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Brown's Gas Welder

 

Financial Return Analysis of the BN-2000 Brown's Gas Welder

"The Water Welder"

Independent Study Report prepared by

Academy Institute Technologies

[Report Date: May 1997]

Executive Summary

The Brown's Gas Welder is called a "Water Welder" because it uses an electrical

energy source to convert ordinary tap water into a fuel for welding, brazing, burning and

cutting virtually any metal. Brown's Gas is a perfectly proportioned (stoichiometric)

mixture of oxygen and hydrogen. Rather than burning or exploding, the "flame" of this

gas implodes. It generates a melting/sublimation temperature at the weld/burn contact

point which is completely dependent upon the material in which the "flame" comes into

contact.

The following analysis illustrates the line of reasoning which supports the following hypothetical savings which the Brown's Gas Technology offers over

conventional metal cutting, braising, and welding methods.

Brown's Gas offers:

1) 66% operational savings over oxyacetylene welding/braising

2) 67% operational savings over TIG and ARC welding

3) 40% operational savings over MIG welding

4) 50% operational savings over oxyacetylene cutting operations

5) cost benefit over a plasma cutter has not yet been estimated

1) Estimate of the Operational Costs of Oxyacetylene Welding/Braising:

-Oxyacetylene "rig" purchase price... approx. $300.00

-Operating Costs for an 8 hour day of continuous operation:

One tank of oxygen (8 hours of usage) $20.00 per tank

One tank of acetylene (8 hours of usage) $30.00 per tank

Cost of welding/braising rods (8 hours) $16.00 per day

Total operational costs per day $66.00 per day

2) Estimate of the Operational Costs of TIG Welding/Braising:

TIG welder cost... approx.

Power consumption cost calculation:

[220 volt at 45 amp for 8 hours at $0.1 0/kw with 50% duty = $4.00 per day]

TIG power consumption (8 hours of usage) $4.00 per day

Welding rods (4 times normal cost) $64.00 per day

Total operational costs per day $68.00 per day

3) Estimate of the Operational Cost of MIG Welding/Braising:

MIG welder cost... approx. $1,500.00 (MIG adapter $1,000.00 each)

MIG power consumption cost $4.00 per day

Welding Wire (mild steel 2x normal cost) $34.00 per day

Total operational costs per day $38.00 per day

4) Estimate of the Operational Cost of the Brown's gas Welder/Braiser/Cutter

Manufacturer's suggested retail price of the BN 2000... $12,000.00

Electrical power consumption estimation:

The BN 2000 will produce a maximum of 2,000 liters of Brown's Gas per hour.

The electrical power consumption at theta maximum production rate is 8.5 kilowatt per

hour. Therefore the maximum electrical power cost per day is $6.40

[(8.5 kw)(8 hr/day)($0.l0 per kw) = $6.80 per day]

To perform equivalent work as the above conventional methods of welding and

braising, the BN 2000 would only be working at 20% of capacity producing 400 liter of

as per hour). For purposes of conservatism in our estimation we shall assume a 50% of

capacity gas production cycle rate or 1,000 liters per hour.

[(4.25 kw)(8 hr/day)($0.l0 per kw) = $3.40 per day]

Brown's Gas power consumption cost $3.40 per day

Normal (most inexpensive) welding rod cost $16.00 per day

BWT Welding Solution consumption $3.00 per day

Total operational cost per day $22.40 per day

Important Note: The BN 2000 has the capacity to comfortably supply 3 torches

simultaneously. This analysis does not make further mention of this important

productivity/cost reduction benefit.

Approximately 1,000 liters/hour are needed to cut 3/4 inches of steel. The same

amount of oxygen is needed as with the acetylene fuel source. Thus, the BN 2000 could simultaneously supply 2 torches for this type of cutting work.

Overview of Welding/Braising - Cost Analysis

A) Oxyacetylene vs. Brown's Gas

Oxyacetylene Brown's Gas Brown's Gas Brown's Gas

Cost I Day Cost I Day Savings/Day Savings I Year (250 day/yr)

$66.00 $22.40 $43.60 $10,900.00

 

B) TIG I ARC vs. Brown's Gas

(Note: Most shops weld with an ARC Welder at about the same cost as TIG, and braise

and cut with oxyacetylene.)

TIG I ARC Brown's Gas Brown's Gas Brown's Gas

Cost I Day Cost I Day Savings/Day Savings I Year (250 day/yr)

$68.00 $22.40 $45.60 $11,400.00

C) MIG vs. Brown's Gas

MIG Browns' Gas Brown's Gas Brown's Gas

Cost I Day Cost I Day Savings I Day Savings I Year (250 day/yr

$38.00 $22.40 $15.60 $6,900.00

Comparison of Brown's Gas to oxyacetylene for a hypothetical welding/metal cutting shop.

Estimate for a hypothetical welding shop cutting operation cost:

Typical oxyacetylene usage

15 bottles/week of oxygen at a cost of $20.00 per bottle $300.00/week

15 bottles/week of acetylene at a cost of $30.00 per bottle $450.00/week

Total fuel/energy cost $750.00/week

Estimated equivalent Brown's Gas technology

15 bottles/week of oxygen at a cost of $20.00 per bottle $300.00/week

Electrical power consumption $34.00/week

[(8.5 kw)(8 hrs/dy)(5 dys/wk)($0.10 per kw) $34.00]

[This electrical power consumption rate can sustain the operation of three torches in

simultaneous operation.]

BWT Welding Solution consumption cost $16.00/week

Total fuel/energy cost $350.00/week

Estimated Brown's Gas savings per week... $400.00/week (53% cost reduction)

($750.00/week - $350.00/week $400.00/week savings)

Estimated Savings per (50 week) year... $20,000.00