in the temperature range of 70 to 80 F, namely,
(1) various small-scale experiments, (2) 1/2-scale experiments, and (3) fully.
scale experiments; and that the proportion of water used during the Task
Order No. C experimentation would be utilized. The results of the experiments
are summarized in Table 1, and discussed in the following.
Small-Bcale Experiments
The first six runs were small-scale experiments. The first three
showed that the generation of hydrogen at temperatures above 70 F might be
too rapid for this application. Three experiments were then made with the
HydripillPbeing added in two batches. As a result of this work, it was
believed that satisfactory generation could be achieved by adding the
Hydripills? in batches. The letters next to the Run No. designations in the
table identify discrete additions of the chemical pellets. In all instances,
the relative total quantities of Hydripills and water were those used in
the full.scale generation.
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TABLE 1. RESULTS OF DIFFERENT HYDROGEN.-GENERATION EXPERIMENTS
Run No.
Weight of
Pellets
Volume of
Water
Temperature, F
Total
Time
Vessel and Remarks
Initial
Final
min:sec
1
12.5g
550 ml
73
112
13:50
1,500ral beaker
2
12.9 g
570 na
73
116
11:15
1,500oom1 beaker
.3
428. g
18.6 liters
72
120
10:10
6.-gal tub;
D/h (water) = 15.5 in/6.0 in.
4A
6.25 g
550 ml
72
90
24:00
1,500m1 beaker
6.25 g
90
111
6:30
Total
12.5 g
550 m1
72
111
30:30
5A
6.25 g
550 m1
8o
1oo.1/2
12:20
1,500,,m1 beaker
6.25 g
aft:*
100-1/2
121.'1/2
3:30
Total
12.5 g
550 ml
80
121.1/2
15:50
6A
214g
18.6 liters
8o-1/2
' 104
12:20
2111. g
..
104
127
410
6-gal tub
428 g
18.6 liters
80..1/2
?
127
16:30
Total
7A
5.5 lb
56 gal
8171/2
11a)
3:30
Halfscale test:
B(b)
2.7 lb
ka)
3:30
(a) Temp. indeterminate
C(c)
2.8 lb
.(a)
136.1/2
2:00
(b) Added 28..1/2 min after
t=0
Total
11.0 lb
56 gal
81-1/2
136-1/2
34:3o(d)
(c) Added 321/2 min after
t=0
(d) Includes "wait periods"
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TABLE 1. (Continued)
Weight of
Run No. Pellets
Volume of
Water
Temperature, F
Initial Final
Total
Time
min:sec
Vessel and Remarks
8A
6.o lb
6.o lb
5.5 lb
5.5 lb
112 gal
Total 23 lb 112 gal
9A 6.25 g 550 ml(a)
6.25g
ern ?
Total 12.50 g 550 ml
10A 6.25g 550 m1(
6.25g
Total 12.50 g 550 ml
7.0.1/2
80
95
8o
80
103
80
.(a)
?
Ia
1321/2
132;1/2
95
96
96
4:00
3:3o
2:3o
1:30
7;73717)
18:
2-275T
103
11:00
124.1/2
4:o0
124,..1/2
15:00
Full..scale test:
-Temp. indeterminate
b Includes time between
additions
(a)
(b)
4 g of PittabF(Ca0C12)
in water
Reaction was proceeding
very slowly
(a) 5 ml of Na0C1 in water
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?16.
Runs Nos. 9 and 10 were made to determine what effect, if any, two
selected water.purification chemicals would have on the generation time.
11A ,
The chemicals used for this purpose were Pittabs kCa0C12 pills) (Run No. 9)
and Na0C1 (Run No. 10). These chemicals were added at about 100 times the
recommended concentration for normal water-purification purposes, to obtain
abetter appreciation of the effect of the excess calcium or sodium ions
on the hydrogen.generation reaction. -As noted in the table, the excess
calcium had a retarding effect on the generation time. Ekcess sodium had no
noticeable effect. Thus, it is concluded that a water.purification chemical
4/
which is a sodium.bearing compound, such as Chlorox (Na0C1), can be used withs
out concern relative to unfavorable effects on the generation reaction.
Half. and Full.Scale Experiments
Half.scale,Run No. 7 was originally intended to be a "two addition"
test. The first :batchH of Hydripills reacted so rapidly, however, that the
second batch was added in two parts. It became evident from the temperature
ID
measurements made during this experiment that the Hydripills were not mixing
with the water in the large.scale experiment nearly as rapidly as they did in
the small.scale experiments. As a result, the reaction was occurring
primarily in the water layer at the top of the pool, the reaction temperatures
were higher than before, and the reaction was proceeding very rapidly.
On the basis of the half.scale test results, a full-scale test
(No. 8) was set up as a four-addition experiment. Although full.scale
4D
requirements called for only 22 lb of Hydripills to generate 750 cu ft of
hydrogen, 23 lb were used to provide a slight safety margin for our calculations.
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417.
The experiment was completed very smoothly in a total time of 150,1/2 minutes,
including the time which elapsed between the end of each reaction period and
the addition of another batch of HydripillP.
On March 7 1962, a fullsscale field test was carried out at a
special site arranged for by the Sponsor. -For this test all items were
packaged as they would be for actual field usage. The generator was set up
and water was added to a predetermined level. The water temperature at the
start of generation was 87 F; 3 oz of Na0C1 was added to the water prior
to the run to simulate "purified" water. A 750scusft balloon was attached to
the generator. A total of 24 lb of Hydripills packaged in eight 30.1b
batches, were to be used. A chronology of events starting with the water
in the generator is given in Table 2.
On the basis that 3 lb of HydripillsID yield approximately 100 Cu
ft of hydrogen, it appeared. that approximately. 550 cu ft of hydrogen had been
loaded into the balloon because only 5.01/2 additions were needed. It could
not be determined whether the balloon capacity was actually less than 750 Cu
ft (as was suspected), or whether the volume difference (between 750 -and
about 550 cu ft) represented water vapor trapped in the hydrogen.
-During the week of April 9, 1962, another fullsscale field test was
conducted by the Sponsor and his associates to determine loadslifting capability
and balloon-maneuverability factors under specialized conditions-and within
specific limitations as to available space; the time involved-in the-operation
was of immediate concern. In preparation for this fullsscale operation,
several simulated tests were conducted using helium as the lifting gas. These
tests provided the experience necessary to determine the appropriate balloon
filling, handling, loading, and release techniques to be used in the final
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18.
TABLE 2. CHRONOLOGY OF FULL.SCALE, FIELD,
HYDROGENGENERATION TEST
Chronological
Time,
minutes
Operation
0
Proper amount of water in generator.
Operator started carrying packages to the generator.
Balloon unrolled.
8 Balloon staked down.
11 Last check of water temperature; T = 87 F.
17 Neck of balloon taped to generator.
22 1st addition of Hydripills6)
(generation tine 3 minutes 2 seconds)
25 Balloon tied down in better position
(operator assisted by others)
28 2nd addition (generation time 3 minutes 3 seconds)
34 Neck of balloon cut down and re.taped to generator
37 3rd addition (generation time 2 minutes 37 seconds)
40 4th addition (generation time 2 minutes 10 seconds)
1.1.3 5th addition (generation time 2 minutes 23 seconds)
46 6th addition (generation proceeded for 51 seconds and
the balloon was filled; approximately half of the
hydrogen generated from this addition was vented to
the atmosphere)
49 Balloon tied off and moved around to test maneuver,.
ability. Hydrogen then "dumped".
RET
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application. Following these procedural tests, the fullscale generation
test was completed satisfactorily. (Relative to this full-scale operation,
one of our personnel provided technical advisory services,under Work Order
No. 7, Task Order No. 9.)
Chemical Packaging and Handling
Because of the potential toxic hazards of the Hydripills , there
was a need for care to be used in the packaging and handling of the chemical.
Although it had been shown that the Hydripills could be added in 6.5pound
batches for a satisfactory reaction, experiments showed that one man could not
easily and quietly put 6 pounds of the pellets into the generator in the
dark. Further work showed that he could add the chemical satisfactorily in
3.Tound quantities. Consequently, a package was designed to hold 3 pounds of
pellets. The first packaging containers were made from ridged plastic pipe,
5 inches in diameter and 30 inches long. The diameter was determined by the
size of the opening in the generator. Although this pipe provided a
relatively substantial and moistureoproof package, it proved to be difficult
to disguise and, in addition, was conducive to considerable noise when the
Hydripills were being emptied from it. The plastic pipe acted like a
sounding?board as the solid Hydripills bounced back and forth against the
hard surface when the pellets were being poured from these containers.
Additional efforts resulted in the use of a plastic (polyethylene)
bag. Various diameters and lengths of bags were investigated. The ultimate
bag configuration was determined by the generator opening, by the amount of
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chemical needed, and by the ease with which the containers could be
disguised. The final design of the plastic bags represented two sizes of
bags. One bag was 4 inches in diameter and 26 inches long, and the other
was 5 inches in diameter and 20 inches long (Figure 4). Each bag was
fabricated with an extra 6.inch.long neck, so that this neck could be pushed
through the gas.outlet tube and thus prevent spillage of the chemical pellets.
Each package was sealed against moisture infiltration and placed in
containers previously selected to provide suitable storage capacity and
also appropriate camouflage. The containers used were taken from commercial
food-stuff packages, such as cardboard boxes for crackers, cereals, cookies,
etc., and also commercial detergent packages, as shown in Figure 4; the use
of this type of camouflage reflected the strong recommendation of the
Sponsor's associate.
After careful opening of the bottom flaps of the various boxes,
the original contents were removed and replaced with a selected number of
appropriate bags of pellets. Usually there was either one 14.inch-diameter
bag or one 5-inch.diameter bag fitted into each selected food box. However,
it was possible to pack as many as four of the filled plastic bags in one
OD
large home-laundry-size box of detergent such as AD (Figure 4).
Operating Procedure
In accordance with the objectives of the program, an operating
procedure was evolved for unpacking, setting up, and operating the generator.
This procedure represented a two.step operation. One step involved the set
up and operation of the generator as a water.purification and storage unit,
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*n21?
SEMI
OX1
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4422.
and the second step involved the use of the generator to generate hydrogen.
The components, materials, and supplies needed for this procedure are listed
in Table 3; most of them are shown in Figure 5.
TABLE 3. COMPONENTS, ETC., NEEDED FOR OPERATION
OF THE GENERATOR AS A WATERmPURIFICATION
AND *STORAGE UNIT AND ALSO AS A
HYDROGEN*GENERATION UNIT
1. Generator (neoprener.coated fabric cylindrical tank)
2. Generator stays (eight 1/2",diameter x 30"-long aluminum rods)
3. Generator T-adapter (6"-diameter plastic T)
4. Generator T.-adapter lid
5. Generator 5.adapter support (1/2"-diameter pipe with attached 6"*J-diameter clamp)
6. Packaged chemical pellets
7. Black plastic tape (Scotch Brand No. 33 or equivalent)
8. Scissors, 1 pair
9. Measuring stick (wooden dowel)
10. Thermometer (metal)
11. Water pump, plus inlet and outlet hose
12. Water-purification kit (chlorine solution and chlorine comparator kit)
13. Fabric repair kit
14. Rubber gloves
ET
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.23.
N87938
Figure 5. Components Needed for Operation of the
Generator as a Waters-Purification and
.0Storage Unit and Also as a Hydrogen.
Generation Unit
SERF
56(1
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.*24,
Water-Purification Set Up
The procedure for setting up the generator as a water-purification
and storage unit is as follows:
(1) Remove the contents of the box which houses the generator,
stays, ground cloth, and other related equipment (Figure 5).
(2) Place the ground cloth (6.mil polyethylene sheet or equivalent)
on the ground in the area selected for the water.curification set up.
(3) Place the generator on the ground cloth; untie and unfold
the generator.
(4) Place the generator, with the bottom flat on the ground, in
the center of the ground cloth.
(5) "Tie off" the drain tube by tying two tight knots in the 4"..
diameter tube which extends from the side of the generator close to the
bottom.
(6) Arrange the aluminum stays and the side of the generator in
tee.gpee fashion, with the top of the stays pointed inward toward the center.
(7) Grasp the gas outlet (the tube on the top of the generator)
and pull it upward and outward to make it easy to add water to theienerator.
If a hose is used, place the end of the hose on the bottom of the generator.
(8) Fill the generator with 112 gallons of water. To determine
that the proper amount of water has been added, measure the height of the
water within the generator in either of two ways: (1) use the 1/2" diameter
wooden dowel that is provided, and stop the flaw of water when it reaches
the black mark near the center of the dowel; or (2) measure the actual depth
with an appropriate rule. The height of the water from the bottom of the
generator should average 18".
C ET
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(9) Arrange the aluminum stays and the generator so that it
stands properly. (See Figure 2.)
(10) Install the T..adapter support by placing the support elbows
on the two adjacent aluminum support stays which are located closest to the
gas outlet as shown in Figure 6.
(11) Add the proper amount of waterftpurification chemical
(chlorine0obearing liquid) and test for chlorine content by the method
discussed under "Watep,PUrity Test Procedure".
(12) Place the intake and outlet hoses on the water pump ?, the
long hose on the intake tube and the short hose on the outlet tube as
shown in Figure 3.
..(13) Insert the water.pump assembly through the clamp of the Too
adapter support and intothe gas outlet (Figure 2).
(14) Work the wateropump handle until the pump becomes primed.
If the pump does not prime, check the intake hose to be certain that the
hose end is under water, and work the pump handle again.
Waterc4Purity Test Procedure
After the chlorine*solution purification chemical kChlorox ) is
added to the water, a test should be run to be sure that the water, so
treated, can be drunk with safety. Two methods for checking the water are
described below; either of these methods can be used with confidence:
Procedure 1. Add approximately 10 drops of wateropurification
solution per one gallon of water to be treated. After at least 30 minutes,
smell or taste a sample of the water. If the water has an odor or a taste
SECRET
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Atin\I
0,26.
Figure 6. T-Adapter Support With Elbows
Attached to Two Aluminum Stays
Near Generator Gas Outlet
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of chlorine, then enough chlorine is present to render the water safe to
drink. If the water is not relatively clear or if it contains a large
amount of matter, then more than the above.,indicated amount of water.,
purification liquid should be added. The water should always be tested
before drinking, and sufficient chlorine should be added to provide a
noticeable chlorine smell or taste after 30 minutes have elapsed from the
time the addition is made.
Procedure 2. To test for safe water using the chlorine comparator
kit furnished, the following procedure should be followed:
Add approximately 10 drops of watermpurification liquid for each
one gallon of water to be treated. After at least 30 minutes have elapsed,
take a sample of the water and add five drops of orthotolidine reagent
provided in the kit. After another 30 minutes, compare the color of the water
sample with the comparator standard from the kit provided and note the
reading. This reading indicates the amount of residual chlorine in the water..
If the residualchlorine content is in the range of 0.1 to 0.3 ppm (part per
million) or higher, the water is safe for drinking. If the residual-chlorine
content is lover than 0.1 ppm, add more chlorine solution and repeat the
procedure.
Hydrogen-Generation Set Up
The procedure for generating hydrogen is presented in the
following:
If the generator has not been set up as a water-purification and
',storage unit, follow Steps 1 through 10 as described above under "Water..
Purification Set Up". Then, proceed with the instructions presented
SEC ET
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*28,
below (Steps 1 through 11).. If the generator has been set up? as a water,
purification and storage unit remove the waterepump assembly and then
proceed as follows:
(1) Insert the bottom end of the vertical part of the T4
adapter (the end with the flange)through the clamp of the Teadapter support
and into the generator gas outlet as shown in Figure 7. Position the Te
adapter so that the horizontal part of the T (the outlet) faces outward from
the generator. Tighten the clamp screw so as to hold the Teadapter firmly.
Tape the joint between the Teadapter and the gas outlet so that the joint
is gas tight; use the black Scotch Brand No. 33 tape provided.
(2) Check the level of the water with the wooden dowel. Add
water, if necessary. Insert Tmadapter lid in the top of the Teadapter
(Figure 8).
(3)
Place all of the equipment necessary to generate and contain
the hydrogen gas in the relative locations as follows:
(a) Place the bores containing the pellets, the
gloves, the scissors, and the black tape
within 3 or 4 steps of the generator near the
Teadapter (Figure 5).
NOTE: There should be no smoking or fires
from this step on.
(b) Unfold, lay out, arrange, and tie down the
balloon as specified by the instructions ac-
companying the balloon. The balloon should
be arranged in line with the Teadapter outlet
(horizontal part of the T) and far enough sway
ECM
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N87927
Figure 7. Installation of the TpoAdapter
. on the Generator _
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Figure 8. Removal of NAdapter Lid
SEC ET
N87931
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Eqk
to permit the balloon transfer tube to be
just long enough to reach the T*adapter
without kinking or twisting).
(4) Open the "foodstuff" and "detergent" containers housing the
bagged chemical pellets and take out the bags. Lay the bags on the ground
cloth or the equivalent, to keep water or moisture away from the bagged
chemical.
(5) Attach the balloon transfer tube to the Nadapter by sliding
the transfer tube over the horizontal portion of the Nadapter and taping
the transfer tube to the Duadapter with the black tape provided. This
connection must be strong and gastight.
(6) Put on the rubber gloves provided. Remove the Nadapter lid.
Pick up one of the bags of pellets and open it by cutting off the end seal
with the scissors, as shown in Figure 9.
(7) Grasp the neck of the bag with one hand to prevent the
chemical from spilling aut,\and lift the bottom of the bag with the other
hand. Then, while inserting the neck of the bag into the top of the T.
adapter (as shown in Figure 10), invert the bag to permit the pellets to
drop from the bag into the generator.
(8) Quickly replace the T.adapter lid. Adjust the balloon
transfer tube to permit a free flow of gas into the balloon at all times.
Work the balloon so that the gas fills the nose section of the balloon first.
Note: The hydrogen generation slows down usually after
about 3 minutes for each 3t.lb batch of pellets,
at a water temperature of 80+ F. When the generation
slows down, the pormal hissing sound within the
generator gets more and more quiet, and the top of
the generator, which bulges during active generation,
relaxes and resumes its original fairly horizontal
position.
UP, r
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N87935
Figure 9. Cutting of Sealed End of Plastic
Bag Containing Pellets
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N87937
Figure 10. Pellets Being Dropped Into the Generator
SECRET
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(9) Taka another bag of pellets, cut off the sealed end of the
bag, and prepare to add the pellets. As soon as the generation slows
down or stops, add this bag of pellets by repeating Steps 7 and 8.
(10) Continue to add the batches of pellets in this manner until
the balloon is properly filled with hydrogen, as indicated by the instruc,*
tions accompanying the balloon. Then, seal off the balloon transfer tube
with one hand, and cut the tube between the sealedooff section and the TA
adapter with the scissors. Tie off the transfer tube as close to the
balloon as possible with several (3 or 4) simple overhand knots.
(11) Attach the load and associated equipment, and release the
balloon as directed in the balloon instructions.
(12) If the generator was to be repacked for future use, the
following procedure should be followed:
(a) Untie the knots in the generator drain tube and
permit the water and chemical to run out to a
suitable drain...
(b) Untape and remove the T.adapter from the gas
outlet and 5-adapter support clamp. Remove
the T*,adapter support.
(c) If possible, flush the generator until the
water running from the drain tube is clear and
shows no discoloration. Drain all excess
water from the generator and whenever possible,
permit the generator to drain and dry for from
4 to 24 hours.
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(d) Remove the aluminum stays. Fold and roll the
generator into a package approximately 30" long
and 12" in diameter.
) Pack all of the equipment in the original
containers.
NOTES: 1. The hydrogeno.generation process develops considerable heat
within the generator and in the balloon transfer tube. Every
attempt should be made not to touch these items with bare
parts of the body. Gloves and clothing should be worn to
protect the body from such contact.
dD
2. The Hydripills are slightly caustic as is the water plus
chemicals which remains after hydrogen generation. The
eyes and skin should be reasonably protected at all times
from contact with this chemical.
FUTURE WORK
No further work is contemplated at this time in connection with
the 750.cuft hydrogen generator.
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Appendix 1
Drawing of Final Design of
750..cuft Generator
EC ET
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