Chapter X: TECHNOLOGY.--Fabric for Upholstery Purposes.--Full technical (4)

The carbureted water gas has a smell every bit as strong as coal gas, and a leak would be detected with equal facility by the nose; and I think you will agree with me that the cry raised against the use of carbureted water gas, for this reason, is one of the same character that hampered the introduction of coal gas itself at the commencement of this century.

We must now turn to the chemical actions which are taking place in the generator of the water gas plant, and these are more complex in the case of the Van Steenbergh plant than in those of the Lowe type, and, for that reason, yield a gas of more satisfactory composition.

Taking gas as made by the Lowe or Springer process, and contrasting it with the Van Steenbergh gas, we are at once struck by several marked differences.

In the first place the hydrogen is far higher and the marsh gas or methane lower in the Van Steenbergh than in the Lowe process, this being due to the sharper cracking that takes place in the short column of cherry red coke, as compared with the lower temperature employed for a longer space of time in the Lowe superheater. Next we notice a difference of 10 per cent. in the carbon monoxide, which is greatly reduced in the Steenbergh generator by the carbon monoxide and marsh gas reacting on each other as they pass over the red hot surface of coke with formation of acetylene, which adds to the illuminants, this action also reducing the quantity of marsh gas present.

Lowe Van Steenbergh
gas. gas.

Hydrogen..................... 27.14 46.75
Marsh gas.................... 25.35 11.27
Carbon monoxide.............. 26.84 18.65
Illuminants.................. 14.63 7.59
Ethane....................... ---- 6.82
Carbon dioxide............... 3.02 0.50
Oxygen....................... 0.15 0.17
Nitrogen..................... 2.87 8.25
------ ------
100.00 100.00

In the illuminants, if we add the higher members of the methane series present to the olefines, we see they are about equal in each gas, while the low percentage of nitrogen in the Lowe gas is due to more careful working, and could easily be attained with the Van Steenbergh plant by allowing the first portion of water gas to wash out the producer gas before the hopper on top is closed.

The cracking of the naphtha by the red hot coke is undoubtedly a great advantage, for, as I have pointed out, the cracking of rushing petroleum is an exothermic reaction, so that the coke at the top of the generator gets hotter and hotter, and it is no unusual thing to see the coke at the beginning of the make cherry red at the bottom and dull red at the top, while at the end of the make it is almost black at the bottom and cherry red at the top, in this way attaining the same advantage in working that the Springer and Loomis do by their down blast, that is, having the fuel at its hottest where the gas finally leaves it, so as to reduce the quantity of carbon dioxide, and so lessen the expense of purification.

It will be well now to turn for a few moments to the gas obtained by cracking the light petroleum oils by themselves. The Russian and American petroleum differ so widely in composition that it was necessary to see in what way the gases obtained from them differed; and to do this, equal quantities of American naphtha and a Russian naphtha were cracked, by passing through an iron tube filled with coke, and in each case heated to a cherry red heat, the gases being measured, and then analyzed, with the following results:

American. Russian.
No. of cubic feet per gallon... 72 104
---- ----
Hydrogen....................... 26.0 45.3
Methane........................ 41.6 22.3
Ethane......................... 12.5 13.9
Olefines....................... 14.1 11.6
Carbon monoxide................ 3.3 3.5
Carbon dioxide................. 1.7 2.3
Oxygen......................... 0.8 1.1
Nitrogen....................... Nil. Nil.
----- -----
100.0 100.0

Showing that, if the Russian oil is a little lower in illuminants, it quite makes up by extra volume, but it seemed to me to deposit a much larger proportion of carbon.

Taking 21/2 gallons of American naphtha, it would give roughly 180 cubic feet of gas of the above composition, while the remaining gas would be the ordinary water gas. Taking the analysis of this as given, and calculating from it what would be the composition of a mixture of it with the naphtha gas, we obtain:

Calculated. Actual.
Hydrogen...................... 47.09 42.09
Methane....................... 5.48 11.27
Olefines...................... 2.53 7.59
Ethane........................ 2.17 6.32
Carbon monoxide............... 30.07 18.65
Carbon dioxide................ 3.78 2.32
Oxygen........................ 0.56 0.17
Nitrogen...................... 7.17 8.25
Sulphureted hydrogen.......... 1.15 2.84
------ ------
100.00 100.00

Showing how great the effect is of the diluents in the water gas in preventing the overcracking of the hydrocarbons, as shown by the increase in the percentage of them present in the finished gas; while the enormous reduction in the amount of carbon monoxide present is due to the interaction between it and the paraffin hydrocarbons in the presence of red-hot carbon, a point which makes the Van Steenbergh apparatus enormously superior to any of the superheater forms of plant.

After all said and done, however, the reactions taking place, although they have an intense fascination for the chemist, are not the factors which the gas manager deems the most important, the cost of any given process being the test by which it must stand or fall; and it will be well now to consider, as far as it is possible, the expense of enriching coal gas by the various methods I have brought before you.

In order to be well above the prescribed limit of illuminating power at all parts of an extended service, the gas at the works must be sent out at an illuminating power of 17.5 candles and we may, I think, fairly take it that 16 candle coal gas, as made by the big London companies, costs, as nearly as can be, 1s. per 1,000 cubic feet in the holder, and the question we have now to solve is the cost of enriching it from 16 to 17.5 candle power. When this is done by cannel, the cost is 2.6 pence per candle power, so that the extra 11/2 would cost 4d. per 1,000.

Carbureting by the vapors of gasoline by the Maxim-Clarke process costs 13/4d. per 1,000, so that the extra candle power would mean an expenditure of 2.62 d. Unfortunately I have no figures upon which to calculate the cost of producing such a gas by the Dinsmore process, but with the three important water gas enrichers we can deal.

Using Russian fuel oil, which can be obtained in bulk in London at 3d. per gallon, the proprietors of the Springer plant guarantee 51/2 candle power per 1,000 cubic feet of gas per gallon used, so that, to produce a 22 candle gas, 4 gallons would be used. The cost per 1,000 cubic feet may be roughly tabulated, as the coke used amounts to about 40 lb.

s. d.
Oil.................................... 1 0
Coke................................... 0 3
Labor and purification................. 0 2
Charge on plant........................ 0 1
----
1 6

Twenty five per cent. of 12-candle gas when mixed with 75 per cent. of the 16-candle gas gives the required 17.5 candle gas, which would therefore cost 1s. 11/2d., or the enrichment would have cost 11/2d.

By the Lowe process, an increase of 5.3-candle power is guaranteed for the consumption of a gallon of the same oil, so that the cost would be a shade higher, all other factors remaining the same, while with the Van Steenbergh process both grade of oil and consumption of fuel vary from either of these processes. In order to obtain a thousand cubic feet of 22-candle gas, two and a half gallons of the lighter grade oil would be consumed, and I am informed that there is now no difficulty in obtaining oil of the right grade in London in bulk at 4d. per gallon, which would make the cost:

s. d.
Two and a half gallons of oil........... 0 10
Thirty pounds of coke................... 0 21/4
Labor and purification.................. 0 2
Charge on plant......................... 0 03/4
------
1 3

And the enriched coal gas would, therefore, cost 1s. 3/4d. per thousand, the extra 11/2-candle power having been gained at an expense of 3/4d. or 1/2d. per candle.

Tabulating these results we have--Cost of enriching a 16-candle gas up to 17.5 candle power per 1,000 cubic feet by cannel coal, 4d.; by Maxim-Clarke process, 2-6/10d.; by Lowe or Springer water gas, 11/2d.; by Van Steenbergh water gas, 3/4d.

In reviewing this important subject, and bringing a wide range of experimental work to bear upon it, I have, as far as is possible, divested my mind of bias toward any particular process, and I can honestly claim that the fact of the Van Steenbergh process showing such great superiority is due to the force of carefully obtained experimental figures, corroborated by an experienced and widely known gas chemist, and by the chief gas examiner of the city.

In adopting any new method, the mind of the gas manager must to a great extent be influenced by the circumstances of the times, and the enormous importance of the labor question is a main factor at the present moment; with masters and men living in a strained condition which may at any moment break into open warfare, the adoption of such water gas processes would relieve the manager of a burden which is growing almost too heavy to be borne.

Combining, as such processes do, the maximum rate of production with the minimum amount of labor, they practically solve the labor question. Requiring only one-tenth the number of retort house hands that are at present employed, the carbureted water gas can be used for enrichment until troubles arise, and then the gas can be used pure and simple, with a hardly perceptible increase in expense, while the rapidity of make will also give the gas manager an important ally in the hour of fog, or in case of any other unexpected strain on his resources.

One of the first questions asked by the practical gas maker will be: "What guarantee can you give that as soon as we have erected plant, and got used to the new process of manufacture, a sudden rise in the price of oil will not take place, and leave us in worse plight than we were before?" and the only answer to this is that, as far as it is possible to judge anything, this event is not likely to take place in our time. A year ago the prospects of the oil trade looked black, as the output of American oil was in the hands of a powerful ring, who seemed likely also to obtain control of the Russian supplies; but, fortunately, this was averted, and, at the present moment, the Russian pipe lines are flooding the market with an abundant supply, which those best able to judge tell us is practically inexhaustible, so that prices may be expected to have a downward rather than an upward tendency. But even should a huge monopoly be created, I think I have found a source of light at home which will hold its own against any foreign illuminant in the market.

For a long time I have felt that in this country we had sources of light and power which only needed development, and the discovery of the right way to use them, in order to give an entirely new complexion to the question of carbureting; and now by the aid of the engineering skill and technical knowledge of Mr. Staveley, of Baghill, near Pontefract, I think it is found.

At three or four of the Scotch iron works the Furnace Gases Co. are paying a yearly rental for the right of collecting the smoke and gases from the blast furnaces. These are passed through several miles of wrought iron tubing, diminishing in size from 6 feet down to about 18 inches; and as the gases cool, so there is deposited a considerable yield of oil.

At Messrs. Dixon's, at Glasgow, which is the smallest of these installations, they pump and collect about 60,000,000 cubic feet of furnace gas per day; and recover, on an average, 25,000 gallons of furnace oils per week, using the residual gases, consisting chiefly of carbon monoxide, as fuel for distilling and other purposes, while a considerable yield of sulphate of ammonia is also obtained. In the same way a small percentage of the coke ovens are fitted with condensing gear, and produce a considerable yield of oil, for which, however, there is a very limited market, the chief use being for lucigen and other lamps of the same description, and for pickling timber for railway sleepers, etc.; the result being that, four years ago, it could be obtained in any quantity at 1/2d. per gallon, while since that it has been as high as 21/2d. a gallon, but is now about 2d., and shows a falling tendency. Make a market for this product, and the supply will be practically unlimited, as every blast furnace and coke oven in the kingdom will put up plant for the recovery of the oil, and as with the limited plant now at work it would be perfectly easy to obtain 4,000,000 or 5,000,000 gallons per annum, an extension of the recovery process would mean a supply sufficiently large to meet all demands.

Many gas managers have, from time to time, tried if they could not use some of their creosote for gas producing, but on heating it in retorts, etc., they have found the result has generally been a copious deposit of carbon, and a gas which has possessed little or no illuminating value. Now, the furnace and coke oven oils are in composition somewhat akin to the creosote oil, so that at first sight it does not seem a hopeful field for search after a good carbureter, but the furnace oils have several points in which they differ from the coal tar products. In the first place, they contain a certain percentage of paraffin oil, and in the next, do not contain much naphthalene, in which the coal tar oil is especially rich, and which would be a distinct drawback to their use.

The furnace oil as condensed contains about 30 to 50 per cent. of water, and in any case this has to be removed by distilling; and Mr. Staveley has patented a process by which the distillation is continued after the water has gone off, and by condensing in a fractionating column of special construction, he is able to remove all the paraffin oil, a considerable quantity of cresol, a small quantity of phenol, and about 10 per cent. of pyridine bases, leaving the remainder of the oil in a better condition, and more valuable for pickling timber, which is its chief use.

If the mixed oil so obtained, which we may call "phenoloid oil," is cracked by itself, no very striking result is obtained, the 40 percent. of paraffin present cracking in the usual way, and yielding a certain amount of illuminants, but if this oil be cracked in the presence of carbon, and be made to pass over and through a body of carbon heated to a dull red heat, then it is converted largely into benzene, the most valuable of the illuminants, and also being the one to which coal gas owes the largest proportion of its illuminating power, it is manifestly the right one to use in order to enrich it.

On cracking the phenoloid oil, the paraffins yield ethane, propane, and marsh gas, etc., in the usual way, while the phenol interacts with the carbon to form benzene--

Phenol. Benzene.
C6H5HO + C = C6H6 + CO.

And in the same way the cresol first breaks down to toluene in the presence of the carbon, and this in turn is broken down by the heat to benzene.

A great advantage of this oil is that the flashing point is 110, and so is well above the limit, thus doing away with the dangers and troubles inseparable from the storage of light naphtha in bulk.

In using this oil as an enricher, it must be cracked in the presence of carbon, and it is of the greatest importance that the temperature should not be too high, as the benzene is easily broken down to simpler hydrocarbons of far lower illuminating value. This fact is very clearly brought out by a series of experiments I have made, in which the phenoloid oil was cracked by passing it through an iron tube packed with coke and heated to various temperatures, the hydrocarbons being much more easily broken up under these conditions than if mixed with diluents, such as water gas:

RESULTS OBTAINED ON CRACKING PHENOLOID OIL.