This gave him the idea of producing a mantle for illuminating purposes and in 1885 he placed such a mantle in commercial use. His first mantles were unsatisfactory, but they were improved in 1886 by the use of thoria, an oxide of thorium, in conjunction with other rare-earth oxides. His mantle was now not only stronger but it gave more light. Later he greatly improved the mantles by purifying the oxides and finally achieved his great triumph by adding a slight amount of ceria, an oxide of cerium. Welsbach is deserving of a great deal of credit for his extensive work, which overcame many difficulties and finally gave to the world a durable mantle that greatly increased the amount of light previously obtainable from gas.
The physical characteristics of a mantle depend upon the fabric and upon the rare-earths used. It must not shrink unduly when burned, and the ash should remain porous. It has been found that a mantle in which thoria is used alone is a poor light-source, but that when a small amount of ceria is added the mantle glows brilliantly. By experiment it was determined that the best proportions for the rare-earth content are one part of ceria and ninety-nine parts of thoria. Greater or less proportions of ceria decreased the light-output. The actual percentage of these oxides in the ash of the mantle is about 10 per cent., making the content of ceria about one part in one thousand.
Mantles are made by knitting cylinders of cotton or of other fiber and soaking these in a solution of the nitrates of cerium and thorium. One end of the cylinder is then sewed together with asbestos thread, which also provides the loop for supporting the mantle over the burner. After the mantle has dried in proper form, it is burned; the organic matter disappears and the nitrates are converted into oxides. After this "burning off" has been accomplished and any residual blackening is removed, the mantle is dipped into collodion, which strengthens it for shipping and handling. The collodion is a solution of gun-cotton in alcohol and ether to which an oil such as castor-oil has been added to prevent excessive shrinkage on drying.
The materials and structure of the fabric of mantles have been subjected to much study. Cotton was first used; then ramie fibers were introduced. The ramie mantle was found to possess a greater life than the cotton mantle. Later the mantles were mercerized by immersion in ammonia-water and this process yielded a stronger material. The latest development is the use of an artificial silk as the base fabric, which results in a mantle superior to previous mantles in strength, flexibility, permanence of form, and permanence of luminous property. This artificial silk mantle will permit of handling even after it has been in use for several hundred hours. This great advance appears to be due to the fact that after the artificial-silk fibers have been burned off, the fibers are solid and continuous instead of porous as in previous mantles.
The color-value of the light from mantles may be varied considerably by altering the proportions of the rare-earths. The yellowness of the light has been traced to ceria, so by varying the proportions of ceria, the color of the light may be influenced.
The inverted mantle introduced greater possibilities into gas-lighting. The light could be directed downward with ease and many units such as inverted bowls were developed. In fact, the lighting-fixtures and the lighting-effects obtainable kept pace with those of electric lighting, notwithstanding the greater difficulties encountered by the designer of gas-lighting fixtures. Many problems were encountered in designing an inverted burner operating on the Bunsen principle, but they were finally satisfactorily solved. In recent years a great deal of study has been given to the efficiency of gas-burners, with the result that a high level of development has been reached.
Several methods of electrical ignition have been evolved which in general employ the electric spark. Electrical ignition and developments of remote control have added great improvements especially to street-lighting by means of gas. Gas-valves for remote control are actuated by gas pressure and by electromagnets. In general, the gas-lighting engineers have kept pace marvelously with electric lighting, when their handicaps are considered.
Various types of burners have appeared which aimed to burn more gas in a given time under a mantle and thereby to increase the output of light. These led to the development of the pressure system in which the pressure of gas was at first several times greater than usual. The gas is fed into the mixing tube under this higher pressure in a manner which also draws in an adequate amount of air. In this way the combustion at the burner is forced beyond the point reached with the usual pressure. Ordinary gas pressure is equal to that of a few inches of water, but high-pressure systems employ pressures as great as sixty inches of water. Under this high-pressure system, mantle-burners yield as high as 500 lumens per cubic foot of gas per hour.
The fuels for gas-lighting are natural gas, carbureted water-gas, and coal-gas obtained by distilling coal, but there are different methods of producing the artificial gases. Coal-gas is produced analytically by distilling certain kinds of coal, but water-gas and producer-gas are made synthetically by the action of several constituents upon one another. Carbureted water-gas is made from fixed carbon, steam, and oil and also from steam and oil. Producer-gas is made by the action of steam or air or both upon fixed carbon. Water-gas made from steam and oil is usually limited to those places where the raw materials are readily available. The composition of a gas determines its heating and illuminating values, and constituents favorable to one are not necessarily favorable to the other. Coal-gas usually is of lower illuminating value than carbureted water-gas. It contains more hydrogen, for example, than water-gas and it is well known that hydrogen gives little light on burning.
It has been seen in a previous chapter that the distillation of gas from coal for illuminating purposes began in the latter part of the eighteenth century. From this beginning the manufacture of coal-gas has been developed to a great and complex industry. The method is essentially destructive distillation. The coal is placed in a retort and when it reaches a temperature of about 700°F. through heating by an outside fire, the coal begins to fuse and hydrocarbon vapors begin to emanate. These are generally paraffins and olefins. As the temperature increases, these hydrocarbons begin to be affected. The chemical combinations which have long existed are broken up and there are rearrangements of the atoms of carbon and hydrogen. The actual chemical reactions become very complex and are somewhat shrouded in uncertainty. In this last stage the illuminating and heating values of the gas are determined. Usually about four hours are allowed for the complete distillation of the gaseous and liquid products from a charge of coal. Many interesting chemical problems arise in this process and the influences of temperature and time cannot be discussed within the scope of this book. Besides the coal-gas, various by-products are obtained depending upon the raw materials, upon the procedure, and upon the market.