CA1039508A - Method of, and composition for, heat transfer for metals, alloys and like materials using new and improved fuel gas compositions and methods of application thereof - Google Patents
Method of, and composition for, heat transfer for metals, alloys and like materials using new and improved fuel gas compositions and methods of application thereofInfo
- Publication number
- CA1039508A CA1039508A CA214,439A CA214439A CA1039508A CA 1039508 A CA1039508 A CA 1039508A CA 214439 A CA214439 A CA 214439A CA 1039508 A CA1039508 A CA 1039508A
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- CA
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- Prior art keywords
- additive
- fuel gas
- fuel
- composition
- amount
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/38—Selection of media, e.g. special atmospheres for surrounding the working area
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10L—FUELS NOT OTHERWISE PROVIDED FOR; NATURAL GAS; SYNTHETIC NATURAL GAS OBTAINED BY PROCESSES NOT COVERED BY SUBCLASSES C10G, C10K; LIQUEFIED PETROLEUM GAS; ADDING MATERIALS TO FUELS OR FIRES TO REDUCE SMOKE OR UNDESIRABLE DEPOSITS OR TO FACILITATE SOOT REMOVAL; FIRELIGHTERS
- C10L3/00—Gaseous fuels; Natural gas; Synthetic natural gas obtained by processes not covered by subclass C10G, C10K; Liquefied petroleum gas
- C10L3/02—Compositions containing acetylene
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- Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Liquid Carbonaceous Fuels (AREA)
- Physical Or Chemical Processes And Apparatus (AREA)
- Nonmetallic Welding Materials (AREA)
Abstract
Abstract of the Disclosure An improved method of heat transfer from improved industrial fuel gas compositions to materials being treated thereby, and new fuel gas compositions. Increased efficiency in the use of fuel gas results in that smaller quantities of fuel gas can be utilized to accomplish a given job in a more rapid amount of time. This is accomplished by adding to an industrial fuel gas such as propane, butane, natural gas or acetylene an additive such as a liquid hydrocarbon, alcohol or ester.
Description
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 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.
. . . . . . - -- . . .
' . ' : : ' - 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.
... .. . . .
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,
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 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.
. . . . . . - -- . . .
' . ' : : ' - 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.
... .. . . .
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, ~ _ .
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-
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, ~ _ .
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,
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.
~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%
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%
Fl - inches cut/minute with additive.
F2 - inches cut/minute with natural gas only.
Oxygen savings = 01-02 x 100%
l ~ inches cut/ft3 02 with additive.
2 ~ inches cut/~t3 02 with na.ural gas only.
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0 3 1~ ) p. 1-- ID ' O P.~: rr ~ O ~
C C O D ~ 3 t' Y ~J ~ (D El 3 rt Dl tD 3 C 1~ ~- 3 rt ~ ID X 3 ` Vl PJ ~ (D ~- 3 ,t rD
c o o ,. D 3 o ~ 2~ ~ ~ .. 3 .'n 3 ~D ~ 3 ~, O O ~ O ~ W N ~ n ~ ~ ~I ~ W Ul ~
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. .
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.
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.
:
~)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.
.
~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.
- .- - .
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.
~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%
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%
Fl - inches cut/minute with additive.
F2 - inches cut/minute with natural gas only.
Oxygen savings = 01-02 x 100%
l ~ inches cut/ft3 02 with additive.
2 ~ inches cut/~t3 02 with na.ural gas only.
` - iO395~8 O O ~ ~ ~V' ~ W ~ 1-- 0 ~D CD .~1 0~ Ul L~ N i-- ¦Z t~
11 ~t 3 O O ID
,_ 3 ~ 3 3N 1- n ~ 3 :I N :~ n 1-2 .r ~ V ~ g o 3 ~ X tq ~ ~ n I rr n ~ :r n ~
0 3 1~ ) p. 1-- ID ' O P.~: rr ~ O ~
C C O D ~ 3 t' Y ~J ~ (D El 3 rt Dl tD 3 C 1~ ~- 3 rt ~ ID X 3 ` Vl PJ ~ (D ~- 3 ,t rD
c o o ,. D 3 o ~ 2~ ~ ~ .. 3 .'n 3 ~D ~ 3 ~, O O ~ O ~ W N ~ n ~ ~ ~I ~ W Ul ~
oo ooo~n~ ~ WUl~ ~n 0O~lOOO n tD ~
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co O ~ o o ~ ~ ul ~ o o ~ ~
U~ ~n o C~ D W ~ ~I ~ o (AJ ~ ~ O
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.
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.
:
~)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.
.
~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.
- .- - .
Claims (12)
1. An industrial fuel composition comprising, in combination, an industrial fuel gas and as an additive from about 0.1% by volume of said gas up to and including a vapor saturation amount of a normally liquid, at ambient conditions, hydrocarbon, alcohol, ester, or mixtures thereof, the additive being selected from the group consisting of C5 to C20 straight and branched chain alkanes and cycloalkanes, C5 to C20 straight and branched chain alkenes and cycloalkenes, C5 to C20 straight and branched chain alkynes and cycloalkynes, mono and polynuclear aromatics having less than 20 carbon atoms and C7 to C20 arenes.
2. The composition of claim 1 wherein said additive is an alcohol selected from the group consisting of C5 to C20 mono, di, and polyalcohols.
3. The composition of claim 1 wherein said additive is a C5 to C20 chain length ester.
4. The composition of claim 1 wherein said additive is a C5 to C8 cycloalkane.
5. The composition of claim 1 wherein said additive is a C5 to C8 alkene.
6. The composition of claim 1 wherein said additive is a C5 to C8 cycloalkene.
7. The composition of claim 2 wherein said alcohol has a chain length of from C5 to C8.
8. The composition of claim 3 wherein said esters are C5 to C8 chain length esters of C1 to C4 alcohols and aliphatic carboxyllic acids.
9. The composition of claim 1 wherein the amount of said additive is from about 1 lb/100ft3 of said fuel gas to about 1 lb/300ft3 of said fuel gas.
10. In a method of cutting or bracing workpieces consisting of solid state ceramic materials, including metals, by heat energy transfer, including radiant energy absorption, the steps of compounding a fuel gas mixture by mixing a gaseous base fuel selected from the group consisting of methane, propane, acetylene, and mixtures thereof, with a supplemental organic heat additive, and oxygen, said supplemental organic heat additive consisting of a series of combustible hydrocarbons which, when combusted, emit radiation energy waves within the range of greatest absorbability of the materials to be cut or brazed, and which are non-corrosive with respect to the material being cut or brazed, said supplemental organic heat additive being added to the gaseous base fuel in an amount of from 1/2 to 20% by weight of the gaseous base fuel, preparing the workpiece material for cutting or brazing by increasing the temperature of a localized area of the workpiece material to be cut or brazed to a temperature suitable for cutting or brazing, and combusting said fuel gas mixture containing said supplemental organic heat additive in such juxtaposition to said workpiece material whose temperature has been increased as aforesaid as to transfer radiant heat energy within the range of wave lengths of greatest absorbability of the workpiece material, and convective heat energy, to said workpiece material in an amount sufficient to cause a change of state of said workpiece material.
11. The method of claim 10 further characterized in that said supplemental organic heat additive is added to the gaseous base fuel in an amount of from 2% to 10% by weight of the gaseous base fuel.
12. The method of claim 11 further characterized in that the supplemental organic heat additive is added to the gaseous base fuel in an amount from 1 1/2% to 7 1/2%
by weight of the gaseous base fuel.
by weight of the gaseous base fuel.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US41827173A | 1973-11-23 | 1973-11-23 | |
| US49953374A | 1974-08-22 | 1974-08-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1039508A true CA1039508A (en) | 1978-10-03 |
Family
ID=27024056
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA214,439A Expired CA1039508A (en) | 1973-11-23 | 1974-11-22 | Method of, and composition for, heat transfer for metals, alloys and like materials using new and improved fuel gas compositions and methods of application thereof |
Country Status (12)
| Country | Link |
|---|---|
| JP (1) | JPS50112401A (en) |
| BE (1) | BE865147Q (en) |
| CA (1) | CA1039508A (en) |
| DD (1) | DD121732A5 (en) |
| DE (1) | DE2455727A1 (en) |
| FR (1) | FR2252399B1 (en) |
| GB (1) | GB1496139A (en) |
| GR (1) | GR61542B (en) |
| IT (1) | IT1032141B (en) |
| NL (1) | NL7415338A (en) |
| NO (1) | NO744221L (en) |
| SE (1) | SE7414712L (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2418058A1 (en) * | 1978-02-27 | 1979-09-21 | Elf Union | Flame temp. increasing additive for oxy:propane cutting burners - comprises soln. of organic peroxide in liquid hydrocarbon |
| FR2528064B1 (en) * | 1982-06-02 | 1986-04-04 | Union Gaz Modernes | FUEL FOR AN EXPLOSION ENGINE CONSTITUTING THE MIXTURE OF A FUEL GAS AND A LIQUID ADDITIVE |
| JPH0515418Y2 (en) * | 1987-08-31 | 1993-04-22 | ||
| US5236467A (en) * | 1992-06-12 | 1993-08-17 | Excellene Limited | Double fortified hydrocarbon and process for making and using the same |
| US5380346A (en) * | 1992-06-12 | 1995-01-10 | Fritz; James E. | Fortified hydrocarbon and process for making and using the same |
| EP1886485A1 (en) * | 2005-05-30 | 2008-02-13 | Givaudan SA | Gas odorant comprising a cycloalkadiene |
| CN112818505B (en) * | 2020-12-22 | 2022-11-04 | 中国人民解放军火箭军工程大学 | Method for predicting combustion heat of hydrocarbon fuel per unit mass |
| CN115125040B (en) * | 2022-06-29 | 2024-02-09 | 圣火能源科技(广东)有限公司 | Pentane-based cutting fluid additive and preparation method and application thereof |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1352465A (en) * | 1963-03-29 | 1964-02-14 | Process for improving the combustion of fuels and adjuvant for activating this combustion | |
| US3591355A (en) * | 1968-07-29 | 1971-07-06 | I G Corp | Industrial gas |
| JPS4916083A (en) * | 1972-06-07 | 1974-02-13 |
-
1974
- 1974-11-22 CA CA214,439A patent/CA1039508A/en not_active Expired
- 1974-11-22 SE SE7414712A patent/SE7414712L/xx unknown
- 1974-11-23 GR GR5599A patent/GR61542B/en unknown
- 1974-11-25 IT IT54212/74A patent/IT1032141B/en active
- 1974-11-25 GB GB50976/74A patent/GB1496139A/en not_active Expired
- 1974-11-25 NL NL7415338A patent/NL7415338A/en not_active Application Discontinuation
- 1974-11-25 DE DE19742455727 patent/DE2455727A1/en not_active Ceased
- 1974-11-25 JP JP49135419A patent/JPS50112401A/ja active Pending
- 1974-11-25 DD DD182568A patent/DD121732A5/xx unknown
- 1974-11-25 NO NO744221A patent/NO744221L/no unknown
- 1974-12-16 FR FR747441335A patent/FR2252399B1/fr not_active Expired
-
1978
- 1978-03-21 BE BE186144A patent/BE865147Q/en active
Also Published As
| Publication number | Publication date |
|---|---|
| SE7414712L (en) | 1975-05-26 |
| AU7571274A (en) | 1976-05-27 |
| GB1496139A (en) | 1977-12-30 |
| JPS50112401A (en) | 1975-09-03 |
| DE2455727A1 (en) | 1975-05-28 |
| DD121732A5 (en) | 1976-08-20 |
| NL7415338A (en) | 1975-05-27 |
| FR2252399B1 (en) | 1979-02-09 |
| IT1032141B (en) | 1979-05-30 |
| BE865147Q (en) | 1978-07-17 |
| GR61542B (en) | 1978-11-23 |
| FR2252399A1 (en) | 1975-06-20 |
| NO744221L (en) | 1975-07-07 |
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