CALCIUM CARBIDE INDUSTRY OF THE USSR

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• Document Page Count: 71
• Document Creation Date: December 27, 2016
• Document Release Date: May 23, 2013
• Sequence Number: 5
• Publication Date: February 27, 1953
• Content Type: REPORT

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COPY NO.
ASSISTANT DIRECTOR
ital/R`tL"
FOR RESEARCH AND REPORTS 50X1
SECRET
ECONOMIC INTELLIGENCE REPORT
CALCIUM CARBIDE INDUSTRY
OF THE USSR
CIA/RR 20
27 February 1953
U.S. OFFICIALS ONLY
CENTRAL INTELLIGENCE AGENCY
OFFICE OF RESEARCH AND REPORTS
oDt 7
SECRET
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WARNING
This material contains information affecting
the National Defense of the United States
within the meaning of the espionage laws,
Title 18, USC, Secs. 793 and 794, the trans-
mission or revelation of which in any manner
to an unauthorized person is prohibited by law.
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ECONOMIC INTELLIGENCE REPORT
CALCIUM CARBIDE INDUSTRY OF TEE USSR
CIA/RR 20
CENTRAL INTELLIGENCE AGENCY
Office of Research and Reports
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FOREWORD
Calcium carbide has been a standard product of the chemical
industries of most countries since the early part of the twentieth
century. For many years its principal uses were for the welding
and cutting of steel and for illumination.
In the years immediately preceding World War II, however,
practical recognition was given to the fact that acetylene, derived
from calcium carbide, was an organic building block from which
many useful products could be synthesized. The results of intensive
research in acetylene chemistry were translated into commercial pro-
ductiot of synthetic rubbers, plastics, chlorinated solvents, chemical
warfare agents, explosives, pharmaceuticals, and many other products
essential to modern industrial economies. Thus calcium carbide assumed
a vital role as the parent chemical in a new and highly significant
branch of organic synthesis, and today, in most countrie chemical uses
for calcium carbide have surpassed its uses for the welding and cutting
of steel and for illumination.
The purpose of this report is to present the outstanding features
of the calcium carbide industry in the USSR and to point out the
capabilities and vulnerabilities of this industry. It is believed
that these data will assist in accurately evaluating Soviet industrial
and military strength.
It should be emphasized that this report is based on information
available as of July 1952 and that it is subject to revision as
additional information becomes available.
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Summary
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COlITENTS
Page
1
I. Introduction 4
II. Technology 5
III. Input Requirements 7
1. Primary Raw Materials 7
2. Electric Power 7
3. Fuel 8
IV. Supplies
10
1. Production
10
2. Locations and Estimated Production of Plants
12
3. Stockpiles
14
it. Trade
18
5. Total Supply
18
V. Requirements
18
VI. Capabilities, Vulnerabilities, and Intentions
20
1. Capabilities
20
2. Vulnerabilities
21
3. Intentions
21
Appendixes
Appendix A. Calcium Carbide Plants in the USSR
23
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Appendix C. Methodology
63
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SECURITY INFORMATION
THE CALCIUM CARBIDE INDUSTRY OF THE USSR*
Summary
Calcium carbide is Important principally because, when reacted
with water, it generates acetylene, a gas universally used for the
welding and cutting of steel; for special-purpose illumination; and
for the production of synthetic rubbers, plastics, chemical warfare
agents, explosives, pharmaceuticals, and many other chemical inter-
mediates and end products. It is widely used also for the manufacture
of fertilizer, for the processing of ores and metals, and for other
less important purposes.
Calcium carbide has been a product of the Soviet chemical industry
since before World Wax I, and at the outbreak of World War II, in 1939,
production reached an estimated 100,000 tons,** equivalent to about
66 percent of US calcium carbide production in that year. The extent
of wartime damage in this Soviet industry is not known, but Lend-Lease
shipments of calcium carbide, in addition to Lend-Lease shipments of
large quantities of fabricated steel and other products requiring
acetylene in their manufacture, give testimony to the shortage of
this chemical during World Wax II. The postwar status of calcium
carbide production is Obscure because the USSR has published no in-
formation of significance concerning the output of this industry since
1935. Analysis of Soviet requirements for calcium carbide, combined
with analysis of plant information and trade information, has, however,
indicated a 1952 production of about 300,000 tons (probable range,
260,000 to 330,000 tons), equivalent to about 38 percent of estimated
US production in 1952.
Soviet technology in the manufacture of calcium carbide is comparable
to that in the US and other highly industrialized countries, although
Soviet specifications concerning quality are lower than corresponding US
specifications, indicating that the quality of Soviet calcium carbide
is lower than that of US calcium carbide.
* This report contains information available to CIA as of 1 July 1952.
** Throughout this report, tonnages are given in metric tons.
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The primary input requirements of the Soviet calcium carbide industry
in 1952 are estimated at about 270,000 to 288,000 tons of lime, 135,000 to
146,000 tons of coke, 6l000 to 12,000 tons of carbon electrodes, and
840 million to 900 million kilowatt-hours (kwh) of electricity.
The plants producing calcium carbide are well dispersed through-
out the USSR, the major regions* of production being the Transcaucasus,
Central European USSR, and Kazakh SSR.
Although information concerning stockpiling of calcium carbide is
entirely lacking, large reserves are improbable because of the fire
and explosion hazards involved. The total inventory at producing and
consuming plants probably does not exceed several months' requirements,
at the very maximum.
Soviet net imports of calcium carbide in 1952 are estimated at
35,000 tons, most of which were to be supplied by East Germany, with
Poland and, possibly, Rumania supplying relatively small quantities.
Soviet requirements for calcium, carbide in 1952 are estimated
'broadly at 321,800 tons, allocated as follows: about 90 percent
for the manufacture of synthetic rubber, chemicals, and plastics and
for autogenous welding; and 10 percent for the manufacture of fertilizer,
for illumination, and for other miscellaneous uses.
The total supply of calcium carbide available to the USSR in 1952,
consisting of production and net imports, but excluding the inventory,
is estimated at 335,000 tons (probable range, 285,000 to 370,000 tons),
which is considered to be sufficient to meet all of the principal re-
quirements. Should a general war in the near future cause an increase
in calcium carbide requirements beyond this level of supply, large
quantities could be made available from East Germany, Poland, and
Czechoslovakia by a decrease in the production of these Satellites of
calcium cyanamide fertilizer and other nonessential production involving
calcium carbide. If the effects of wartime destruction are ignored, the
supply of calcium carbide actually and potentially available to the
USSR is adequate to sustain a prolonged military effort of major
proportions.
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The Soviet calcium carbide industry is not vulnerable to economic
warfare, and effective restriction of supplies can be achieved only
by actual destruction of the producing plants or their power plants.
Although the size of the inventory is not known, effective restriction
of calcium carbide supplies probably would reduce, within a few
months, Soviet capacity to manufacture essential military products.
A decrease in production of calcium cyanamide or a reduction in
allocations of this product for fertilizer use would be fairly good
indicators that increased quantities of calcium carbide and calcium
cyanamide were being allocated for more essential uses, such as
synthetic rubber and rubber products, armaments and implements of war,
chemical warfare materials, and explosives and plastics, all of which
would be needed in large quantities for the prosecution of a major
war ?
Table 1 presents the figures for total supply and requirements
of calcium carbide in the USSR.
Table 1
Estimated Total Supply and Requirements
of Calcium Carbide in the USSR
1952
Tons
Production
300,000
Imports
35,000
Total Supply
335,000,
Requirements
321,800
Table 2* presents the figures for the input requirements of the
calcium carbide industry in the USSR.
* Table 2 follows on p. 4.
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Table 2
Estimated Input Requirements of the
Calcium Carbide Industry in the USSR
1952
Lime (Tons)
Coke (Tons)
Anthracite (Tons)
Carbon Electrodes (Tons)
Electricity (Kwh)
I. Introduction.
270,000 to 288,000
135,000 to 146,00o
4o,000 to 50,000
6,000 to 12,000
8!o, 000,000 to 900,000,000
Calcium carbide is produced in the form of a grayish-black material
having the appearance of crushed stone and weighing about 138 pounds
per cubic foot. In the US, the crude commercial product contains
about 83 to 85 percent calcium carbide; 14 percent lime; 1 percent
carbon; and small amounts of silicides, phosphides, and sulfides.
The indic4ions are that the quality of calcium carbide produced in
the USSR is lower than that produced in the US. 1/*
Calcium carbide is important principally because, when reacted with
water, it generates acetylene, a gas universally used in the welding
and cutting of steel; for special-purpose illumination; and for the
production of certain types of synthetic rubbers, chemical warfare
agents, explosives, plastics, rayon, alcohols, glycols, solvents,
synthetic lubrication oil, and many other chemical intermediates
and end products.
Calcium carbide also is used in producing calcium cyanamide, which
is used as a fertilizer; in the casehardening of steel; in the
manufacture of explosives, cyanides, plastics, dyes, synthetic rubbers
and fibers; and in accelerators for the vulcanization of rubber.
In addition, calcium carbide has a few small-volume, direct uses.
It is used as a dehydrating agent for alcohol and foods, as an agent
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for ripening fruits, as a deoxidant in the processing of copper and
steel, and as 4 reducing agent in processing metallic ores.
II. Technology.
At the present time there is only one accepted economical process
for the production of calcium carbide. This process consists in
reacting lime and coke, or another form of carbon such as anthracite
or charcoal, in an electric arc-resistance furnace, where, in the
intense heat of the electric arc (22000?C or higher), the lime is
reduced to metallic calcium, which unites with the excess of carbon
present to form calcium carbide.
Two types of electric arc-resistance furnaces, the ingot furnace
and the tapping furnace, are used to produce calcium carbide. The
ingot furnace is similar to that used for the production of fused
aluminum oxide, the most widely used synthetic abrasive. A carbon
electrode is lowered into a carbon-lined steel furnace on a car and
strikes an arc with the bottom. The charge is added from time to
time, and the electrode is raised until the furnace is full. The furnsPe
is disconnected and cooled, and the ingot is removed. The tapping
furnace consists of a steel shell lined with carbon, which is about
the only refractory material capable of withstanding the extremely hot,
alkaline conditions encountered in this process. The arc is generally
produced by three electrodes connected to three-phase electric current.
The lime and coke are charged continuously, and the molten calcium
carbide at about 1,800?C is tapped either intermittently or continuously,
depending on the size of the furnace.
The solidified calcium carbide from either type of furnace is broken
into pieces and graded for size in an atmosphere of nitrogen to prevent
the possibility of explosion from any acetylene that may have been formed.
This process has been used commercislly for many years, and. Soviet
technology in this industry is comparable with that in the US, Germany,
and other highly industrialized countries.
The US Government specification for calcium carbide requires a
minimum purity of 80 percent calcium carbide, and the technical grade
sold in the US averages 83 to 85 percent calcium carbide.
Information in Soviet literature refers to the State All-Union
Standard (Gosudarstvenny obshchesoyuznyy standart 5agl7) for calcium
carbide (GOST 1460-46) and quotes specifications for yields of
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acetylene from certain grades of calcium carbide. ,?_/ This information
indicates that three different grades of calcium carbide are used in
the USSR. The specifications for the first grade State that the
yield of acetylene per kilogram of calcium carbide, depending on the
size of the calcium carbide lumps, must be not less than 250 to 280
liters at 200C and 760 millimeters of mercury pressure, which is
equivalent to a product containing 65.6 to 73.5 percent calcium carbide.
The specifications for the second grade state that the yield of
acetylene per kilogram of calcium carbide must be not less than 230
to 260 liters, equivalent to a product containing 60.3 to 68.2 percent
calcium carbide. Specifications for a third grade of calcium carbide
also are given in this source,which states:
"For factories equipped with low-power furnaces (up to
1000 kw) and operating on local, low-grade raw materials,
an output of calcium carbide with an acetylene yield of
not less than 220 liters per kilogram (for all lump sizes)
is permitted." 1/
Thus a product containing only about 57 to 58 percent calcium carbide
would be acceptable as third-grade calcium carbide. The proportionate
production of the various grades of calcium carbide in the USSR is not
known, but, considering the above specifications and other information
concerning the allowable impurities in raw materials, it is doubted
that the average purity of Soviet calcium carbide exceeds the minimum
specifications for the first grade, about 65 to 74 percent.
Also, in contrast to US practice, in which petroleum coke is the
preferred source of carbon because of its low ash content and high
resistivity, the Soviet calcium carbide industry reportedly uses hard
coal* coke and anthracite as the principal sources of carbon. Petroleum
coke and charcoal are more rarely used. )1/
A new method of producing calcium carbide without using electrical
energy is claimed by Soviet scientists. A. blast furnace is charged
with a mixture of chalk and coke, and a blast of air enriched with
oxygen (60 to 70 percent) is introduced in order to secure a temperature
of 2,200?C to 21400?C. 2/ Successful development of this process has not
been confirmed, and there are no indications that it is being used on a
commercial scale.
* This so-called "hard coal" would be known as bituminous coal in
the US.
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III. Input Requirements.
1. Primary Raw Materials.
The following is a translated extract from a book recently
published by the USSR concerning its calcium carbide industry:
"In plant practice it has been established, that if
the composition of the raw materials satisfies the
specifications given on pages 53-60, then on the
average for one ton of carbide, one kilogram of
which will yield under normal conditions 250 liters
of acetylene, it is necessary to expend:
Lime 900 to 960 kilograms
Coke 600 to 650 kilograms
Electrodes 20 to 40 kilograms
Electrical Energy 2,800 to 3,000 kilowatt-hours
If the fusion is carried out with anthracite instead
of coke, the consumption of it (anthracite) will be
equal to approximately 580-620 kilograms." g
Using this information as a basis, the estimated quantities of primary
raw materials required by the USSR in 1952 for the manufacture of about
300,000 tons* of calcium carbide, having an average purity of about
65 to 74 percent, are presented in Table 3.**
2. Electric Power.
Calcium carbide is produced by an electrothermal process requiring
large quantities of electricity. Recently published Soviet information
states that the consumption of electrical energy per ton of calcium
carbide, 1 kilogram of which yields 250 liters of acetylene under normal
conditions, is 2,800 to 3,000 kilowatt-hours (kwh). // Therefore, based
on an estimated production of 300,000 tons of calcium carbide, having
an average purity of 65 to 74 percent, the consumption of electricity
by the Soviet carbide industry in 1952 is estimated at 84o million to
900 million kwh.
* Throughout this report, tonnages are given in metric tons.
** Table 3 follows on p. 8.
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Table 3
Estimated Raw Material Requirements for the Manufacture
of Calcium Carbide in the USSR
1952
Tons
Raw Material
Lime
Coke
Anthracite
Electrodes
AMount
270,000 to
135,000 to
4o,00Q to
6,000 to
288,000
146,000
50,000 2/
12,000
a. An estimated 25 percent of the total carbon
requirement is in the form of anthracite.
3. Fuel.
In the manufacture of calcium carbide, fuel is required as the
source of carbon in the electric arc-resistance furnace reaction; for
the manufacture of the raw materials, lime and coke; and for the
generation of electricity in thermoelectric power plants servicing
the calcium carbide industry. The latter requirement is not considered
in this report. The estimated fuel requirements for the first two
.purposes follow.
a. For the Source of Carbon in the Electric Arc-Resistance
Furnace Reaction.
It is estimated that about 25 percent of the carbon required
in the electric arc-resistAnce furnace reaction for the manufacture of
calcium carbide in the USSR is supplied by anthracite. The balance of
the carbon is in the form of hard coal coke. Since the estimated total
carbon requirement is 180,000 to 195,000 tons, and since slightly less
anthracite than coke is required for this reaction, the 1952 anthracite
requirements of the USSR are estimated at 40,000 to 50,000 tons.
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b. For the Preparation of Raw Materials.
The fuel requirements for the preparation of raw materials
for the calcium carbide industry consist of anthracite coal and hard
coal. The anthracite coal, according to published Soviet information,
is used as a source of heat in converting limestone to lime. Hard
coal is used for the manufacture of coke, which in turn serves as
the principal source of carbon in the electric furnace reaction.
Estimates of the fuel requirements for the preparation
of lime and coke for the Soviet calcium carbide industry in 1952
are given in Table 4.
Table 4
Estimated Fuel Requirements for the Preparation of
Raw Materials for the Calcium Carbide Industry in the USSR
1952
Tons
?
Amount of Type of Fuel
Raw Material Raw Material Required
?
Lime 270,000 to 288,000 Anthracite coal
Coke 12_/ 135,000 to 146,000 Hard coal
Amount of Fuel
Required
37,800 to 40,300 2/
185,000 to 200,000 s/
a. With respect to the fuel used in the preparation of lime for the
manufacture of calcium carbide, recently published Soviet information
states that the temperature in the lime kiln is usually provided by burning
anthracite coal dust and waste gases from calcium carbide furnaces. These
waste gases contain about 6o percent carbon monoxide. The stated consump-
tion coefficients for the manufacture of one ton of lime are 130 to 150
kilograms of anthracite and 600 to 700 cubic meters of furnace gas.
b. It is assumed that 75 percent of the carbon used is in the form of hard
coal coke and 25 percent is in the form of anthracite, and that all the
coke is derived from hard coal and none from petroleum.
c. These figures are based on an estimated 73-percent yield of coke
from coal that has been washed in preparation for the coke oven.
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IV. Supplies.
1. Production.
Before World War I, calcium carbide was manufactured in
Russia only in the Perun plant in St. Petersburg (now Leningrad) and
in a plant in Slavyansk. The first named plant could produce 4,000
tons of calcium carbide a year, whereas in Slavyansk only an undetermined
amount for use in the area was manufactured. 2/
From World War I to 1927, Soviet production of calcium carbide
is not known but probably was insignificant, since annual production
in 1927-28 has been reported as 3,351 tons. 12/ It is probable that
this production originated in the plants at Leningrad and Slavyansk,
although there is some indication that a plant in Kirovakan was
operating in 1927. A plant in Dzerzhinsk was put into operation in
1928 but probably contributed little or nothing to the production re-
ported for 1927-28.
The First Five Year Plan (1928-32) saw substantial progress
made in this industry, and production in 1932 has been reported as
29,230 tons. 22/
During the Second Five Year Plan (1933-37), expansion of
calcium carbide capacity continued. The first unit of a 70,000-ton
plant at Yerevan was put into operation; the plant at Kirovakan was
put into operation or, at least, the second unit of this plant was
started; and a unit containing three electric furnaces reportedly was
built at Voroshilovgrad. E/ Undoubtedly, other plants were built or
expanded during this period, but further information is lacking. By
1935, output had risen to 45,760 tons, an increase of 57 percent over
1932 production. 12/ Production in 1936 and 1937 is not known, but
one source has stated that "output is supposed to have increased by
1937 to about 60,000 tons." 2111
With respect to calcium carbide, the Third Five Year Plan
(1938-42) stated only that "an expansion of calcium carbide production
for autogenous welding and for acetylene and products derived from
acetylene is foreseen." 22/ The 1941 State Plan, however, visualized
a production of 145,200 tons for that year. lg Assuming that the
production of 6o,00o tons estimated for 1937 is accurate and that the
1941 planned output of 145,200 tons was realistic and would have been
attained had not the German invasion interrupted production in many
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of the plants, output of calcium carbide in the intervening years,
as determined by interpolation, probably was as given in Table 5.
Table 5
Estimated Production of Calcium Carbide in the USSR
1938-40
Tons
Year Production
Probable Range of Production
1938
80,000 _al
70,000 to 100,000
1939
100,000
90,000 to 110,000
1940
120,000
100,000 to 130,000
a:71
estimate 1938 production
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at 100,000 tons. 21/
Production of calcium carbide during the war years from 1941
to 1945 is not known and is almost impossible to estimate, because
of the inadequacy of the plant information concerning that period.
Loss of plants because of occupation and bombings undoubtedly re-
duced capacity considerably, but the actual tonnage lost is not known.
Lend-Lease shipments of 775 tons of calcium carbide, as well as
Lend-Lease shipments of large quantities of fabricated steel and
other products requiring acetylene in thedr manufacture, give
testimony tothe wartime shortage of this chemical. 1!!'
The Fourth Five Year Plan (1946-50), as published, did not
give a goal for the production of calcium carbide and gave no information
from which this goal could be estimated. Furthermore, the yearly and
quarterly reports concerning fulfillment of the State Plans during this
period throw no light on the status of production of this chemical.
estimate 1949 production at 200,000
tons. 22/ Accepting this as a sound estimate) an attempt has been made
to determine production for 1950) 1951, and 1952 by first establishing
1952 output and then interpolating for 1950 and 1951 production. The
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41.
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estimates thus made indicate that production of calcium carbide in
these years probably was as given in Table 6.
Table 6
Estimated Production of Calcium Carbide in the USSR
1950-52
Tons
Year
Production 2/ Probable Range of Production y
1950
233,000
200,000 to 270,000
1951
267,000
230,000 to 300,000
1952
300,000
260,000 to 330,000
a. The methods used in arriving at the production figures
given are explained in Appendix C.
b. The inadequacy of postwar information concerning the.
calcium carbide producing plants and requirements for
carbide necessitates the use of the wide margins listed.
Soviet production of calcium carbide sine 1927 is given
in Table 7.*
For the purpose of comparison, production of calcium carbide
in the USSR and in the US in certain years is given in Table 8.**
2. Locations and Estimated Production of Plants.
The locations and estimated outputs of Soviet calcium carbide
plants are given in Table 9.*** It is not certain, however, that all
of the plants listed are actually producing calcium carbide, because
in some cases the information is not conclusive. Neither is it certain
Table 7 follows on p.13.
** Table 8 follows on p.14.
*** Table 9 follows on P.15.
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Table 7
Estimated Production of Calcium Carbide in the USSR
1927-52
Tons
Year
Production 2/
Probable Range of Production
1927-28
12/
3,351
1928-29
12/
6,911
1930
21,562
1931
23,437
1932
29,230
1933
29,841
1934
40,612
1935
45,760
1936
N.A.
1937
6o,000
1938
80,000
70,000 to 100,000
1939
100,000
90,000 to 110,000
1940
120,000
100,000 to 130,000
1941 (Plan)
145,200
1942-48
N.A.
1949
200,000
170,000 to 240,000
1950
233,000
200,000 to 270,000
-951
267,000
230,000 to 300,000
1952
300,000
260,000 to 330,000
a. The production figures listed for 1927 through 1935 are
figures published by the USSR. 221/ All other figures are
estimates except the 1941 figure, which was the planned
goal. LI'
b. It is assumed that the production figures refer to
annual production reported on a noncalendar year basis.
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Table 8
Estimated .Production of Calcium Carbide in the USSR
As Compared with Production in the US
1933, 1935, 1937, 1939, 1949-52
Year
Amount of Production
(Tons)
Soviet Production as
Percent of
US Production
USSR
US
1933
29,841
92,000
32.4
1935
45,760
133,000
34.4
1937
6o,000
175,000
34.3
1939
100,000
152,000
65.8
1949
200,000
550,000
36.4
1950
233,000
609,000
38.3
1951
267,000
703,000
38.0
1952
300,000
781,000 22/
38.4
that the list includes all of the producing plants nor that the pro-
duction listed for every plant is factual. Detailed plant studies
are attached to this report in Appendix A.
3. Stockpiles.
Calcium carbide is a dangerous material to store, because,
if it becomes wet or moist, the acetylene gas which is liberated is an
extreme fire and exp1osion hazard. Normally, because of the risks
inherent in storing this material, stocks are kept at minimum levels
and, in the US, usually approximate 2 weeks' production. The size
of the stocks maintained by the USSR is not known, but the difficulties
involved in keeping the metal drums dry, tight, and free of corrosion
undoubtedly preclude large stockpiles. Because of these risks and
difficulties, it is improbable that calcium carbide is among the chemicals
stockpiled in the state reserves of the USSR, although this is not
certain. In conformity With Soviet regulations regarding emergency
stockpiles of materials at plants, stocks undoubtedly are maintained
at producing or consuming plants. These stocks more than likely exceed
a normal working inventory, but their sum total is, in all probability,
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Table 9
Locations 2/* and Estimated Production of Calcium Carbide Plants
in the USSR
1952
Tons
Economic Region and City
Northwest (Ia)
Kirovsk
Leningrad
Ukraine (III)
Makeyevka
SlavyanSk
Voroshilovgrad
Zaporozh'ye
Lower-Don - North CaucaSusKIV)
Groznyy
Transcaucasus (V)
Baku-Zykh
Kirovakan
Yerevan
Volga (VI)
Beketovka
Kuybyshev
Plant Names
Calcium Carbide Plant
Krasnyy Avtogen, No. 1
Calcium Carbide Plant
Krasnyy Khimik Soda Plant
Locomotive Works
Calcium Carbide and
Ferroalloys Plant
Calcium Carbide Plant
Sverdlav Acetylene Factory
Myasnikan Chemical Combine
Kirov Synthetic Rubber
Combine
Chemical Plant, No. 91
Calcium Carbide Plant
Footnotes to Table 9 follow on p.17.
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Production
N.A. 12/
15,000
3,000
N.A. 12/
N.A. 12/
20,000
N.A.
10,000
35,000
70,000
N.A.
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Table 9
Locations 2/* and Estimated Production of Calcium Carbide Plants
in the USSR
1952
(Continued)
Tons
Economic Region and City
Central European USSR (VII)
Plant Name Production
Aleksin Chemical Combine, No. 100 N.A. 12/
Bryansk Calcium Carbide Plant N.A. 12/
Dzerzhinsk Kalinin Chemical Combine 20,000
Lipetsk Calcium Carbide Plant 35,000
Stalinogorsk Stalin Chemical Combine - 50,000
Voronezh Synthetic Rubber Plant,
SK-2 N.A.
Urals (VIII)
Berezniki Voroshilov Chemical Combine N.A-
Kardbash Calcium Carbide Plant N.A. .9./
Kirovograd Kalata Chemical Combine N.A.
West Siberia (IX)
Novosibirsk Calcium Carbide Plant N.A.
Kazakh SSR (Xa)
Balkhash Calcium Carbide Plant 7,500
Kantagi Calcium Carbide Plant N.A. 12/
Temir-Tau Calcium Carbide Plant,
No. 727 30,000
Central Asia (Xb)
Chirchik Calcium Carbide Plant N.A. 12/ .
East Siberia (XI)
Ulan-Ude Calcium Carbide Plant 7,200
Footnotes to Table 9 follow on p. 17.
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Table 9
Locations 2/ and Estimated Production of Calcium Carbide Plants
in the USSR
1952
(Continued)
a. Calcium carbide plants have been reported at the following
locations, either as under construction, as planned, or as in
operation, but production at these plants has not been confirmed:
Kadiyevka and Shostka in the Ukraine Economic Region; Gergebel in
the Lower Don-North Caucasus Economic Region; Chapayevsk in the
Volga Economic Region; Kushkovo in the Central European USSR
Economic Region; Chelyabinsk in the Urals Economic Region; Kemerovo
in the West Siberia Economic Region; and Petrovsk-Zabaykallskiy in
the East Siberia Economic Region.
b. Probably small.
c. Very small.
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relatively small and sufficient for, perhaps, several months' full
operation at the very maximum.
4. Trade.
The USSR is believed to be exporting small quantities of
calcium carbide to Albania. There are no records of Soviet exports of
calcium carbide to any other Soviet Bloc country.
The USSR was scheduled to receive 28,000 tons of calcium
carbide from East Germany under the 1951 trade agreement, and it
is believed that the entire amount was received. 21/ Smaller
quantities also may be imported from Poland and Rumania. In 1949,
Rumania reportedly delivered 5,500 tons of calcium carbide to the USSR.
No later information is available. Large quantities were imported from
North Korea until UN bombings halted production there.
There are no known records of Soviet trade in calcium carbide
with non-Soviet Bloc countries.
It is apparent from the trade pattern in recent years that
the USSR is a net importer of calcium carbide. Although information
for 1952 is not available, Soviet net imports for this year are
estimated at about 35,000 tons.
5. Total Supply.
The estimated total supply of calcium carbide available
to the USSR in 1952, exclusive of a possible stockpile, is given
in Table 10.*
V. Requirements.
Estimated Soviet requirements for calcium carbide in 1952?
are given in Table 11.** The requirements for calcium
carbide in the Third Five Year Plan, as reported by the
USSR, are given in Table 12.xxx A cbmparison of these
requirements with the estimated 1952 requirements shows that
19.
*
Table
10 follows on p.
**
Table
11 follows on p.
19.
***
Table
12 follows on p.
20.
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Table 10
Estimated Supply of Calcium Carbide in the USSR
1952
Tons
Source of Supply
Amount Probable Range
Production 300,000 260,000 to 330,000
Net Imports 35,000 25,000 to 40,000
Total Supply 335,000 286,000 to 370,000
Table 11
Estimated Requirements for Calcium Carbide in the USSR L.ai
1952
Use
Requirements
,(Tons)
Percent of Total
Synthetic Rubber
120,500
37.5
Chemicals and Plastics
87,600
27.2
Autogenaus Welding
78,000
24.2
Calcium Cyanamide
25,700
8.0
Miscellaneous
10,000
3.1
Total
321,800
100.0
a. The methods used in arriving at these estimates are
presented in Appendix C.
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Table 12
Reported Requirements for Calcium Carbide in the USSR
in the Third Five Year Plan .?.V
1938-42
Percent
Use Percent of Total
Autogenous Welding
Manufacture of Calcium Cyanamide
Manufacture of Synthetic Rubber
Manufacture of Vinyl Resins
Manufacture of Synthetic Acetic Acid
49.2
11.1
21..4
10.7
7.6
synthetic rubber and chemicals and plastics have replaced autogenous
welding as the principal uses for calcium carbide, the former uses
now consuming almost three times as much calcium carbide as the
latter.
VI. Capabilities, Vulnerabilities, and Intentions.
1. Capabilities.
The supply of calcium carbide available to the USSR in 1952
is estimated at 335,000 tons (probable range, 285,000 to 370,000),
equivalent to about 43 percent of the estimated US production in 1952.
This supply is considered sufficient to meet Soviet requirements in
1952. Should a general war in the near future cause an increase in
calcium carbide requirements beyond this level of supply, large quantities
could be made available from East Germany, Poland, and Czechoslovakia
by reducing the production of calcium cyanamide fertilizer and other non-
essential items in those countries. If the effects of wartime destruction
are ignored, the supply of calcium carbide actually and potentially
available to the USSR is adequate to sustain a prolonged military effort
of major proportions.
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2. Vulnerabilities.
The Soviet calcium carbide industry is self-sufficient and,
therefore, not vulnerable to economic warfare. Imports of this
commodity represent only about 10 percent of the total supply and are
received entirely-from within the Soviet Bloc. Effective restriction
of supplies can be achieved only by actual destruction of the producing
plants or their power plants. Although the size of the inventory is
not known, effective restriction of supplies probably would reduce
Soviet capacity to manufacture essential military products within a few
months.
About 40 percent of Soviet calcium carbide production.
capacity is concentrated in three plants, located in Yerevan,
Kirovakan, and Leningrad, all three of which are vulnerable with.
respect to bombing.
3. Intentions.
A decrease in production Of calcium cyanamide or a reduction in
allocations of this product for fertilizer use would be fairly good
indicators that increased quantities of calcium carbide and calcium
cyanamide were being allocated for more essential useal such as synthetic
rubber and rubber products, armaments and implements of war, chemical
warfare materials, explosives, and plastics, all of which would be
needed in large quantities for the prosecution of a major war. Other than
this, it is unlikely that any conclusions regarding Soviet intentions
could be drawn from the calcium carbide industry, unless detailed in-
formation concerning allocations of calcium carbide to Soviet consumPrs
were available.
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APPENDIX A
CALCIUM CARBIDE PLANTS IN THE USSR
I. Plants on Which There Is Reliable Information.
1. Calcium Carbide Plant.
a. Location. KiroVsk, Murmansk Oblast (Northwest Economic Region).
b. Estimated Production of Calcium Carbide. Not available -
probably small.
c. Production Information. None.
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide.
"February 1944: Authorized to ship one carload of
calcium carbide to plant No. 204 in Tambov for
February. March 1944: Authorized to ship one car-
load of calcium carbide to "Donbas-EnergO" plant in
Gorlovka for March." L/
h. Comment. Production of calcium carbide at this plant is not
conclusive, being deduced only from the above information
regarding shipments of calcium carbide.
2. Krasnyy,Avtogen No. 1.
a. Location. Leningrad, Leningrad Oblast (Northwest Economic
"Tgi-a717.
"This plant is located on the Tarakanovka River,
Andreevskaya Ulitsa."
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b. Estimsted Production of Calcium Carbide. 15,000 tons
per year.
c. Production Information.
"This plant produces calcium carbideloxygen, and
acetylene. Plant was in operation in 1946.
Postwar in-
formation is based on personal Observations during
November and December 1946, contacts with industrial
managers, and conversation with Leningrad
residents." 2.1/
""The acetylene shop contained three Russian
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generators and one wooden German one. The
generators were operated as follows ... .
Numerous rows of flasks were constantly being
filled with acetylene ...
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several hundred steel flasks were
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filled per day ... . the
German 50X1
generator was installed in 1947. It was of modern
construction and permitted the use of carbide* dust
for manufacture of acetylene. This dust used to be
disposed of by giving it to the workers or selling
it, as the Russian generators could only handle
small blocks of carbide. 40 to
45 tons of carbide were manufactured in a 24-hour
period ... . The carbide furnaces melted coal and
limestone at a temperature of 315000Celsius. The
hot fluid was then released from the furnaces into
large cast iron buckets holding one ton each. It
takes from 15 to 16 hours for them to cool off.
The ready-made carbide was then lifted out of the
buckets, broken up, and ground ... ." 2111/
* "Carbide" and "calcium carbide" are synonymous.
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d. Plant Equipment.'" ... Six electric furnaces, each four
meters high and three meters in diameter. ... Three
Russian acetylene generators and one wooden German
one ... ." 22/
e. Source of Raw Materials. "This plant receives power from
the city power plant ... ." 22/
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide.
"Part of the carbide was utilized for the production
of acetylene gas, but larger amounts were despatched
by rail to Kiev and Kaliningrad or transported in
trucks to Estonia." 11/
h. Comment.
the production of
calcium carbide in 1949 amounted to 40 to 45 tons per
24-hour period which is equivalent to about 15,000 tons
per year. Since there has been no information concerning
expansion of this plant, it is estimated that production
in 1952 will be the same -- namely, 15,000 tons.
3. Calcium Carbide Plant.
a. Location. Makeyevka, Stalino Oblast (Ukraine Economic
Region). "A carbide plant is located in the south part of
M,keyevka.'
b. Estimated Production of Calcium Carbide. 3,000 tons per
year. 1.V
c. Production Information.
d. Plant Equipment.
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it produces only carbide.' 34 50X1
"The plant has two iron or steel furnaces about
25 meters high." 22/
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e. Source of Raw Materials.
"Electric power is transmitted from Zavod imeni
Kirova, where the central transformer for
industrial installations in and around Makeyevka
is located." ]?./ This power plant also is
located at Makeyevka.
f. Storage Facilities. No information.
g.
Distribution of Calcium Carbide.
"The entire output is taken to Zavod imeni Kirova,
21/
(Note: Zavod imeni Kirova is a large steel plant.)
4. Krasnyy Khimik Soda Plant.
a. Location. Slavyansk, Stalino Oblast (Ukraine Economic
-R7i717.
b. Estimated Production of Calcium Carbide. Not available
probably small.
c. Production Information.
"Before World War I, calcium carbide was manufactured
in Russia only in the Perun plant in St. Petersburg
(Leningrad) and in Slavyansk. The first named plant
could produce 4,000 tons of carbide a year while in
Slavyansk only an undetermined amount for use in the
area was manufactured." 12/
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d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide. No information.
h. Comment. The information concerning the installation of
a calcium carbide manufacturing plant here is very scant.
It is believed that, if a calcium carbide plant does
exist at this location, it is a small plant. A large
plant in this locality almost certainly would have been
Observed by PW's in the area and probably would receive
at least some publicity in the Soviet press.
been seen in Soviet press extracts
5. Locomotive Works.
no mention of it has
a. Location. Voroshilovgrad, Voroshilovgrad
Economic Region).
b. Estimated Production of Calcium Carbide.
probably small.
c Production Information. None.
d. Plant Equipment.
"In Voroshilovgrad in the East part of the Ukraine,
a locomotive plant built its awn carbide unit having
three electric furnaces in 1936. Also the necessary
electrodes were manufactured in their own plant.
Cpncerning the capacity of this unit there is nothing
even estimated. This means that the requirements of
the locomotive works must be completely satisfied ... ."111/
Oblast (Ukraine
Not available --
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
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Distribution of Calcium Carbide. No information.
h. Comment. A small plant supplying calcium carbide
principally to the Locomotive Works evidently existed
here before World War II. It was probably destroyed
during the war, and, although postwar information is .
lacking, it may have been restored since the war.
6. Calcium Carbide and Ferroalloys Plant.
a. Location. Zaporozh'ye, Zaporozh'ye Oblast (Ukraine
Economic Region).
b. Estimated Production of Calcium Carbide. 20,000 tons
per year.
c. Production Information.
a calcium carbide and ferroalloys plant was
built in Zaporozh'ye in 1931-32. Neither the designed
capacity nor the annual production of this plant is
known. LV
"It has been said that within the borders of the
large Dniepr combine in Zaporozh'yel a carbide
plant has been built having a capacity of 20,000 tons
per year. How much carbide actually is being
produced is unknown." Lg./
d. Plant Equipment.
If
... French Miguet furnaces, single phase, 5,000 kw
normal capacity. Number of furnaces not known." 1.1Y
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide. No information.
h. Comment. The above information indicates the existence of a
calcium carbide plant at this location prior to World Wax II.
This plant was destroyed during the war, but interrogation of
returned German PW's has established that it was reconstructed
following the war and is now operating. Lacking quantitative
information concerning postwar production, it has been
assumed that this plant was restored to its original capacity.
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7. Calcium Carbide Plant.
a. Location. Groznyy, Groznyy Oblast (Lower Don-North
Caucasus Economic Region).
b. Estimated Production of Calcium Carbide. Not available.
c. Production Information. A translated extract of the
Soviet newspaper Trud dated 24 May 1947, indicates that
calcium carbide is one of the chemicals produced in
Groznyy.122/
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide. No information.
h. Comment. None.
8. Sverdlov Acetylene Factory.
a. Location. Baku-Zykh, Azerbaydzhan SSR (Transcaucasus
Economic Region).
"The transport address of the factory is Baku-
ToVarnaya (freight) Zak, railway station. The
telegraphic address is Baku Avtogentrest. The
telephone number is 27-06." LY
b. Estimated Production of Calcium Carbide. 10,000 tons
per year.
c. Production Information.
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"1943: Products: Oxygen, acetylene, carbide
(10,000 tons per year planned). Carbide factory
under construction; start of operation planned
in 1943."
"Requires 225 tons of petroleum coke and 135
tons of Donets coke for the production of
carbide during the first quarter of the
year (1944)." )22V ?
"This factory produces oxygen, acetylene and
welding equipment. It was established in 1914,
and is under the All-Union Autogenous Welding
Trust (VAT), which is under the Chief Administra-
tion of the Machine Construction Industry
(Glavmashprom)." 22/
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide. No information.
9. Myasnikan Chemical Combine.
a. Location. Kiravakan, Armenian SSR (Transcaucasus
Economic Region).
b. Estimated Production of Calcium Carbide. 35,000 tons per year.
c. Production Information.
"Produces calcium carbide and lime . . ."
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"Products are primarily carbide made of limestone.
Product is shipped by RR in drums weighing 60 to
80 kilograms." 22/
"A second carbide plant with a capacity of 20,000
tons is located in Kirovakan." 22/
"Products: Calcium carbide (1942: planned 12,000
tons), cyanamide, silicate, oxygen, acetic acid
(1942: 5,000 tons). Planned: explosives." 2I/
"Products: carbide. Planned annual production
33,000 tons. Program for 1927 called for 27,000
tons. Oxygen capacity: 800,000 cubic meters.
Cyanide capacity: 8,900 tons per year. Also
produces acetic acid; oxygen, calcium arsenite,
plastics and cyanide ... . Experimental smelting
of ferrosilicon undertaken." 58/
d. Plant Equipment.
... four large lime kilns which were built about 17
years ago." 22V
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"Lime calcining section consists of four fire-
brick kilns, each 25 meters high, housed in two
wooden sheds ... . New carbide calcining section
known as shop 202 equipped with American roasting
ovens." .?.9./
"Workship 20 (carbide factory) ... equipped with
three electric furnaces, each about 5 meters in
height and 7 meters in diameter." ?1/
e. Source of Raw Materials.
"Limestone is shipped in by train from
Yerevan."
"Power is received from the Sevan Power Plant.
Power supply is sufficient. Fifteen thousand volt
current is transmitted via high tension lines to
the transformer station where it is transformed to
350 volt alternating current of 6o amperes." ..q.5.1
g. Distribution of Calcium Carbide.
"Carbide is delivered to Tiflis in 6o to 801 ,
kilogram barrels." .?.//
h. Comment. This plant receives considerable publicity in
the Soviet press and is one of the best known of the
Soviet calcium carbide factories. It is believed that
the production of this plant now exceeds the 33,000
tons reported
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10. Kirov Synthetic Rubber Combine.
a. Location. Yerevan, Armenian SSR (Transcaucasus
Economic Region).
"The carbide factory is located in the eastern
part of town."
b. Estimated Production of Calcium Carbide. 70,000 tons
per year.
c. Production Information.
"The Yerevan Chemical Plant has fulfilled the
third quarter plan lowering the estimated pro-
duction cost by one-half. During the last nine
months it has saved 52,000 kwh af electricity.
The carbide shop fulfilled its year plan at the
end of September, producing 90 percent first-
class products, as against the planned 80 per-
cent." 12/
"The Yerevan chemical factory was built before
the war. During the war, the factory was engaged
in defense work; but after the war it began its
own special production again. The factory has
three main shops; a carbide shop, a plastic shop,
and a glass goods Shop . The plastic shop
produces plastic consumer goods. In 1947, the
factory produced over 400,000 articles of various
sorts, mainly of a small size. In.Decether 1947,
the factory received new pressing molds for plastic
goods from Moscow ... . The polyvinyl acetate works
1
is an entirely new factory under the Ministry of the
Chemical Industries of the USSR; it is still under
construction ... . The factory is to produce plastic
articles of polyvinyl acetate for the electrical
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industryl mainly insulating equipment. Since
the middle of 191.1.7 the plastic shop has been
in partial operation with a small number of
specialized workers but so far produces only
consumer goods." 12/
"Through their own innovations, workers at the
Yerevan Carbide Plant are perfecting production,
mechanizing labor processes, and increasing the
productivity of machines . Without stopping
the carbide furnaces, workers of the carbide
shop did away with the vapor lock. This resulted
in great savings. Much iron was saved by changing
the design of electrode cases . Attachments
were produced which give warning when elevator
shafts become Obstructed or when materials are
defective; devices which insure safe operation
of crushers also have been developed." 22/
"The Rubber Combine in Yerevan is employing the
carbide process (which was taken over from the
US DuPont Corp.) and has the largest carbide
capacity (6o,000 - 70,000 tons)." 13./
"The greatest carbide plant is at Yerevan, part
of the "Kirov" synthetic rubber combine. Planned
potential capacity 60,000 tons per annum, begun
in 1936." /1?/
"Synthetic rubber (on the basis of acetylene)
planned capacity: 10,000 tons per year. In
addition, the following installations belong to
the Sovprene plant of the Yerevan combine:
.carbide plant (planned 50,000 tons); acetylene
plant (planned 16,000 tons); chlorine plant
(planned 10,000 tons); monavinylacetylene plant
(12,000 tons)." 72/
"Carbide furnace shop. There were six carbide
furnaces in this shop. But only four of these furnaces
were always in operation, for the other two were
always defect. The repair of these furnaces lasted
four to six months ... . Each furnace had three
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chambers . One ton of carbide was molten
within one hour in one chamber; that means
three tons in one furnace .,.- ." 1g
(Note: Considering four furnaces always
in operation, this would amount to about
288 tons of carbide per 24 hours or to
about 100,000 tons per year. Normal
?process interruptions, however, such as
reloading furnaces, replacing electrodes,
and so forth, would result in a production
lower than the 100,000-ton figure calculated.
Thus the annual production of 70,000 tons
estimated for this plant seems reasonable.)
"Products: Carbide. Planned potential capacity
6o,000 tons per year. 20,000 tons were produced
the first year of operation *(1936) in the first
section of this plant. This carbide plant is part
of the Kirov synthetic rubber plant." IV
d. Plant Equipment.
"Carbide factory (6 carbide furnaces); 2 acetylene
generators ... chlorine department with three
furnaces ... ."
"Carbide furnace shop. There were six carbide
furnaces in this shop ... . Such a furnace was made
of chamotte stones. It was six meters long, four
meters wide, and three meters high. Behind these
furnaces there were six chimneys which were made of
bricks and which were 30 meters high piercing the
roof of the building ... ." 12/
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"The carbide department consisted of about 10
buildings, mostly iron concrete structures, a
battery of 8 lime kilns with grinding mills,
an installation of 6 carbide furnaces and of
accessory carbide-crushers." f21/
e. Source of Raw Materials.
"Limestone from the quarries of Davalu at the Ararat
railroad station." 1.14/
"Lime of good quality is received from the Ararat
Lime Factory ... ."
"Coke used to come from the Shcherbinskiy Coke and
Chemical Works; but as it had an ash content of up
to 22 percent, the carbide produced was of bad
quality and did not satisfy requirements. Since
November 1947, the factory has received coke with
an ash content of not more than 11 percent from
other works." 1811/
"The power station with its two diesel engines
can only be considered an emergency installation
used during power breakdown periods. Its trans-
formers serve to convert the current supplied by
the Kanakir Power Plant."
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide. Detailed information re-
garding the distribution of carbide from this plant is
not available. It is almost certain, however, that most
of the carbide produced here is used within the combine
for the generation of acetylene, which is used in the
manufacture of Sovprene synthetic rubber and polyvinyl
acetate plastic. Small amounts of acetylene are probably
bottled for local welding purposes, and small amounts of
carbide are probably shipped to other acetylene generating
plants.
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h. Comment. This is the largest of the Soviet calcium
carbide producing plants and, as does the Kirovakan
plant, receives considerable publicity in the Soviet
press. It is believed that intensification of pro-
duction in this plant has raised its annual output
to about 70,000 tons of calcium carbide.
11. Chemical Plant No. 91.
a. Location. Beketovka, Stalingrad Oblast (Volga Economic
-17a737.
"A new installation was under construction about
1,600 feet south of the main plant. It will be a
hydrogenation plant for gasoline synthesis and a
carbide plant. Operation had not started in
February 1949." .811/
b. Estimated Production of Calcium Carbide. Not available.
c. Production Information.
"Products: Several types of poisonous gases; liquid
gas resembling oil; chlorine; acetylene; hydrochloric
acid." 2/
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
g ?
Distribution of Calcium Carbide.
"May 1944 - The Yenakievo Metallurgical Works authorized
to receive one carload of calcium carbide from the
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_ _ _ _ _ _
Stalingrad Plant No. 91." 22/
(Note: This is probably the Beketovka
plant.)
h. Comment. The existence of calcium carbide on the
premises of this plant has been confirmed, the
production of acetylene has been reported, and the
construction of a calcium carbide plant also has
been reported. Based on this information and the
known production of lime, one of the necessary raw
materials, production of calcium carbide at this
plant is probable but not conclusive.
12. Calcium Carbide Plant.
a. Location. Kuybyshev, Kuybyshev Oblast (Volga
Economic Region.).
"Karbit Zavod, a carbide plant, 1 kilometer
north of the Samara River and 500 meters south-
east of the Aircraft Engine Plant ... ." 21/
"Carbide plant, south part of Bezmyanka, a
suburb of Kuybyshev ... ." 2.V
b. Estimated Production of Calcium Carbide. 5,000
tons per year.
c. Production Information.
tt ... Production - carbide - 10,000 to 15,000
kilograms daily ... . Limestone rocks are
burned to lime. Three-fourths of lime and
one-fourth of coal and coke are melted in ovens
with electrodes for 2 hours, and the finished
carbide is then placed in barrels." 22/
... Production 200 tons carbide per day.
Twenty-five freight cars of carbide shipped
each week. Remainder of carbide used in
Bezmyanka ." 212/
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d. Plant Equipment.
"Carbide shop ... contains two ovens with three
electrodes, 12,000 amps. each ... . Limestone
shop ... contains one gas-operated oven for
burning limestone." 22/
"Carbide department had three bow-shaped
ovens, one German make, two Russian." 2Y
e. Source of Raw Materials.
"Limestone arrives from a quarry in Krasnaya
Glinka ffrasnyye Glinkg (5318N-5012E). Thirty
cubic meters, are used daily ... . Coal and
coke arrive in 3-4 RR cars (60 tons) per
month ... . Electric power comes via under-
ground cable from the Bezmyanka Power Plant.
An underground gas pipeline leads from the
power plant to this installation." 21/
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide.
"Carbide is shipped from here to destinations
throughout Russia. Carbide is loaded onto RR
cars immediately after it is filled into
barrels, not stored in the plant area." 2Y
"Twenty-five freight cars of carbide shipped
each week. Remainder of carbide used in
Bezmyanka." 22/
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13. Chemical Combine No. 100.
a. Location. Aleksin, Tula Oblast (Central European USSR
Economic Region).
b. Estimated Production of Calcium Carbide. Not available
probably small.
c. Production Information.
"Factory still in process of being constructed.
Source observed manufacture of calcium carbide
in one small factory building in area. Calcium
carbide production was based on very primitive
methods." 100/
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g ?
DistribUtion of Calcium Carbide. No information.
h. Comment. None.
14. Calcium Carbide Plant.
a. Location. Bryansk, Bryansk Oblast (Central European USSR
Economic Region).
"Carbide plant - located south of the Desna River.
Five kilometers southeast of the Krasnyy Oktyabr
Locomotive Factory which is located on an island in
the Desna River; 3 kilometers southeast of a cement
plant." 101/
b. Estimated Production of Calcium Carbide. Not available
probably small.
c. Production Information. None.
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
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f. Storage Facilities. No information.
g. Distribution of Calcium Carbide. No information.
h. Comment. A calcium carbide plant of small capacity is
believed to be installed here.
15. Kalinin Chemical Combine.
a. Location. Dzerzhinsk, Gor'kiy Oblast (Central European USSR
Economic Region).
... Located in Chernorech'ye, at the Dzerzhinsk
station, 13 kilometers west of Gorkiy (formerly
Nizhni Novgorod) ... ." 102/
b. Estimated Production of Calcium Carbide. 20,000 tons
per year.
c. Production Information.
"There is only one calcium cyanamide plant in the
USSR. It belongs to the Kalinin Chemical CoMbine,
located in Chernorech'ye, at the Dzerzhinsk station,
13 km west of Gorkiy (formerly Nizhni Novgorod). It
possesses a capacity of 6,000 tons per year of nitro-
gen and was erected with the technical aid of the
A.B. phosphate factory of Stockholm. It was put into
operation in 1928. Furthermore, a calcium carbide
factory l with a capacity of 20,000 tons, as well as an
/Carbon/ electrode factory, is included in the cyanamide
factory. The /carboj electrode factory probably serves
primarily in the self-sufficiency of the carbide
factory." 103/
"The Kalinin (Dzerzhinsk) plant was producing at
the time of my visit in 1930, nitric acid, ammonia
nitrate, sulfuric acid, chlorine, calcium carbide
and ammonia ... ." 104/
" Zavod Kalinin - the carbide was packed in
rusty metal kegs, 50 kgs., about 1 - 1.2 meters
high and about 1/2 meter in diameter.
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"In the shop between Chlorine Tsekh and Foundry
probably carbide was produced." 221/
"Carbide production - This was a continuation
of the process begun in point 17. (Limestone
crushing.) The carbide stones being reduced
in their sizes now, were brought over from
point 17 to this production shop. The
pulverized carbide was filled in tin cans
which had two wing bolts as the stopper. A
tin can was about 6o cms high and 50 cms in
diameter. There was no lettering printed on.
Source was very certain that this powder was
carbide." 221e/
d. Plant Equipment.
... Four furnaces - Capacity 20,000 tons yearly." 109/
... In 1930 ... four to six carbide furnaces ... ." 112/
tt
... The lime burning shop contains three lime kilns in
operation ... ." 111/
Source of Raw Materials. Limestone is brought to the plant
by boat on the Oka River. 112/ The source of this lime-
stone is not known.
... Power is furnished by "high line," probably by
the TEM plant several kilometers to the east." 113/
f. Storage Facilities. No information.
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Distribution of Calcium Carbide. The capacity of the
calcium cyanamide plant associated with this calcium
carbide plant is reported as 17,000 tons yearly. 22.12/
To manufacture this quantity of calcium cyanamide
would require about 16,200 tons of calcium carbide.
The remaining calcium carbide (about 3,800 tons) is
probably used for the generation of acetylene for the
manufacture of vinyl resins and possibly other
chemicals and for autogenous welding purposes.
h. Comment. The estimated production of this plant is
based on prewar information. It is possible that
this plant has been expanded since the original
installation in order to meet the increased .calcium
carbide requirements of the chemical plants in this
vicinity, which have expanded greatly since prewar
times. No information is available, however, con-
cerning expansion of calcium carbide capacity in this
plant.
16. Calcium Carbide Plant.
a. Location. Lipetsk, Voronezh Oblast (Central European USSR
Economic Region).
b. Estimated Production of Calcium Carbide. 35;000 tons per
year.
c. Production Information.
"A carbide plant with a yearly capacity of 38,000
to 40,000 tons has been built in Lipetsk in Central
Russia. The complete operation should have started
at the end of 1939." 115/
The calcium carbide production of this plant in
1942 is reported to have been 36,000 tons per
year.
the 1941 planned capacity
of this plant was 20,000 tons of calcium carbide,
that the 1942 planned capacity was 40,000 tons and.
that this plant was evacuated. 121/
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d. Plant Equipment.
"The works operates with two furnaces; the
equipment was made principally by the
domestic machine construction industry. The
plant is extensively mechanized ... ."
this plant contained
'8 furnaces. 112/
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide. No information.
h. Comment. Production of calcium carbide at this plant is
not conclusive. No postwar information is available,
and it is somewhat doubtful that construction plans for
this installation ever materialized. It has been in-
cluded among the producing plants merely to avoid the
dangers of omission and underestimation.
17. Stalin Chemical Combine.
a. Location. Stalinogorsk, Moscow Oblast (Central European
USSR Economic Region).
b. Estimated Production of Calcium Carbide. 50,000 tons
per year.
c. Production Information.
"Capacity planned for 1932 - 50,000 to 75,000 tons
per year. Plant evacuated to Siberia but reported
to have been returned." 120/
"Products: Dyes; sulfuric acid; chlorine compounds;
calcium carbide; carbonic acid; aluminum compounds;
methyl alcohol; aluminum; nitrogenous fertilizers;
technical nitrogenous products." 21/
d. Plant Equipment. No information.
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e. Source of Raw Materials. No information.
f. Storage Facilities. No information
g. Distribution of Calcium Carbide. No information.
h. Comment. No postwar information is available concerning
this calcium carbide plant. The total lack of publicity
in the postwar Soviet press suggests that this plant is
perhaps of much smaller capacity than that reported as
planned for 1932.
18. Synthetic Rubber Plant SK-2.
a. Location. Voronezh, Voronezh Oblast (Central European
USSR Economic Region).
b. Estimated Production of Calcium Carbide. Not available.
c. Production Information.
"Immediately adjacent to Kirov plant anew
plant is under construction for the manufacture
of synthetic rubber. One part presumably pro-
duces Russian type synthetic rubber, while the
other is said to be of the same type as that
produced at Bunawerke, Schkopau." 22/
old plant produced rubber
by alcohol, while new plant would use calcium
carbide. 22.V
"Old rubber plant produced rubber from alcohol.
New plant is to produce rubber through use of
carbide, which was to be more economical and
easier to process." 124/
d. Plant Equipment,
"Buna Works, Dept. 15 ,.. 7 electric arc
furnaces ... ." 125/
"Six large furnaces where carbide was burnt." 126/
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e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide. No information.
h. Comment. The information concerning the construction of
a new synthetic rubber plant based on the calcium carbide
process, combined with the information concering the
existence of electric arc furnaces in this plant are
fairly good indicators of calcium carbide production.
A quantitative production estimate cannot be made, how-
ever, until further information is received.
19. Vorodhilov Chemical Combine.
a. Location. Berezniki, Molotov Oblast (Urals Economic
717E13nT.
b. Estimated Production of Calcium Carbide. Not
d. Plant Equipment. No information.
e. Source of Raw Materials. The sources of raw materials
used by the entire Berezniki combine, without specific
reference to calcium carbide production, are reported as
follows: limestone from Vaevolodo-Vil'va 6o kilometers
distant, coal from Kizel, and coke from Gubakha. 1E2/
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_ _ _ _ _
With regard to electric power it is reported that
"one power plant is located south of the nitrogen
plant and uses coal dust as fuel. Built by Borsig,
it operates by steam and produced 83,000 kw in 1936
and 105,000 kw in 1941. The other power plant is
operated hydraulically (9) and is of most modern
construction, consisting of six turbines ... .
Branch stations receive their power from the main
plant and from the Solikamsk-Gubakha net. Additional
power is received from the plant at Solikamsk." 22/
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide. No information.
h. Comment. Production of calcium carbide at this plant is
not conclusive and is deduced from the meager information
concerning production of calcium cyanamide. No estimate
of calcium carbide output can be made until XUrther in-
formation is received.
20. Calcium Carbide Plant,
a. Location. Kardbash, Chelyabinsk Oblast (Urals Economic
71;i77117).
"The mining administration kin Karabash) maintains
a small carbide factory located in a stone building
7 x 7 x 4 meters, northwest of the tsentralny
shaft." 2...U/
b. Estimated Production of Calcium Carbide. Not available
very mall.
c. Production Information.
"Here, in a primitive furnace, by means of an
electric arc, carbide is produced from lime-
stone and coke. This factory operated only at
intervals." 22/
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d. Plant Equipment.
. . primitive furnace ? *"
e. Source of Raw Materials. NO information.
f. Storage Facilities. NO information.
g ?
Distribution of Calcium Carbide. No information, but
probably for miners' lamps and other illumination
purposes in the area.
h. Comment. None.
21. Kalata Chemical Combine.
a. Location. Kirovograd, Sverdlovsk Oblast (Urals Economic
-FgETE;E).
b. Estimated Production of Calcium Carbide. Not available.
c. Production Information.
"Kirovograd, Kalata chemical cobbine; affiliated in-
stallations; sulfuric acid factory; pyrite sulfur
factory; fluorine factory; copper factory; calcium
factory ... Products include calcium carbide. Dji/
"The Soviet regime at one time set up an extensive
expansion program for the calcium carbide industry.
The production was to be increased to the point
where it made possible the manufacture of large
quantities of nitrogen of lime after the requirements
for autogenous metal processing had been met. These
plans then had to be abandoned. The amount of carbide
manufactured did not reach the quantity required for
acetylene production and consequently there was none
available for the production of nitrogen of lime. So
far as is known, only one of the few carbide plants
is located in the Urals. This is in Kirovograd, in
the Sverdlovsk province, and represents a section of the
chemical combine located there. Production quantity is
unknown." 1...U./
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d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide. No information.
h. Comment. Production of calcium carbide at this plant
conclusive,
is not
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22. Calcium Carbide Plant.
a. Location. Novosibirsk, Novosibirsk Oblast (West
Siberia Economic Region).
b. Estimated Production of Calcium Carbide. Not available.
c. Production Information. According to a Soviet press re-
port, the calcium carbide plant in the Ministry of Heavy
Machine Building in the City of Novosibirsk, Novosibirsk
Oblast, fulfilled the January 1949 Plan 124.1 percent. Lg
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide. No information.
h. Comment. No other information is available concerning
this plant, which is probably of small capacity.
23. Calcium Carbide Plant.
a. Location. Baikhash, Karaganda Oblast (Kazakh SSR
Economic Region).
"Located approximately 7 miles east-southeast of
the Baikhash RR station and 550 yards from Lake
Balkhash." 137/
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b. Estimated Production of Calcium Carbide. 7,500 tons per year.
c. Production Information.
equal amounts of coal and soda
(probably means lime were placed in a brick oven
which measured 2 and 3/4 yards square and fired.
Two of these ovens were observed. The molten liquid
from these ovens was allowed to harden in crude molds,
which were about 50 cm deep and about 50 cm in dia-
meter. About 100 hard, black solids were produced in
these molds daily." 12/
d. Plant Equipment.
"Two brick ovens each 2 and 3/4 yards square ." 140/
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide. No information.
h. Comment. From the measurements of the molds given above, it
is calculated that each of these molds contained about 48o
pounds of calcium carbide. Using the production figure
of 100 of these molds daily, the output of calcium carbide
would amount to about 48,000 pounds, or 22 tons per day.
Based on 340 working days per year, the annual production
of this plant would be about 7,500 tons.
24. Calcium Carbide Plant.
a. Location. Kantagi, South Kazakhstan Oblast (Kazakh SSR
Economic Region).
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"A carbide plant in one wooden building 80 feet
by 65 feet with a galvanized iron: roof is re-
ported to be located about one-fourth mile west
of the Kantagi RR station."
b. Estimated Production of-Calcium Carbide. Not available
probably small.
c. Production Information. None.
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide.
"The plant processes local carbide ore into
carbide which is plated in steel containers
and taken to an unknown mine in Kantagi.
Some carbide is also sent to Achisay."1112/
h. Comment. None.
25. Calciaum Carbide Plant No. 727.
a. Location. Temir-Tau, Karaganda Oblast (Kazakh SSR
Economic Region).
" ...Located 25 km northwest of the RR station
at Karaganda." 114.2/
" ... Located in the southern outskirts of
Temir-Tau." 144/
" ... Located approximately 220 yards south-
west of the Temir-Tau RR station." 21.?2/
b. Estimated Production of Calcium Carbide. 30,000 tons per year.
c. Production Information.
"Carbide plant consisting of two 600 foot by 65 foot
brick building, was located 25 km NW of the RR station
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at Karaganda. 60 tons of coke and 230 tons of
lime were brought daily from Karaganda to this
plant. Finished product was shipped at night
to an unknown destination. Factory No. 727
which was under construction was believed to be
a carbide plant. Carbide production probably
about 100 tons per day." 211?/
"Carbide is manufactured and the following
methods are used: Limestone, which allegedly
arrives from Karaganda is burned in furnaces.
There are four or five furnaces, in one of two
buildings, which make up the carbide plant. The
burned mass is then poured into tilt cars, which
transport it on tracks into the second building.
There it is again poured into one large furnace.
After this operation, the original limestone
mass comes out in liquid form. It is poured in-
to square forms and transported away in trucks
to an unknown destination. The color of the
final product is a dark gray ... . Three shift
operation ... . A six day work =week prevails
with Sundays off." 21E/
"Limestone, the principal raw material utilized
in making carbide, was transported 'by rail from
an unknown source and used at the rate of
approximately 300 tons per day. The output of
carbide was not known. The plant was equipped
with six large brick ovens which together con-
sumed approximately one ton of coke every 24
hours. According to hearsay, this coke was
shipped in by rail from Karaganda. The carbide
was packed in cans and shipped to an unknown
destination on freight cars." 2E/
(Note: 300 tons per day of limestone would
yield about 160 tons per day of lime, which,
in turn, would yield about 148 tons per day
of carbide, which is believed to be too high
an estimate for carbide production at this .
plant.)
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... The resulting calcium carbide was re-
moved from the furnaces, crushed with sledge
hammers and placed in iron drums approximately
3 ft. in length and 25 inches in diameter for
storage. The weight of a drum of calcium
carbide and the production rate of the plant
were not known. the pro-
ducts of this plant were used in the Temir-Tau
area and in Karaganda. Six 60-ton freight cars
of limestone and three 60-ton freight cars of
coke were brought to this plant every other
day."/
(Note: Based on the stated deliveries of
limestone to this plant, the production
of calcium carbide would amount to about
100 tons per day.)
d. Plant Equipment. The information concerning the number of
calcium carbide furnaces installed in this plant is con-
flicting; from two to five furnaces.
The number of lime kilns installed is uncertain, but
the existence of six furnaces which may be
the lime kilns. 150/ The use of conveyor belts for
intraplant materials transportation is reported. 121/
e. Source of Raw Materials.
"Limestone for the plant was delivered by rail from
a quarry approximately 25 miles northeast of
Temir-Tau." 222/
"According to hearsay, coke was shipped in by rail
from Karaganda." 153/
(Note: There is no coke plant installed at
Karaganda, but the rail line to Temir-Tau probably
passes through Karaganda. The Kemerovo and/or
Chelyabinsk coke plants probably supply coke for
the Temir-Tau plant.)
Electric power is probably supplied by a large steam
power plant which is reported to be situated in the
vicinity of the calcium carbide plant. 1212/
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f. Storage Facilities.
g ?
"These pieces (of carbide) were put into 200
to 220 pound cans which were stored in a
wooden warehouse measuring approximately 165
feet by 65 feet. From this warehouse the cans
of calcium carbide were loaded by Japanese PW
onto 60-ton freight cars, 150 to 200 cans per
car and shipped to an unknown destination." 155/
"The plant area also contained a few other
buildings including ... numerous warehouses.
These warehouses contained carbide products,
machine parts, and a considerable amount of
German-made synthetic rubber plant machinery." 12W
Distribution of Calcium Carbide.
"The finished carbide products were canned in 220
pound cans, 15 inches in diameter and 35 inches
'high, and shipped from the plant daily on 20- and
30-ton railroad freight cars. An average of two
30-ton freight cars per day were loaded. The
actual production and the destination of the finished
Products was not known. the carbide
would be used as a raw material for synthetic rubber
manufacture in the near future and that the present
products were only of average grade.:' 157/
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was producing ea/tide to make synthetic rubber; how-
ever, during the period he worked here, carbide was
being shipped by rail to Karaganda. 50X1
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south of the carbide factory was to produce synthetic
rubber when completed." 12/
h. Comment. Prior to 1946 the town of Temir-Tau was known as
Samarkand, and some of the earlier PW reports concerning
this plant use the old town name. The consensus of a
number of Japanese PW, who were employed at this plant, is
that the production of calcium carbide during 1948 was
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approximately 100 tons per day. There have been no
substantiated reports of expansion of calcium carbide
production at this plant, and it is estimated that
1952 production will be about 30,000 tons.
Before 1951 the entire production was shipped out to
destinations and for purposes unknown. It ?is believed
that the synthetic rubber plant, which was under con-
struction at this location, was put 'into operation in
1951, and it is probable that, in 1952, at least half
of the calcium carbide production of this plant will
be used for the manufacture of synthetic rubber.
? 26. Calcium Carbide Plant.
a. Location. Chirchik, Tashkent Oblast, Uzbek SSR
?(C;7778a Asia Economic Region). -
b. Estimated Production of Calcium Carbide. Not available
probably small.
c. Production Information.
Factory was believed to be
operated 24 hours a day ... . Rumors among
the PW were that this was a carbide factory.
"During the period from December 1945 to
May 1948, while commuting to work on a train,
a carbide manufacturing plant
located approximately 2-1/2 miles west-south-
west of the Chirchik Railroad Station." 1?2/
d. Plant Equipment. No information.
e. Source of Raw Materials. No information.
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_ _ _
f. Storage Facilities. No information.
g. Distribution of Calcium Carbide. No information. ?
h. Comment. The scarcity of information concerning this plant
precludes 4 production estimate. This very lack of in- ?
formation, combined with other information concerning the
chemical industry of this locale, indicates that this is
probably a small plant.
27. Calcium Carbide Plant.
a. Location. Ulan-Ude, Buryat-Mongol ASSR (East Siberia
Economic Region).
"A carbide plant ... is reported to be located
within the compound of the locomotive factory
situated 1-1/2 miles east of the Ulan-Ude RR
station." 161/
b. Estimated Production of Calcium Carbide. 7,200 tons per year.
c. Production Information.
"A single-track spur line extends to the plant
from the RR station, and Fit's believe that about
450 tons of coke and 900 tons of silicon (?) are
unloaded monthly ... . An estimated 600 tons of
carbide packed in steel cans 4 feet by 2 feet are
produced monthly." 162/
(Note: 1.150 tons of coke per month would pro-
duce about 720 tons of calcium carbide, if all
the coke were used for calcium carbide production.
Some coke, however, probably is used for manufacture
of lime, and, therefore, the estimated calcium
carbide production of 600 tons per month seems
reasonable. Assuming that the silicon referred
to is limestone, the production of calcium carbide
from 900 tons per month would be about )45 tons.
Assuming that the silicon is lime, the production
of calcium carbide would be about 830 tons.)
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"December 43: Authorized to ship 3 carloads
of calcium carbide to the Irkutsk NKRF."
"The (locomotive manufacturing) plant com-
pound covered an area 1,980 yards by 440
yards enclosed by an 8 foot board fence and
consisted of 25 brick buildings and 2 woven
buildings, including a new locomotive plant,
an iron works, an automobile repair shop, a
carbide processing plant ... ." 1f11
d. Plant Equipment. No information.
e. Source of Raw Materials.
"Electric power was supplied underground
from a thermoelectric power plant located
directly south of the plant." 165/
f. Storage Facilities. No information.
g ?
Distribution of Calcium Carbide.
"Most of the carbide produced at the plant
was allocated to local factories." 1.6.,Y
h. Comment. None.
II. Plants on Which There Is Insufficient Information.
In addition to the foregoing plants, the majority of which undoubtedly
produce calcium carbide, some evidence exists concerning calcium carbide
production at the installations listed below. These plants are not con-
sidered as producers of calcium carbide, however, either because of
insufficient information or for the particular reasons stated.
1. Calcium Carbide Plant.
a. Location. Kadiyevka, Stalino Oblast (Ukraine Economic
-17qUarT),
b. Information. A calcium carbide plant was stated to be
under construction here in September 1949. !Li No
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further information. This plant probably is
intended to supply calcium carbide to a synthetic
rubber plant reported to be under construction
here.
2. Chemical Plant or Powder Factory No. 9.
a. Location. Shostka, Sumy Oblast (Ukraine Economic Region).
b. Information. in 1930 the
Shostka chemical plant produced calcium carbide. 168/
Production of calcium carbide at this plant has
not been confirmed.
3. Calcium Carbide Plant.
a. Location. Gergebel, Dagestan ASSR (Lower Don-North
Caucasus Economic Region).
b. Information. A calcium carbide plant was stated to be
under construction in 1937 at Gergebel in Dagestani
capacity to be 240 tons a year. 1.2/ This information
is not confirmed.
4. Calcium Chemical Plant No. 102.
a. Location. Chapayevsk, Kuybyshev Oblast (Volga Economic
Region
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5. Plastics Plant.
a. Location. Kushkovo, Moscow Oblast (Central European USSR
Economic Region).
. Nitrogenous Fertilizer Factory.
a. Location. Kemerovo, Kemerovo Oblast Neat Siberia
Economic Region).
b. Information. It has been reported that a chemical plant,
located on the bank of the Tom' River and a short
distance north of the RR station at Kemerovo, produced
ebonite, calcium carbide, hydrochloric acid, sulfuric
acid, and alcohol from coal. 173/
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the basis of the information available up to July 1952,
production of calcium carbide at Kemerovo cannot be
substantiated.
7. Plant Name Not Available.
a. Location. Petrovsk-Zabaykal'skiy, Chita Oblast (East
Siberia Economic Region).
b. Information.
"A carbide plant consisting of one steel framed
building was located 2.5 miles south of the RR
station at Petrovsk . Steel containers were
used to store the gas produced at the plant." 175/
"Plant which manufactured gas from coal was
situated 2.5 miles east of the RR station at
Petrovsk . Gas produced at this plant was
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compressed into steel tanks 2 feet in diameter
and 6 feet long." .12/
The possibility that calcium carbide is produced
here is admitted. The available information
indicates, however, that the plant referred to
is more likely to be only an acetylene generator
plant.
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APPENDIX C
METHODOLOGY
I. Methods Used in Estimating Total USSR Production.
The methodology used in estimating the annual production of
calcium carbide in the USSR from 1937 through 1940 consisted in
accepting an apparently sound estimate of 60,000 tons for 1937 and
in assuming that the 1941 planned goal of 145,200 tons was realistic.
Starting with these two figures, production estimates for the
intervening years were arrived at by interpolation. The production
figure given for 1949 is an accepted estimate
The figure of 300,000 tons estimated for 1952 production
was derived from estimates of plant production and from estimates
of Soviet requirements for calcium carbide, taking into consideration
the net imports. The plant analyses indicate that 1952 production
will be in excess of 300,000 tons, but the many gaps and uncertainties
in these data suggest that considerable caution be exercised in using
them. Soviet requirements for calcium carbide in 1952 are estimated
broadly at 321,800 tons, about 35,000 tons of which will be supplied
by imports, indicating that, in order to meet requirements, Soviet
production in 1952 must be approximately 286,800 tons. Thus,
considering both the plant information and the calculated requirements,
it appears that Soviet production of calcium carbide in 1952 will be
on the order of 300,000 tons. The production estimates for 1950 and
1951 were derived by interpolating between the estimates for 1949 and
1952.
II. Methods Used in Estimating Soviet Requirements.
1. Synthetic Rubber.
Production of Sovprene synthetic rubber in the USSR in 1952
is estimated at 30,000 tons. 177/ Using an estimated consumption
coefficient of 3.3 tons of Soviet calcium carbide per ton of this
type of rubber, the calcium carbide requirement in 1952 for the
manufacture of Sovprene rubber is estimated at approximately 99,000 tons.
Soviet production of Buna rubber by the calcium carbide process
in 1952 is estimated by CIA to be 5,000 tons. Using an estimated
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consumption coefficient of 4.3 tons of calcium carbide per ton of
Buna rubber, the Soviet calcium carbide requirement in 1952 for
the manufacture of Buna rubber is estimated at about 21,500 tons.
The total Soviet calcium carbide requirement in 1952 for the
manufacture of synthetic rubber, therefore, is calculated at
120,500 tons.
2. Chemicals and Plastics.
The reported Soviet requirements for calcium carbide in the
Third Five Year Plan, as given in Table 12, state that the require-
ments for the manufacture of vinyl resins and synthetic acetic acid
would amount to 10.7 and 7.6 percent, respectively, of the total
calcium carbide requirements, presumably in 1942. It is assumed for
the purpose of this calculation that the 1940 requirements were
approximately the same, percentagewise, as those given for the Third
Five Year Plan. Therefore, based on the estimated Soviet calcium
carbide production of 120,000 tons in 1940, which is assumed to have .
been equal to the total requirements for that year, the calcium carbide
requirements in 1940 for the manufacture of vinyl resins and synthetic
acetic acid probably amounted to a total of about 21,900 tons.
An article in a 1946 Soviet periodical stated that, in 1950,
production of plastics, other than phenolaldehyde types, would increase
approximately four times over 1940 production. 178/ Assuming the achieve-
ment of this goal in 1952 for vinyl plastics and all other acetylene
chemicals, Soviet calcium carbide requirements in 1952 for the manufacture
of acetylene chemicals and plastics are estimated at about 87,600 tons,
equivalent to about 26 percent of US 1950 calcium carbide requirements
for these purposes. Obviously, the information upon which this
estimate was based is inadequate, but the general level of Soviet
industrial production indicates that calcium carbide requirements for
these purposes probably are in the range from 50,000 to 100,000 tons.
3. Autogenous Welding.
There is no good basis for computing calcium carbide requirements
for autogenous welding in the USSR. There is almost no Soviet informa-
tion, and the available US data are not broken down adequately for
analytic use.
The only Soviet figure on this use is a percentage figure given
in the Third Five Year Plan (1938-42). An application of this
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percentage figure is likely to lead to a serious Overestimate of
consumption because of the following reasons: (a) the extent of
the impact on the requirements for calcium carbide, caused by in-
creased Soviet utilization of electric welding since 1940, is not
known; (b) the growth of the other uses for calcium carbide has
caused the percentage figures from prewar years to diminish in reli-
ability.
These Soviet data, however, do offer a possible method for
estimating the calcium carbide requirements for autogenous welding.
This method consists in using the data given in Table 12, in which
the Soviet requirement for calciumicarbide for autogenous welding in
the Third Five Year Plan was reported as 49.2 percent of the total
calcium carbide requirement. Presumably, this referred to the 1942
requirement. The planned goal for 1942 production was not published
in the Third Five Year Plan, and the actual quantity of calcium
carbide represented by this percentage figure is not known. The 1941
goal for production of calcium carbide was published, however, as
145,200 tons. Therefore, for the purpose of this calculation, it is
assumed that the 1941 planned calcium carbide requirement for autogenous
welding was approximately the same, percentagewise, as the 1942 planned
requirement. Based on this assumption, the Russians apparently planned
to use about 71,500 tons of calcium carbide in 1941 for autogenous
welding. The planned Soviet steel production in 1941 was 22.4 million
tons. Using this calcium carbide to steel ratio and an estimated
1952 steel production of 33.3 million tons, Soviet calcium carbide re-
requirements for autogenous welding in 1952 may be calculated at about
107,000 tons.
Another possible estimate of Soviet consumption of calcium
carbide for autogenous welding can be made by assuming that the
consumption of calcium carbide for this purpose will vary directly
with the steel production. Production of steel in the US in 1950 was
about 87 million tons. In this same year in the US, approximately
206,000 tons of calcium carbide were consumed in autogenous welding. 179/
Using this calcium carbide to steel ratio and an estimated 1952 Soviet
steel production of 33.3 million tons, Soviet consumption of calcium
carbide in 1952 for autogenous welding may be calculated at about
78,000 tons.
The estimate based on US practices seems more accurate than
the estimate based on the percentage figure from the Third Five Year
Plan for the reasons cited above.
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4. Calcium CysnAmide.
Two plants in the USSR are known to be producing calcium
cyanamide: one at Kirovakan with a reported capacity of 10,000
tons per year and the other at Dzerzhinsk with a reported capacity
of 17,000 tons per year. Production of calcium cyanamide also has
been reported at Berezniki, but this is not confirmed. On the
basis of the information available, calcium cyanamide production
in the USSR in 1952 is estimated at about 27,000 tons. Published
Soviet information states that "the practical yield of calcium
cyanamidefromcarbide varies in the range from 83 to 85 percent
of theoretical." 180/ Theoretically, 21,600 tons of calcium
carbide would be required to produce 27,000 tons of calcium cyanamide.
Therefore, 25,700 tons of calcium carbide are required for the
production of 27,000 tons of calcium cyanamide in the USSR.
The methods used in arriving at estimates of input re-
quirements and estimates of production of individual plants are
fully explained in the text where the estimates are Made.
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