Innovation of Metal Cutting Gas

Dissolved Oxygen (DA)

Thanks to Mr. Thomas Fletcher of Warrington, England who discovered helped the world by
discovering in 1885, that Oxygen can be used be for metal cutting. He directed a jet of Oxygen to
a portion of metal which cut the metal in a small time. This way he helped the world to get rid of
the cumbersome method of making the metal to red hot before separating in different pieces or
join the two metal pieces to gather and beat them with heavy hammer. This method was apart
from being laborious was time consuming, used more manpower, was inaccurate and was
dangerous as several will get burn injuries or get heavily fatigued.

Though this method was accepted in 1885, its commercial application started 20 years later. In
the later years mixing of dissolved Acetylene (DA) started to make the metal cutting faster and
easier than making the metal parts red hot.

Acetylene is the primary fuel for oxy-fuel welding and is the fuel of choice for repair work and
general cutting and welding. Oxy-fuel cutting has produced far reaching changes in industrial
practices relating to cutting and shaping of steel. Acetylene gas is shipped in special cylinders
designed to keep the gas dissolved.

Acetylene cylinders are available in 1cfm, 60cfm,100 cfm and 300 cfm capacity.

There is about 1700 kPa (250 psi) pressure in the tank when full. Acetylene when combined with
Oxygen burns at 3200 °C to 3500 °C (5800 °F to 6300 °F), highest among commonly used
gaseous fuels. As a fuel Acetylene's primary disadvantage, in comparison to other fuels, is high
cost and it is not easily available.

While the cutting of metal has been done using Oxy-Acetylene Metal Cutting Gas Composition
traditionally, Acetylenes is expensive and has availability constraints. Pure Oxygen is used in the
Acetylene to increase its flammability. An Acetylene/Oxygen flame burns at about 3,500 °C.
Acetylene is not just flammable; in certain conditions it is explosive. Although it has an upper
flammability limit of 81% in air, Acetylene's explosive decomposition behaviour makes this
irrelevant. If a detonation wave enters the Acetylene tank, the tank will be blown apart by the
decomposition. Ordinary check valves that normally prevent back flow cannot stop a detonation
wave because they are not capable of closing before the wave passes around the gate. For that
reason a flashback arrestor is needed. It is designed to operate before the detonation wave makes
it from the hose side to the supply side.

To obtain different flames, it needs to be Oxygen and Acetylene needs to be mixed in different
rations viz.
Carburising Flame : Oxygen : Acetylene : 1:3, Oxidising : 3: 1 and Neutral Flame : 1:1.
Oxydising flame is normally used for cutting pupose.

Safety Concerns

 Acetylene gas is shipped in special cylinders designed to keep the gas dissolved. The
cylinders are packed with porous materials (e.g. kapok fibre, diatomaceous earth, or
(formerly) asbestos), then filled to around 50% capacity with acetone, as Acetylene is
soluble in acetone. This method is necessary because above 207 kPa (30 lbf/in²) (absolute
pressure) Acetylene is unstable and may explode.
 As Acetylene is unstable at a pressure roughly equivalent to 33 feet/10 meters
underwater, water-submerged cutting and welding is reserved for hydrogen rather than
Acetylene.
 Conventionally metal cutting application involves usage of Oxy Acetylene
mixture which has higher degree of hazard potential due to high shock sensitivity
and very large flammability range.
 The method of using oxy-Acetylene gas for metal cutting applications is
fraught with potential hazard of explosion during usage as well as storage and
hence discouraged worldwide despite of its high flame temperature and calorific
value. The issue of high cost and hazards associated with Acetylene calls for an
alternative which is safer, cheaper, and easily available.
 This has prompted the usage of Liquefied Petroleum Gases (LPG) for metal cutting
applications. However, the lower flame temperature of LPG has been an adverse
aspect, which limits the use of LPG in high temperature applications such as metal
cutting.

LPG

LPG was introduced in India as cooking gas for the kitchens being bottled by the Indian
petroleum Industry. This is mixture of Propane and Butane in the ratio of 11:9. Sometimes LPG
is it sold as only butane without mixing of propane. There not much difference in the calorific
value of LPG mixed with propane and butane and sold only as butane. Domestic LPG being sold
in 14.2 Kg cylinders. For commercial application it was being sold in 19, 35 and 47.5 kg
Cylinders by BPCL and 19 Kg Cylinders by Indian Oil. However, contractors preferred 14.2 Kg
cylinders as the same LPG was being filled in 19, 35 and 47.5 Kg as 14.2 Kg cylinders being
domestic LPG was subsidized.

It gained its popularity as contractors for cutting application as used domestic LPG cylinder due
to its low weight and easy availability.

So another Alternative which was better in cutting applications and have several other
advantages over Dissolved Acetylene (DA) was developed by the Indian petroleum industry.
Bharat Metal CuttingGas (BCMG) Bharat Petroleum and Indian Oil revolutionized the world of
cutting, welding and brazing by introducing innovative metal cutting products. Bharat
Petroleum corporation limited has branded it as Bharat Metal Cutting Gas (BMCG) sells the
metal cutting gas under brand name Bharat Metal Cutting Gas (BMCG) while Indian Oil sells it
under the brand Indane Nano Cut.

LPG is a mixture of commercial butane and commercial propane having both saturated and unsaturated
hydrocarbons. LPG is inherently dangerous on account of fire, explosion and other hazards. This calls for
special attention on the manner in which it is bottled, transported or used. These hazards can have an
impact on both the plants and the public. As a consequence of this special emphasis has been placed on
the safety regulations in its handling system design, etc.LPG at atmospheric pressure and temperature is
a gas which is 1.5 to 2.0 times heavier than air. It is readily liquefied under moderate pressures. The
density of the liquid is approximately half that of water and ranges from 0.525 to 0.580 @ 15 deg. C The
pressure inside a LPG storage vessel/ cylinder will be equal to the vapour pressure corresponding to the
temperature of LPG in the storage vessel. The restriction on vapour pressure is stipulated by IS-4576
which in turn regulates the lighter ends of hydrocarbons and this governs the design parameters for
storage vessels.

The vapour pressure is dependent on temperature as well as on the ratio of mixture of hydrocarbons. At
liquid full condition any further expansion of the liquid, the cylinder pressure will rise by approx. 14 to
15 kg./sq. cm. for each degree centigrade. This clearly explains the hazardous situation that could arise
due to overfilling of cylinders.

We should not use LPG for gas cutting in industrial fabrications and other jobs. LPG is a mixtureof Butane
and Propane only whether used domestic or Industiral.

BPCL has painstakingly studied the needs of the industry which need metal cutting gasto cut
metal and came up with Bharat Metal Cutting Gas (BMCG), an ideal substitute for Acetylene.
BMCG offers superior cutting at a low cost and is an ideal fuel for cutting and brazing
applications.

Advantages of Bharat Metal Cutting Gas are:

 Superior cutting at low cost (better cutting speed, kerf formation and surface finish)
 Low Oxygen consumption
 Reduces cylinder inventory by at least three times compared to Oxy Acetylene
 Low slag formation
 BMCG can easily cut 12 inch (300 mm) thick metal and even more.
 Has a lower explosive limit in air and Oxygen than Acetylene. Hence has lower band of
inflammability than Acetylene
 The cylinder pressure of BMCG (6-7kg/cm2) is one third of Acetylene (17-18 kg/cm2).
Hence they are safe to use.
 BMCG cylinders are easier to handle due to lighter weight
 BMCG cylinders are available in a range of pack sizes (19kg, 35kg & 47.5kg) to suit
specific requirement of customers.
 Awareness and education programs on safety to the end users
 The difference between Acetylene vs
LPG / Propane as a cutting or heating
fuel gas
  
 Acetylene is one of the industry standard methods of cutting of all the Industrial Thermal
Cutting Processes, but when Propane (LPG) was introduced to the market the whole
thermal cutting process changed and the battle between Propane (LPG) and Acetylene
was born.
 Which gas really Cuts better?
 Let’s go on and discuss some advantages and disadvantages of our contenders…
 Acetylene
 Advantages:
 • Acetylene produces the hottest flame temperature for oxy fuel cutting and welding
 • The hotter temperature creates a quicker piercing of materials
 • Oxy Acetylene can be used on sites with no power supply
 • It is quite a versatile process and can be used to weld most metals.
  
 Disadvantages:
 • Acetylene weld lines are rougher in appearance and need more finishing
 • Acetylene is unstable and expensive
 • There are more safety issues with oxy Acetylene, because there is a naked flame.
  
 Propane
 Advantages: 
 • Propane has greater total heat combustion
 • Oxy propane is easy to obtain and cheaper
 • Propane is more stable.
  
 Disadvantages:
 • Propane produces a lower flame temperature
 • There is increased pre-heat time
 • Flames are less focused, therefore if incorrectly used, piercing is slower
 • Propane can’t be used for gas welding as it doesn’t have a reducing zone
  
 Here are some facts and common misconceptions regarding Propane (LPG) and
Acetylene:
 -      Maximum neutral flame temperature of Acetylene in Oxygen is about 5720 F.
 -      Maximum neutral flame temperature of propane in Oxygen is about 5112 F
  
 But they say that the difference doesn’t matter, what really matters is the thermal output
 -      BTU's of Acetylene is approximately 1470 btu's per cubic foot.
 -      BTU's of Propane is approximately 2498 btu's per cubic foot.
 Acetylene may burn hotter and could pre-heat metal faster, but does that mean that
Propane gives off less heat? Not entirely true, with the proper parts, set-up and
knowledge, it could match-up or even perform better than Acetylene in certain
conditions. In the welding industry the vast majority of preheating is done with Oxygen /
Propane. This is a fact. They don't do it just because it's cheaper but because the available
heat from propane is much higher. If you’d like to have the option of welding with your
torch set up, then you should consider an Acetylene set up.
 With all the facts, advantages and disadvantages it’s still not convincing that you go for
one over the other. That’s because the reason is plain and simple, the advantages depend
on the type of work or how you will use it for a specific project.
 There are very different experiences and opinions, but in the case of comparing
Acetylene and propane as cutting fuels, there’s no denying that both can effectively cut a
lot of metal of various thicknesses. If you take the time to pick up the right equipment for
your propane set up and cut with the edge of the flame (rather than toward the center,
which is common with Acetylene), you’ll be able to cut without any trouble. This is
where the problem lies as Propane releases only a small proportion of heat in the inner
flame cone (less than 10%), so most of the heat in the flame is located in the outer cone.
Acetylene releases almost 40% of its heat in the inner flame cone. 
 When you talk to metal workers and welders, you’ll find that many shops and scrap yards
use propane, in addition to hobby welders and metal workers. By learning a slightly
different technique and picking up the right torch tips, hoses and regulators, you’ll be
able to start cutting without too much of a difference compared to Acetylene.
 Safety
 Acetylene will ignite at mixtures from 2.5% to 82%, Propane is 2.1% to 9.5%. From
these figures, Acetylene burns faster than Propane. From this, we could come up with a
conclusion that Acetylene is far more dangerous than Propane, correct? But that is not the
case and nor the cause of accidents in most reported explosions.
 Let me give you a simple analogy of safety. Will you hold and lift a hot pan with your
bare hands? I believe your answer is “NO” right?  WHY? Because you know it’s hot, and
you know that you’ll get your hands burned right? So what are you going to do to hold
and lift the pan? Probably grab a pot holder or gloves. The same principle applies when
you’re working with Acetylene and propane. They're both flammable gas and could pose
a great threat to you and those around you. The only way to prevent this is to have
everyone aware of the potential dangers that it could bring and have them all equipped
with the right safety gear and operational procedures.
