Note: Descriptions are shown in the official language in which they were submitted.
10395~3
Background of the Invention
This invention relates broadly to the art of cutting, welding,
brazing, ~lame hardening, heating, melting and gouging metals,
alloys and like materials. In a typical operation in this art
as applied to metal cutting, a cutting torch is connected ts a
source of fuel ~as and to a source of oxygen. The oxygen and
fuel gas mixture is combusted while being placed in contact witn
a work piece o~ metal alloy or like material which is to be treated.
Typically, there is a preheating period during which the amount of
oxygen in the fuel gas mixture is at a somewhat lower level. ~ow-
ever, after the metal which is to be treated has risen to a pre-
determined temperature, i.e., after the preheating stage is over,
the percentage of oxygen in the oxygen uel gas mixture is increased
in order to increase the temperature of the flame. The increased
temperature of the flame then provides a suitable source of heat
for cutting, welding, gouging, flame hardening, melting, or the
like of the metal or alloy which is to be treated.
1039S~8
Typical fuel gases utilized for these purposes, and for heating
and other heat transfer purposes as well, include natural gas,
propane, acetylene, and butane. These gases when combusted with
oxygen can provide very Aot flames in the general range of from
4,500 degrees F. up to and perhaps slightly above 5,500 degrees F.
As can well ~e appreciated the cost of natural gas, propane,
butane and acetylene is not an inconsequential amount. Therefor~,
it is desirable to have the greatest efficiency of treatment per
quantity of industrial fuel gas employed. This is especially true
when the supply of natural gas, propane, butane and acetylene is
somewhat limited. The efficiency of an industrial fuel gas, and
of industrial gases utilized for home heating and other heat transfer
purposes, it measured by the quantity of gas needed to perform a
givenjob and t~ sFeedof performance. For example, and wi~h respect
to fuel gases utilized for metal working, a measure of the cutting
speed is required. Of course, a decrease in quantity of fuel gas
needed to perform a given operation, coupled with an increase in
cutting capacity, will mean an increased speed in feed per hour and
a corresponding increase in money saved per foo~ of cut or welding,
heat treating or like treatments. Thus, an ideal fuel gas would be
one which would provide rapid treatment with a minimum quantity of -
fuel and oxygen employed.
In addition to the consideration mentioned above, the accept-
ability of a fuel gas is also determined by an examination of the
quality of cuts, welds and the like obtained when utiliz~~ng a
certain fuel gas. Also, yet another standard of measurement of
acceptability of fuel gas is its affect upon the metal or alloy which
is being treated. For example, subjecting high carbon containing
steel alloys to high temperatures for extended periods of time is
known to affect the crystal structure of the alloy itself. In
particular, the crystal Lattice of the alloy maybe changed from a
body centered crystal structure to a face centered crystal structure.
... . .
:. .. ~ :. . . - .
.
~39S~
As a result, the steel becomes much more hardened and brittle.
The hardened steel is, of course, much more difficult to machine.
Ho~ever, if a fuel gas could be developed which would accomplish
its objective by high heat within a very short period of time, there
would be insufficient time for the alloy to change crystal lattice
structure and as a result the hardness properties of the alloy would
not be changed. This in turn would mean that the alloy could be
much more easily machined.
Yet another important consideration in determining sui~ability
of a given industri~1 fuel gas, and specifically those fuel gases
utilized for cutting purposes, is the general appearance of the
cut after it is made. A good cut is one which is generally a
straight line appearing cut, has little or no rollback, little or
no evidence of burning of the metal, and little or no sla~ present
along the line of the cut. Conversely, a bad cut is characteri2ed by
an irregular surface along the cut, a general appearance of dishi~g
out along the cut, excessive slag along the line of the cut wlth the
slag sticking to the cut and ~eing very difficult to remove~ and a
general burned appearance over the line of the cut.
Yet another important attribute o~ a good q~ality fuel gas is
that the gas must be completely combustihle to carbon dioxide and
water. Thus, gases which could potentially be useful industrial ~uel
gases but which will provide sulphur or nitrogen oxides as byproducts
are unsuitable because of their undesirable pollution effects.
Surprisingly, in accord with this invention, fuel gas co~posi-
tions and a method of formulating and using fuel gases has been dis
covered which when practiced will allow the utilization of a minimum
quantity of fuel gas to accomplish a given metal treating job in a
minimum of time, and provide high quality cuts, welds, and other
metal treatments, all without having a signiflcant adverse affect
upon the crystal structure of the metal being treated. In addition,
the byproducts of the combustion of the industrial fuel gas
1~395Q8
compositions of this invention are nearly all carbon dioxide and
wa-ter, indicating nearly comple-te combustion. Thus, there is no
utilization of hazardous additives which will provide undesired
polluting combustion byproducts such as sulphur dioxide and
nitrogen oxides. The method of accomplishing these and other
objects of the invention will become apparent from the following
detailed description of the invention.
Detailed Description of the Invention.
In order to more clearly understand this invention a basic
understanding o certain heat energy principles is essen~ial. A
very elementary description of those principles essential to an
understanding of this invention will, therefore, be provided herein.
When a flame is utilized as a heat source, whether in an
industrial fuel for metal treating such as cutting or for heat
transfer in home heating or the like, there are two heat transfer
mechanisms operative while a ~lame is utilized as a heat source.
One arises from the kinetic energy of the combustion of gas molecules,
often referred to as heat transfer by connection, and the other
from the heat energy radiation of the flame. The combustion of a
fuel gas first sets the gas molecules into a rapid state of motion.
These molecules then collide with the surface of the material to be
treated and by transfer of their kinetic energy, set the molecules
of the treating material into rapid vibration. They, in turn,
strike other metal molecules, thus tr~nsferring the motion to the
other side of th~. treating material.
The higher the heat of combustion of a fuel gas, the higher
the temperature of the~flame and the higher the kinetic energy of
the molecules of the gas. Consequently, more ~inetic energy (heat)
can be transferred to a given treating metal surface in a unit time,
thereby producing the required melting or vaporizing of the metal
in a shorter period of time.
In addition, a flame is also a source of electromagnetic
radiation. The relationship between the emission of electromagnetic
--4--
10395~)8
radiation for a heated solid and the absorption of radiation by
another solid is given by Kirchhoff's Law of Radiation. This
~ law sLmply states that the ability of a given substance to emit
t radiation when heated is proport:ional to its ability to absorb
radiation. Thus, when radiation is completely absorbed by a
substance, it is converted into heat, the quantity of heat being
equivalent to the total energy of the radiation absorbed.
Radiant heat rays, like visible light, are electromagnetic
waves and have all the general propertias known to visible light.
In this regard, like with light, the rate at which a body radiates
or absorbs heat depends, not only upon the absolute temperature,
but upon the nature of the exposed surfaces as well. Objects
that are good emitters of heat are also good absorbers of the same
kind of radiation.
The emission and absorption characteristics of radiant energy
of course varies for differing materials. Thus one metal, alloy,
elament, or like material, will have different emission and
absorption characteristics for radiant energy from another ~etal,
alloy or element.
It has now been discovered that those radiant energy waves
having frequencies equal to the natural frequencies of the atoms
of the metal alloy or element to be treated are absorbed with
great efficiency.
Every metal element alloy or other material which is to be
heat treated has a general range of wave lengths of radiant energy
which it can most efficiently absorb. When the metal alloy of
like materiaL is therefore subjected to a source of emission of
radiant energy with the emitting source emitting a high percentage
of those radiant energy waves of the same length that the material
to be treated will most efficiently absorb, a maximum efficiency
of radiant energy transferred is obtained. Thus, a critical
factor in most efficient utilization of a fuel gas is not the
,. ~ . .. . .
~L~)39S08
maximum temperature obtained during combustion of the fuel gas
with oxygen mixtures but whether or not the combusting fuel gas
will emit radiant energy of a wave length most susceptible to
absorption by the material to be treated.
Energy is stored in any fuel gas by virtue of the chemical
properties of that fuel gas due to the arrangement of atoms and
electrons in molecules. Thus, when a fuel is burned, heat is
liberated. The amount of heat given off per unit of mass of
completely burned fuel gas is called its heat of combustion.
Thus, during the burning of a fuel gas, the energy re~uired to
first formthe compounds comprising the fuel gas is now released
upon the combustion of the fuel.
~- An additional measure of the efficiency of a fuel gas is theexamination of the exhaust gases after combustion of the fuel.
Complete combustion of a hydrocarbon fuel gas will provide only
carbon dioxide and water as byproducts. This is extremely
advantageous in that carbon dioxide and water are harmless by-
products, not harmful pollutants. Thus, to the extent that a
fuel gas provides imcomplete combustion and produces, for example,
carbon monoxide, this in an indication of lack of complete com-
bustion, and therefore lack of complete release of the hea* of
combustion of the fuel gas, and therefore lack of efficiency.
In accord with this invention it has now been discovexed that
certain additives, all being compounds which are nontoxic, which
when combusted produce no polluting byproducts, and which are
safe for handling purposes, significantly increase the work
capacity of a fuel. While applicant does not wish to be bound
by any theory, it is believed that the fuel additives of this
invention when added to an industrial fuel gas provide for
increased fuel efficiency and work capacity because of the incxeas-
ed energy rele~sed by the heat of combustion of the fuel additives.
--6--
. . . . . . - -- . . .
' . ' : : '
- i~39S~)~
Thus ~hen industrial ~uel gas such as natural gas, for example,
is saturated with the additives of this invention, it is mixed
with oxygen and burned, much more heat is available to be liberated
by the flame and a much hotter ilame results.
It has further been discovered that efficient heat transfer
results when the additive is one which will emit r~diant energy
at a wave length easily suscepti~le to absorption by the material,
metal, alloy or the like which is to be treated.
The industrial fuel gases utilized in industry are, o~ course,
in a gaseous state. The additives of this invention are at ambiert
conditions in a liquid state. However, in a typical operation
employing a conventional industrial fuel, the fuel is prior to
combustion first passed through a vessel containing khe additives
of this invention. The industrial fuel gas vaporizes an amount
of the liquid additives of this invention directly proportional
to the vapor pressure employed. For complete saturation o~ an
industrial fuel gas with vapors of the liquid additives of this
invention it may be necessary to pass the industrial fuel gas
j through two or more vessels of the liquid additives of this
invention which can be placed in series.
The additives suitable for use with industrial fuel gases as
pre~iously disclosed herein can be described as no~mally liquid
at ambient conditions, compounds which when combusted yield
only carbon and hydrogen containing byproducts and are selected
from the group consisting of hydrocarbons, alcohols, esters, or
mixtures thereof.
The preferred hydrocarbons are C5 to C20 straight and branched
chain alkanes and cycloalkanes, straight and branched chain alkenes
and cycloalkynes; aromatic compounds selected from the group
consisting of mononuclear aromatics, i.e. benzenes, and including
a~ polynuclear aromatics naphthalenes, anthra~enes and phenanthrenes.
Additionally, C7 to C20 arenes, namely straight and branched chain
substituted benezenes.
--7--
... .. . . .
10395~
Examples of suitable C5 to C20 alkanes include n-Pentane, 2-
. Methyl~utane, 2,2-DLmenthylpropane, n-Hexane, 2-Methylpentane, 3-
Methylpentane, 2,2-Demethylbutane; 2,2-Dimethylbutane, n-Heptane 2,
Methylhexane, 3-Methylhexane, 3--Ethylpentane, 2,2-Dimethylpentane,
2,3-Dimethylpentane, 2,4-Dimethylpentane, 3,3-Dimethylpentane,
2,2,3-Trimethylbutane, n-Octane, 2-Methylheptane, 3-Methylheptane,
4-Methylheptane, 3-Ethylhexane, 2,2-Dimethylhexane, 2,3-Dimethylhexane,
2,4-Dimethylhexane, 2,5-Dimethylhexane, 3,3-Dimethylhexane, 3,4-Di-
methylhexane, 2-Methyl-3-ethylpentane, 3-Methyl-3-ethylpentane,
2,2,3-Trimethylpentane, 2,2,4-Trimethy~pentane, 2,3,3-Trimethylpentane,
2,3,4-Trimethylpentane, 2,2,3,3-Tetramethylbutane, n-Nonane,
2-Methyloctane, 3-Methyloctane, 4-Methyloctane, 3-Ethylheptane,
2,2-Dimethylheptane, 2,6-Dimethylheptane, 2,2,4-Trimethylhexane,
2,2,5-Trimethylhexane, 2,3,3-Trimethylhexane, 2,3,5-Trimethylhexane,
2,4,4-Trimethylhexane, 3,3,4-Trimethylhexane, 3,3-Diethylpentane,
2,2-Dimethyl-3-ethylpentane, 2,4-Dimethyl-3-ethylpentane,
2~4-Dimethyl-3-ethylpentane~ 2,2,3,3-Tetramethylpentane,
2,2,3,4-Tetramethylpentane, 2,2,4,4-Tetramethylpentane, 2,3,3,4-
. .
Tetramethylpentane, n-Decane, 2-Methylnonane, 3-Methylnonane,
4-Methylnonane, 5-Methylnonane, 2,7-Dimethyloctane, 2,2,6-Tri-
methylheptane, n-Undecane, n-Dodecane, n-Tridecane, n-Tetradecane,
n-Pentadecane, n-Hexadecane, n-Heptadecane, n-Octadecane, n-Nonadeca,
n-Eicosane.
Examples of suitable C5 to C20 cycloalkanes include Cyclopentane,
Mehtylcyclopentane, Ethylcyclopentane, l,l-Dimethylcyclopentane,
1,cis-2-Dimethylcyclopentane, 1,tran~-2-Dimethylcyclopentane,
1,cis-3-Dimethylcyclopentane, 1,trans-3-Dimethylcyclopentane,
n-Propylcyclopentane, Isopropylcyclopentane, l-Methyl-l-ethycyclopen-
tane, l-Methyl-cis-2-ethylcyclopentane, 1-Methyl-trans-2-ethylcyclo-
pentane, l-Methyl-cis-3-ethylcyclopentane, 1-Methyl-trans-3-ethylcyclo-
pentane, 1,1,2-TrLmethylcyclopentane, 1,1,3-Tximethylcyclopentane,
1,cis-Z,cis-3-Trimethylcyclopentane, 1,cis-2,trans-3-Trimethylcyclo-
pentane, l,trans-2 cis-3-Trimethylcyclopentane, 1,cis-2,cis-4-Tri-
methylcyclopentane, 1,cis-2,trans-4-Trimethylcyclopentane, 1,t:rans-2,
~ _
.
10395Q8
cis-4-Trimethylcyclopentane, n-Butylcy~lopentane, Isobu-tylcyclopen-
tane, sec-Butycyclopentane, tert-ButylCyClopentane, l-Methyl-
cis-2-n-~ropylcyclopentane, 1-Methyl--trans-2-n-propylcyclopentane,
l-Methyl-n-isopropylcyclopentane, 1,cis-2-Diethylcyclopentane,
1,trans-2-Diethylcyclopentane, Cyclohexane, ~ethylcyclohexane,
Ethylcyclohexane, l,l-Dimethylcyclohexane, 1,cis-2-Dimethylcyclohexane
1,trans-2-DLmethylcyclohexane, 1,cis-3-Dimethylcyclohexane, 1,trans-
3-DLmethylcyclohexane, 1,cis-4-Dimethylcyclohexane, 1,trans-4~
Dimethylcyclohexane, n-Propylcyclohexane, Isopropylcyclohexane,
1,1,2-Trimethylcyclohexane, 1,1,3,Trimethylcyclohexane, 1,trans-2,
trans-4-Trimethycyclohexane, n-Butylcyclohexane, Isobutylcyclohexane,
sec-Butylcyclohexane, tert-Butylcyclohexane, l-Methyl-4-
isopropylcyclohexane, Cycloheptane, Ethylcycloheptane, Cyclooctane,
klethylcyclooctane, Cyclononane.
Examples of some of the suitable and representative hydrocarbon
compounds of the group C5 to C20 alkenes include l-Pentene, cis-2-
Pentene, trans-2-Pentene, 2-Methyl-l-Butene, 3-Methyl-l-Butene,
2-~ethyl-2-Butene, l-Hexene, cis-2-Hexene, trans-2-Hexene, cis-3-
Hexene, trans-3-Hexene, 2-Methyl-l-pentene, 3-Methyl-l-pentene,
4-Methyl-l-pentene, 2-Methyl-2-pentene, 3-Methyl-trans-~-pentene,
3-Methyl-cis-2-Pentene, 4-Methyl-cis-2-pentene, 4-Methyl-trans-2-
pentene, 3-Methyl-cis-2-Pentene, 4-Methyl-cis-2-pentene, 4-Methyl-
trans-2-pentene, 2,3-Dimethyl-l-butene, 3,3-Dimethyl-l-butene,
3,3-Dimethyl-2 butene, l-Heptene, cis-2-Heptene, trans-2-~eptene,
cis-3-Heptene, trans-3-Heptene, 4,4-Dimethyl-l-pentene, 2,3-Dimethyl-
2-pentene, 2,2,3-Trimethyl-l-butene, l-Octene, cis-2-Octene, trans-2-
Octene,trans-3-Octene, cis-4-Octene, trans-4-Octene, 2-Methyl-l-
heptene, 2,3-DLmethyl-2-hexene, 2,3,3-Trimethyl-l-pentene, 2,4,4-
Trimethyl-l-pentene, 2,2,4-Trimethyl 2-pentene, l-Nonene, 2,3-Di-
methyl-2-heptene.
Examples of suitable C5 to C20 cycloalkenes include Cyclopentene,
Cyclohexene~ 4-Methycyclohexene-1, 4-Vinyl-cyclohexene-1, 1,5-
Cyclooctadiene.
- . ., - . ~,
~0395~8
Examples of suitable aromatics includ~ benzene, and with
respect to polynucler aromatics, anthrazene and phenanthrene, and
with respect to arenes, toluene, Ethylbenzene, 1,2-Dimethylbenæene,
1,3-Dimethylbenzene, 1,4-Dimethylbenzene, n-Propylbenzene, Isopro-
pylbenzene, l-Methyl-2-ethylbenzene, 1-Methyl-3-ethylbenzene, l-Methyl-
4-ethylbenzene, 1,2,3-Trimethylbenzene, 1,2,4-Trimethylbenzene,
1,3,5-Trimethylbenzene, n-Butylbenzene, Isobutylbenzene, sec-
Butylbenzene, tert-Butylbenzene, l-Methyl-2-isopropylbenzene,
l-Methyl-3-isopropylbanzene, 1-Methyl-4-isopropylbenzene, Styrene,
n-Methylstyrene, cis-Methylstyrene, trans-Methylstyrene, o-Methyl-
styrene, =-Methylstyrene, p-~ethylstyrene, Phenylacetylene.
Of the hydrocarbon additives, the preferred additives are the
C5 through C8 straight and branched chain alkanes and cycloakanes
and the C5 to C8 alkenes and cycloalkenes.
Suitable alcohols are the C5 to C2~ mono,di, and polyalcohols
of the hydrocarbons previously mentioned herein. The preferred
alcohols are the mono,di, and polyalcohols of the C5 through C8
hydrocarbons previously mentioned herein and include pentanols,
hexanols, heptanols, octanols, pentenols, hexenols, heptenols,
and octenols.
Examples of suitable esters are the C5 to C20 containing esters
of both aliphatic carboxyllic acids and aromatic carboxyllic acids
providing that the ester is a liquid under ambient conditions. The
preferred esters are the C5 to C8 containing esters of lower Cl to
C4 alcohols and lower Cl to C4 aliphatic carboxyllic acids.
As briefly mentioned herein previously, it is important that
the additives for the industrial fuels be liquid at ambient con-
ditions for several reasons. The first, the liquid additives are
the easiest to handle, secondly, these lower chain length liquid
additives have a substantial vapor pressure at ambient conditions
and can be readily vaporized for convenient mixture with industrial
fuel gases, and third ~hey are readily available.
--10--.
.... ~ - . .
. ~ - . .
- ~039S~I~
; A chain length of from about C5 to C20 has been Eound
be the practical range of utilization in this invention. Where
the chain length is lower than C5 it has been found that the heat
of the combustion of the hydrocar~on compound, or likewise with
respect to the alcohol and ester compounds, is sufficiently low
that no substantlal Lmprovement in fuel utilization is noted.
On the other hand, where the chain length is above C20 many of
the compounds are not liquid, not readily available, and if
available, and even if liquid, have such low vapor pressures that
no substantial volatilization will occur resulting in a very low
amount of the additive present in an industrial fuel gas.
It is also Lmportant to note that the additives of this
invention are nonsubstituted compounds. That is to say, they are
comprised of only hydrogen and carbon, and with respect to the
alcohols and esters oxygen in addition. There can be no substitu-
tions of, for example, sulphur, chlorine, other hal~gens and the
like. This is extremely important because it has been found that
substituted hydrocarbons, alcohols, and esters will provide un-
desirable polluting byproducts upon combustion. For example,
compounds containing sulphur and nitrogen will provide oxides of
sulphur and oxides of nitrogen which are known to be hazardous
pollutants, Thus, it is Lmportant that all of the sompounds be
nonsubstituted.
The amount of the fuel gas additive employed can, of
course, vary and it goes without saying that generally the greater
the amount of additive mixed with the industrial fuel gas tha
greater the heat of combustion and the greated the potential
for effective heat transfer because of the increased work capacity
of the fuel upon combustion. However, it has been found that
when excessively rich compositions which contain unusually high
?
95V~3
percentages of the fuel a ltlves of this invention are combusted
there is a tendency for incomplete combustion which results in
decreased efficiency and, of course, increased costs and an
increase in the amount of carbon monoxide present. Generally it
has been found that satisfactory levels of the additi~es are
from about 0.1% by volume up to the satùration level at the
given tamperature and pressure conditions of the fuel gas. As
a general guideline~ satisfactory results are obtained when the
amount of additive composition is from about one pound of additive
per 100 cubic feet of fuel gas to one pound of additive to 300
cubic feet of fuel gas with one pound of additive to 200 cubic
feet of fuel gas being preferred.
With respect to fuels which are employed for boilar heating
and home heating fuels, it has been found that from about one
pound of additive to 200 cubic feet of fuel gas to about one
pound per 600 cubic geet of fuel gas is a suitable range with
one pound of additive per 400 cubic feet of fuel gas being most
preferred.
In general it can be said that straight chain compounds
perform better than branched chain compounds and are, thereore,
preferred; alkenes perform slightly better than saturated compounds
and are, therefore, preferred; long chain compounds perform very
well on pre-heating and ara, therefore, preferred for compositions
which are designed to provide a quick pre-heat; strained ring
compounds perform better than stabilized rings, i.e. cyclopentene
is a better add:itive than cyclohexane.
The following examples are offered to further illustrate but
not limit the invention disclosed herein.
12-
~0395~
EXAMPT~S 1-19
In examples 1 through 17, as shown in the table here below,
the fuel gas employed was natural gas which is comprised nearly
completely of methane. Generally it can be said that the amount
of methane present in natural gas comprises about 97~ of the natural
gas. The remaining portion comprises lower alkanes, usually C2 to
C5 all in minor amounts. In addition, the table below includes in
examples 18 and 19 utilization of propane as the industrial fuel gasO
Control numbers 1 and 2 are shown in the table to indicate ~he
performance of natural gas alone without any fuel additives.
In conducting the tests shown in the table setting forth
examples 1 through 19, the following prodedure was employed.
Dual experimental generators were constructed. These identical
units were capable of providing a variable liquid level of additive,
thus providing a means for controlling the vapor concentration in
the fuel gas. The cutting torch utilized was of con~entional con-
struction and had a standard HF-7 nozzle, all analyses reported
in Examples 1 through 19 were performed by gas chromatograph
employing either flame ionization or thermoconductivity detectors.
The standard cutting conditions which were utilized to make the
experimental cuts in order to evaluate the effectiveness of the
fuel gas were established for each fuel tested by adjusting the
flame until optimum cutting conditions were established for the
fuel with no additive addition. This cut then served as the
standard for judging the quality of torch cuts for the evaluation
of fuel additive effectiveness. At the beginning of each test
the generator was filled to its maximum capacity with liquid
additiveu The fuel gas was then passed through the generator
to vaporize a quantity of the additive which was then carried by
the fuel gas into the burning torch. The torch was adjusted for
an optimum flame and a maximum acceptable cutting speed was
established.
.,...... ~ ,
-. : . . . , ;. '
.; . . . .. ..
103~5~8
The liquid level was tnen reduced in the vapor generator
by adjusting its heighth to 12 inches and the cutting test
described above was again repeated. Again, the generator liquid
level was adjusted to 6 inches and the cutting test was once
again repeated. Of the three tests run for each sample, that
test giving the optimum cutting speed was chosen for further
evaluation. A test bar of high carbon steel having an
appro~imate tnickness of two inches was employed. A pre-heat
time was then esta~lished for the flame by timing the lapse of
time which occured until a localized spot on the metal upon the
first heating was pierced. The exhaust gases were sampled and a
sample of the fuel gas plus the additive was remo~ed for analysis.
In each of the experiments reported in Examples 1 through 19
the fuel and oxygen ratios were adjusted until the best possible
cutting flame was achiéved under each set of experimental conditions.
In each example the same steel stock was employed~ Likew~se the
same torch was used for all tests. In each of Examples 1 through
19 the cut was a good cut showing a straight-line cut with little
or no rollback, no evidence of any irregular surface and dishing
out, and there was little slag present and what slag was present
was easily removable. Examples 1-17 used natural gas as the fuel
and Examples 18 and 19 used propane.
Fuel savings, oxygen savings and production sa~ings were
calculatad as follows:
Production savings = Sl-S2 x 100%
S2
Sl - cut speed in inches/minute with test additive.
S2 ~ cut speed in inches/minute with natural gas only.
Fuel savings - Fl-F2 x 100%
F2
Fl - inches cut/minute with additive.
F2 - inches cut/minute with natural gas only.
Oxygen savings = 01-02 x 100%
02
l ~ inches cut/ft3 02 with additive.
2 ~ inches cut/~t3 02 with na.ural gas only.
-14-
` - iO395~8
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O V~ -- ~ ~D ~I C~ O -- W ~ ~ U- ~1 ~ ~ Nl ~ I Ll
W O ~ O ~ u~ W C~ o o~ dP 3 P.
CO ~ 1--0 ~ J W O ~JI O~ Ul 1--W O W Vl 11- --O C
1 ~; ~D~O
. .
1~39503~
In the above examples the fuel savings, oxygen savings,
and production increase were calculated as indicated above.
- As can be seen, when comparing the fuels employing the
fuel additives of this invention wilh the control fuels in
controls #1 and #2 a substantial increase in cutting speed was
noted, the fuel and oxygen efficiencies were greatly increased,
the pre-heat time was decreased and as previously explained
the quality of the cut was better.
EXAMPLE 20
The following example is an example of an industrial fuel
employed for boiler heating. The fuel was comprised of four
parts by volu~e normal pentane, four parts by ~olume iso-pentane,
and one part isomers of hexane. In this example this will herein-
after be denoted as additive composition.
The boiler employed was a Model 3 Powermaster unit having a
boiler HP rating of 200, a BTU per hour output of 6,6~5,000,
pounds of steam per hour rating of 6,900 and a hot water capacity
per square foot of 44,800. The overall dimensions of the boiler
were length 17 feet, 6 inches, width 6 ft. 6 ins., and height
9 ft. 6 ins.
Feed water to the boiler consisted of condensate from several
heating units at various locations throughout a manufacturing
plant. Natural gas was fed to the combustion chamber through
a conventional burner arrangement. Air to the burner was supplied
at a constant volume and pressure by a 5 HP blower. Fuel supplied
to the hurner was automatically controlled by conventional valving.
The boiler stPam pressure was maintained at 10 lbs. psig with a
moisture content of less than 0.5%. Two runs were made with this
boiler. In a first run natural gas only was fed to the burner
with air being supplied to the burner by a constant speed blower
unit powered by a 5 HP motor.
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:
~)39SO~
Energy outputs consisted of dry saturated steam at 10 psig,
flue gases at 300 to 325 F. and radiation from the boiler
surface.
The boiler tests were conduc:ted using 1,000 ~TU/Cu. Ft. of
natural gas as supplied and an exact duplicate test was utilized
using natural gas containing the additive composition of a level
of 2.46 pounds per 100 cubic feet: of natural gas.
RESULTS
Fuel Used:
Natural Gas - No additive = 1534.5 Cu. ~t. /Xr.
Natural Gas - With additive= 1040.4 Cu. Ft. /Hr.
Fuel Increase 494.1 Cu. Ft./Hr.
1,040.4 (100)
= 47%
WATER SUPPLIED TO BOILER:
Time at pressure (13.5 psig)
Total Feed Time/Hr.
Without additive = 10.7 minutes
With additive = 10.8 minutes
The most significant development occuring in this test is the
remarkable saving in fuel obtained when natural gas is employed
with the additive composition of this invention. In term of
additional fuel required, 47~ more natural gas without the
additive composition is required to do the same amount of work
as 47% lesser amount of natural gas with the additi~e composition
of this invention.
It should be noted that the additi~e should be non-corrosive
with respect to the metal alloy or like material which is to be
treated. Further it should emit radiant energy at a wave length
within the range of greatest absorptivity for the metal alloy or
like material which is to be treated.
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.
~0;~95~8
If one or more of the above described non-corrosive
additives is present, radiant energy will be emitted at a wave
length within the wave length range of greatest absorptivity for
the material to be treated~ The result is an increased rapidity
in performing the job, utilization of a minimum quantity of fuel
gas, an increased quality of cuts, welds, brazing, gouging,
melting, heating or like treatment, and because the job is
accomplished very quickly a noticeable lack of change in hardness
characteristics of the metal alloy or like material being treated.
Accordingly, since the hardness characteristics have not been
changed and the crystal structure is not under stress, the metal
can be more easily subsequently machined. Thus, as can be seen,
the invention accomplishes all of its stated objects.
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