Traditionally in our country, cutting of metal / sheets has always been done using the oxy-acetylene mixture. Being a rare and expensive product, smooth running of an industry is often hindered. “Necessity is the need of innovation.” Bharat Petroleum understood the same and its R&D department came up with Bharat Metal Cutting gas as a successful replacement of Acetylene. Bharat Metal Cutting gas is a hydro carbon based fuel and is fortified with additives.
In today’s parlance cost is one of the most important factors and Bharat Metal Cutting gas gives an edge over Acetylene by a saving of over 30 to 35 % which is very huge. When compared with LPG / Oxygen cutting, it gives a saving of almost 12-15 % as the oxygen requirement comes down drastically.
- Trials at customers’ unit.
- Necessary technical assistance.
- Regular awareness and safety education.
- Uninterrupted supply.
- Round the clock help line.
- Achieves flame temperature around 3000°C which is closer to Acetylene's temperature 3150°C.
- High penetration and faster cutting speed.
- Very effective for cutting metals of higher thickness (40 mm & above).
- Smooth cutting surface and reduction in slag formation.
- Clean, narrow kerfs.
- Impossible no backfire or flashback.
- Less cylinder handling cost and less necessity for changing the apparatus.
- No sooty flame.
- Flame is much less luminous, so less harmful to eyesight.
- Greater volume of fuel gas can be mixed with oxygen for use in heating torches, opening up new avenues of torch-heat application.
- Faster, easier cutting on rusty, greasy surfaces (as in scrap) because of freedom from “popping” and backfire.
- Saving in fuel gas cost is much higher.
- Since it is marketed in kg's, it can me measured easily.
- Less carbon formation. Hence low maintenance and long life of nozzles.
- Operator friendly.
- Safer as the operating pressure is lower in cylinder.
- Faster cutting rate as secondary flame is higher (19080 vs 8570 DA Kcal).
- Competitively priced.
The Bharat Metal cutting gas can be used at
- Metal sheet cutting / fabricating shops.
- Cylinder manufacturing Units.
- Steel Tank Manufacturing Units.
And can be used for
- Gas Surfacing
- Flame spraying
- Flame straightening and hardening
- Stress relief
- Bharat metal cutting gas is completely safe and operator-friendly.
- Explosive limits (flammability) % in air
Has lower explosive limits in air than acetylene, therefore, BMCG is less flammable than acetylene.
- BMCG ----- 2.3 – 9.5
- Acetylene -- 2.5 – 80
- Bharat metal cutting gas is non-toxic and has no backfire.
- In case of a leak, Bharat Metal Cutting Gas can be detected easily because of its unique pungent smell.
- Bharat metal cutting gas is stored at lower pressure, therefore, safer than acetylene.
Hazards Of Acetylene Gas
Acetylene is the most common gas used for fueling cutting torches. When mixed with pure oxygen in a cutting torch assembly, an acetylene flame can reach a temperature of 5700°F. ACETYLENE IS EXTREMELY FLAMMABLE AND EXPLOSIVE. Many users may not be aware of the unique characteristics of acetylene that create special hazards compared to other fuel gases. These hazards include the following
- Acetylene is Chemically unstable which makes it very sensitive to conditions such as excess pressure, excess temperature, static electricity, or mechanical shock exposure as any of these conditions can cause it to undergo a violent, explosive decomposition reaction. If this reaction or ignition occurs within the torch base or supply hose it can propagate back into the storage cylinder causing it to explode violently.
- Acetylene is very easy to ignite. In fact, the energy from a static spark capable of igniting acetylene is lower than for any other fuel gas except hydrogen. This static charge developed by walking across a carpet floor on a dry day can be 1700 times greater than that needed to ignite acetylene! When unburnt acetylene gas is discharged from a torch, static electricity can be generated at the torch tip. If the tip comes in contact with a ground path, a static spark capable of igniting the gas can occur.
- Acetylene burns at a very fast rate. The Very fast burn rate can accelerate the rate at which pressure is generated in an explosion beyond what would occur for other fuels. This makes acetylene explosions more violent than those of other fuels.
Comparison In Basic Properties And Behavior Of Da And Bmcg
- LEL for BMCG=2.5% LEL FOR DA=2.5%
- HEL for BMCG=9.5% HEL for DA=80%
- Operating pressure for BMCG = 0.5 Kgs/cm2
- Operating pressure for DA = 3 Kgs/cm2(around 40 psi)
- BMCG cylinder pressure = 18 to 20kg/cm2.
Bharat Metal Cutting Gas: Approvals
- Research Design and Standards Organization
- (RDSO), Lucknow
- Welding Research Institute (WRI), Trichy
- Naval Material Research Institute (NMRI), Ambernath
- Naval Head Quarters Approval
- Chief Controller of Explosives (CCOE), Nagpur
- Messer, Germany for BMCG usage for gas equipment
- Delhi Metro Rail Corporation
Easy Change Over From Da To Bmcg
For BMCG the same torch used for DA can be used. Only the cutting nozzle has to be changed. 3seater torch/nozzles give better economy and lesser flash back.
Heating Value Of Fuel Gases
||Bharat Metal Cutting Gas
|Neutral flame temp. deg. F
|Neutral flame temp. deg. C
|Heat Emission Kcal/m3
|Total heat value Kcal/kg