(SANITIZED)REPORT ON THE IRON AND STEEL INDUSTRY OF COMMUNIST CHINA(SANITIZED)

Document Type: 
Collection: 
Document Number (FOIA) /ESDN (CREST): 
CIA-RDP81-01043R000600010004-6
Release Decision: 
RIPPUB
Original Classification: 
S
Document Page Count: 
430
Document Creation Date: 
December 22, 2016
Document Release Date: 
July 28, 2010
Sequence Number: 
4
Case Number: 
Publication Date: 
February 6, 1957
Content Type: 
REPORT
File: 
AttachmentSize
PDF icon CIA-RDP81-01043R000600010004-6.pdf48.2 MB
Body: 
Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010108118: CIA-RDP81-01043R000600010004-6 50X1 -HUM Next 4 Page(s) In Document Denied Q ARMY review completed. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 M. Technique and Technical Training 1. Outline 2. Detainment of Japane se technicians 3. Introduction of Soviet techniques 4. 5. Absorbing the technique of various free nations Favorable treatment of technical workers b. Liaison with schools and training sections 7. Teacher-student agreement $. Study system Estimate of the technical level Supplement: Yang-ch'uan Ironworks A. Name of Enterprise P. Form of Enterprise and Affiliation C. Location and Plant Layout D. Tapes of Operations E. Type of Plant F. Various Aspects of Plant Location G. History H. Principal Equipment I. Labor Force J. Raw Material and Motive Power K. Production 1. Pig iron a. Annual output Products C. Destination of products d. Percentage of products meeting specifications e. Effective utilization. coefficient Cast-iron pipes and other products L, Technique Small Blast Furnace SPECIAL. iANi~L NG REQ~ IRED N'OT FRE~.FASA!1 TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SEcREI Doc No 90225 (10) (PB) Charts No 10-1. General Sketch of the Vicinity of the T'ai-yuan Iron and Stee 1 Works No 10-2. Plant Layout of the T'ai-yuan Iron and Steel Works (Separate Volume) Operational System of the T'ai-yuan Iron and Steel Works No 10-4. Consumption Within the Works and Outside Sale of Principal Products of the T'ai-yuan Iron and Steel Works No 10-5. Distribution of Mines in Operation in SHANSI and Ne ighboring Prov ince s No 10-6. Plant Layout of the Coke and Chemical Departments of the T'ai-yuan Iron and Steel Works (Separate Volume) No 10-7. No 10-$. No 10-9. No No No No No 10-10. 10-11. 10-12. 10-13. 10-14. No No No No No No No 10-15. 10-16. 10-17. 10-21. No 10-22. No 10-23. Flow Sheet of Coal Washing Plant No 1 Flow Sheet of Coal Washing Plant No 2 Flow Sheet of the Coking Plant Coke Conveyance Method Damaged Condition of Poorly Operating Oven Flow Sheet of the Ammonium Sulphate Plant By-products Processing System Layout of Plant Facilities of the Pig-iron Manufac- turing Department Operational Setup of the Pig-iron Manufacturing Departn~ nt Operational Process of the Blast Furnaces Facilities Layout for Open-hearth Process of the T'ai-yuan Iron and Steel Works (Separate Volume) Cross Section of the Open-hearth Furnace Building Structure of the 50-Ton Open-hearth Furnace Gas and Air Ports of the Open-hearth Furnace (Moll Type) Brick-laying Method for the Regenerator of the Open-he arch Furnace Structure of the Ladle Car Structure of the Molten Steel Ladle 19 L SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SELREI Doc No 90225 (10) (PB) No 10-24. Shape of the.Ingot Case (680-kg) for Rimmed Steel No 10-25. Open-hearth Steel Manufacturing Process No 10-26. Layout of Ingot Making (Casting) Facilities No 10-27. Oxygen Supplying Device of the Open-hearth Furnace No 10-28. No 10-29. No 10-30. No 10-31. No 10-32. No 10-33. No 10-34. No 10-35. Na 10-36. No 10-37. No 10-3$. No 10-39. No 10-40. No 10-41. No 10-42. No 10-43. No 10-44. No 10-45 No 10-46. No 10-47? No 10-48. No 10-49. No 10-50. Shape of Steel Ingot From the Open-hearth Furnace Layout of the Electric Furnace Plant Facilities Structural Layout of the Medium and Small Bar Mill S Facilities Layout of the Medium Bar Mill of the T'ai-yuan Iron and Steel Works (Separate Volume) Shape of the Medium Bar Rolls New Heating Furnace and Preheating Apparatus for Medium Bar Mill Preheating Apparatus for the Old Heating Furnace of the Medium Bar Mill Conveyor of the Medium Bar Mill Medium Bar Mill Press Straightener Medium Bar Mill Roller Straightener Medium Bar Rolling Process Layout of Small Bar Mill Facilities Shape of the Small Bar Finishing Roll Small Bar Mill Roll Bearing Installation of the Small Bar Finishing Roll Heating Furnace of the Small Bar Mill Operation of the Suspension Lever for Small Bar Rolling Structure of the Rollgang for the Small Bar Roughing Roll Structure of the Cooling Bed of the Small Bar Mill Winders of the Small Bar Roll Portable Ground Crane Operational Process for Small Bar Rolling Small Bar Roughing Roll Pass and Operational Process 20 SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONALS I SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) No 10-51. Small Bar Finishing Roll Pass and Operational Process Tables No 10-52. No 10-53. No 10-54. No 10-55. No 10-56. No 10-57. No 10-58. No 10-59. No 10-60. No 10--61. No 10-62. No 10-63. No 10-64. No 10-65. No 10-66. No 10-67. No 10-68. No 10-69. No 10-70. No 10-71. No 10-72. No 10-1. No 10-2. Finishing Pass of Roll No 7 Facilities Layout of the Sheet Mill of the T'ai- yu.an Iron and Steel Works (Separate Volume) Cross-section of the Heating Furnace of the Sheet Mill Cross-section of the Foil Sheet Furnace of the Sheet Mill Sheet Roll Coupling Procedure Sheet Roll Three-stage Reduction Gear Structure of the Sheet Mill's Continuous Annealing Furnace Sheet Rolling Operation at the T'ai-yuan Iron and Steel Works Sheet Roughing Roll Operation Cross Section of the Chilled Casting Plant Building Essentials on the Riser in Chilled Roll Casting Layout of Facilities of Power Plant No 3 Water Intake and Water Supply Facilities Organization of the Technical Supervison Section Ericksen Cupping Test Procedure Management Structure of the T'ai-yuan Iron and Steel Works Operational Setup of the Steel Manufacturing De partme nt Housing Plan at KU-CH'ENG-TS'UN Housing Facilities at SHIH-LI-P'U Location of the Yang-ch'uan Ironworks Facilities Layout of the Yang-ch'uan Ironworks Main Equipment of the T' ai-yuan Iron and Steel Works Raw Material Situation of the T'ai-yuan Iron and Steel Works 23 SPECIAL h ANDLING REQE I PEO NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 No 10-3. S.L~.i: _i Itemized Output of Products No 10-1. Changes in Management of the T' ai-yuarn Steel Works No 10-5. No 10-6. No 10-7. No 10-$. No 10-9. No 10-10. No 10-11. No No 10-12. 10-13. Facilities of Coal Washing Plant No 1 Facilities of Coal Washing Plant No2 Iron and Structure and Capacity of Coke Oven No 1 Structure and Capacity of Coke Oven No 2 Composition of Washed Coal Coke Production by Mechanical Ovens Composition and Physical Strength of Coke Produced at the T'ai-yuan Iron and Steel Works Facilities in the Suction Plant of the Coking De partme nt Facilities at the Ammoniun Sulphate Plant of the Coking Department No 10-14. ' Facilities at the Tar Plant of the Coking Depart- ment No 10-15. Facilities at the Benzol Plant of the Coking Department No 10-16. Output of By-products No 10-17. Blast Furnace Equipment No 10-18. Hoisting Apparatus For Blast Furnace No 10-19. Hot Blast Stoves No 10-20. Blowers for Blast Furnace No 10-21. The T'ai-yuan Iron and Steel Works' Purchasing Plan of Iron Ore from Other Provinces for 1953 No 10-22. Amount of Raw Materials Charged into the Blast Furnace s No 10-23. Variation in the Daily Output of Pig Iron (Unit: ton) No 10-24. Variations in the Annual Output of Pig Iron (Unit: ton) No 10-25. Floor Space of the Buildings of the Steel Manu- facturing Department No 10-26. Data on the Open-hearth Furnace Facilities No 10-27. Refractory Materials for the Open-hearth Furnaces 22 I SPECI AL HANDLING BEQL I BED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 S " : r a k? Doc No 90225 (10) (PB) No 10-2$. Gas Producers for the Open-hearth Furnaces No 10-29. Accessories for Open-hearth Steel Manufacture No 10-30. Improvement on Open-hearth Furnace Steel Manufac- turing Equipment No 10-31. Increase in Open-hearth Steel Manufacturing Equipment No 10-32. Amount of Heat Maintained by Producer Gas No 10.33. Distribution of Producer Gas Heat No 10-34. Distribution of Personnel in Open-hearth Furnace Steel Manufacture No 10-35. Variation in the Mixing Ratio of Raw Materials for Open-he arth Stee 1 Manufacture No 10-36. Amount of Charge in Open-hearth Stee1 Manufacture No 10-37. Charging Order of Raw Materials in Open-hearth Steel Manufacture No 10-33. Supply and Demand Plan of Raw Materials for Open- hearth Steel Manufacture No 10-39. Specifications for Carbon Steel Ingot No 10-40. Electric (Furnace) Steel Manufacturing Facilities No 10-41. Production of Steel (crude steel) Manufactured by Electric Furnaces No 10-42. Buildings of the Rolling Department No 10-43, Medium Bar Rolling Facilities No 10-44. Heating Furnace and Other Equi.prr nt of the Medium Bar Mill No 10-45. Accessory of the Medium Bar Mill No 10-46. DetE:ils on Production at the Medium Bar Mill No 10-47. Variations in Products Produced by the Medium Bar Mill No 10-48. Comparison of Time Required for Rieplacerr~nt of Rolls No 10-49. Transition in the Supply of Rollers For the Medium Bar Mill No 10-50. Order List For Medium Rolls at the T ? ai-yuan iron Manufacturing and Mining Office No 10-51. Equipment of the Small Bar Mill No 10-52. Accessory Equipment of the Small Bar Mill 23 [_SPECIAL HANDLING REQC,IRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET No 10-53. Heating Furnace for the Small Bar Mill No 10-54. Improvements of Facilities of the Small Bar Mill No 10-55. Distribution of Key Workers in the Small Bar Mill No 10-56. Changes in Actual Daily Output at the Small Bar Mill No 10-57. Replenishment of Small Bar Rollers No 10-5$. Details of the Sheet Mill No 10-59. Details of Furnace Facilities of the Sheet Mill No 10-60. Details of Accessory Equipment of the Sheet Mill No 10-61. Distribution of Workers in the Sheet Mill No 10-62. Estimated Capacity of Sheet Rolling Facilities No 10-63. Production Plan for Various Products of the Sheet Mill No 10-64. Chilled Casting Equiprrnt No 10-65. Actual Production of Chilled Castings No 10-66. Amount of Refractory Material Consumption No 10-67. Principal Facilities in the T'ai-yuan Power Plant No 3 No 10-6$. Equipment in B*iler Room No 2 No 10-69. Physical Test Equipment No 10-70. Chemical Products No 10-71. Specifications For Coke No 10-72. Specifications For Gypsum No 10-73. Specifications For Carbide No 10-74. Specifications For Coke By-products No 10-75. Specifications For Silica Fire-proof Materials No 1x76. Specifications For Alumina Fire-proof Materials No 10-77 . Specifications For Fire Clay No 10-7$. Specifications For Silica Brick No 1x79 , Specifications For Roll (chilled cast iron) No 10-- 3O. Specifications For Triangle Bars No 10-$1. Specifications For Light Rails 24 ------------ HANDLING REC~LR'L~ 0 RELEASABLE T0- FOREIGN NATIONALS 1 S~'EC~A~. HA~~3 1 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc.No 90225 (10) (PB) No 10-$2. Specifications For Steel Blooms No 10-$3. Specifications For Small Bar Steel Material No 10-$4. Specifications For Medium Bar Steel Material No 10-$5. Specifications For Carbon Steel No 10-$6. Specifications For Pig Iron No 10-$7. Organizational Setup of the Production and Technical Section of the T'ai yuan. Iron and Steel Works No 10-$$. Organizational Setup of the Technical Supervision Section of the T' ai-yuan Iron and Steel Works No 10-$9. Plan on the Work Index of the Blast Furnace in the Pig Iron Department (Plan No 1) No 10-90. Plan on the Technical Requirement in the Pig Iron Department (Plan No 2) No 10-91. Plan on the Quality of Products in the Pig Iron Department (Plan No 3) No 10-92. Plan on the work Index of the Open-hearth Furnace in the Steelmaking Department (Plan No 1) No 10-93. Plan on the Technical Requirement in the Steel- making De partme nt (Plan No 2) No 10-94. Plan on the Quality of Products in the Steelmaking Department (Plan No 3) No 10-95. Monthly Operating Plan for the Steelmaking Depart- ment No 10-96. Base Pay by Position Class at T'ai-yuan Iron and Steel Works No 10-97. Principal Equiprr rt of the Yang-chuan Ironworks No 10-9$. Pig-iron Output at the Yang-chuan Ironworks 25 SECRET LiI;EcfAL HANDLING REQLIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) Chapter Ten. T!ai-yuan Iron and Steel Works (Including tFe Yang-ch'uan Ironworks) I. Outline A. Name of Enterprise T'ai-yuan Iron and Steel Works B. Form of Enterprise and Affiliation It is a state-operated enterprise under the Iron and Steel Industry Control Bureau of the Ministry of Heavy Industry. C. Location It is located east of KU-CH'ENG-TS'UN ( .?~4` ~J4 ) (STC 0657/ 1004/2625), four kilometers from the northern suburbs of TtAI-YUAN, SHANSI Province -- see Chart No 10-1. D. Plant Area It covers an area of over 300,000 tsubo. If the grounds of the attached installations such as the hospital, school and workers' housing are included, the total area will be about 700,000 tsubo. Note: The plant area during the Japanese controlled era was about $0,000 tsubo E. Plant Layout See Chart No 10-2 F. Types of Operations The iron and steel works manufactures pig iron, coke, by-products of coke, and steel. It also carries out rolling, casting and forging operations. G. Type of Works It is engaged in the integrated process of steel manufacture H. Principal Facilities See Table No 10-1 I. Operational System See Chart No 10-3 J. Raw Material Situation See Table No 10-2 K. Itemized Producti6n and destination of Products See Table No 10-3 and Chart No 10-4. 26 S~'ECI AL HANDLING BEQt, I BED N'OT BELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) L. Labor Force In early 1953, the total number of workers exceeded 10,000. Of these, about 2,000 were administration and technical staff members. Note: Total number of workers during the Japanese era was four thousand and several hundred. M. Various Aspects of the Work's Location 1. Geographical aspect a. T'AI-YUAN is located in a small basin (elevation, 1,000 meters) along the middle reaches of the FEN Ho, in the central part of SHANSI Province. It is the seat of the Shansi Provincial People's Government. In the latter part of the first half of 1953, the population of this city was about 350,000. The present goal is to build this city into a city with a population of 1,000,000 through town planning in the future. b. SHANSI Province is separated from HOPEH Province by the T'ai-hsing Mountain Range and from SHANSI Province and HONAN Province by the YELLOW River. These natural boundaries make SHANSI a thorough inland province which lies on a mountaneous plateau with an elevation varying from 600 meters to 3,000 meters. C. In SHANSI Province, the temperature is generally lower than HOPEH Province. The winter is comparatively long owing to the wind which blows from MONGOLIA every year from April to May, but in summer the heat is extremely severe. This is a typical continental climate. The annual rainfall averages only 500 millimeters and below, and the highest rainfall is registered during July and August. The winter is very dry. 2. Transportation aspects The North and South Tungpu lines (total length, $66 kilometers) runs through the province. The North Tungpu Line connects with the Chingpao Line and the Shihtai Line links with the Chinghan Line. The North Tungpu Line and the Shihtai Line are standard gauge lines (width of gauge is 1435 millimeters) but the South Tungpu Line is a narrow gauge line (width of gauge is 1067 millimeters). The North and South Tungpu lines are joined between T'AI-YUAN and YUTZ'U (37?39'N 112?44'E). The conversion of the South Tungpu Line into a standard gauge line and the double tracking of the Shihtai Line are planned under the First Five-Year Plan. 3. Raw material aspects a. Various underground natural resources were found abundantly from the past in SHANSI Province. Particularly, raw materials for the manufacture of iron (such as iron ore, coal, limestone, gypsiyn, manganese, fluorite) and various raw materials for refractory materials were deposited ,bundantly in various parts of the province. The iron or de sits are dispersed over 20 hsiens, such as WU-T'AI, CH'UN-YANG ( ~) ) (STC 2504/7122) , T' AI-YUAN, YANG-CH' UAN, LU AN, etc. It is claimed that the total deposit is 30,000,000 tons. The Yang-ch'uan and Lu-an areas have been famous from the past as pig-iron manufactur- ing centers of SHANSI. 27 L SPECIAL HANDLING HEQLI'BED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Northwest (TAI-YUAN) Steel Mill Northwest (T?AI-YUAN) Yu-~tstai Machinery and Tool Plant Northwest Locomotive Plant Northwest Ironworks Northwest Foundry .Northwest Hydraulic Press Plant 2S Doc No 90225 (10) (PB) It is said that the coal deposits, both anthracite and bituminous are inexhaustible. According to the rudimentary survey conducted by RIHITOHOHEN* in the late 19th Century, the coal deposit was estimated at one hundred and several ten billions of tons. However, the present deposit is said to attain one trillion tons (52 per cent of the coal resources of the nation). Lode outcrops are observed every- where within the province and the Yang-ch'uan and Ta-hung coal mines are famous for these outcrops. It is said that there are also inexhaustible deposits of limestone and gypsum. In addition, there are rich deposits of high grade manganese, fluorite and raw materials for refractory material such as sekihaku silica; dolomite and alumina shale. b. However, the iron ore of SHANSI Province belongs to the pocket ore stratum which is peculiar to this province and it is un- favorable for large scale mechanical mining. In addition, the quality of the ore cannot be considered as being good because the iron content is only 40 to 47 per cent. Even the promising Ting-hsiang ore is a flat ore which is considered unfavorable for the manufacture of pig iron. As a result, Communist CHINA abandoned its plans for large-scale mining in SHANSI Province. Since 1953, Communist CHINA changed its policy so that ore used as raw n.terial by this steel works would be composed almost entirely of ore imported from outside the province. The usage of the ore mined within the province was limited to supplementary selling by the small-scale private miners. There is a possibility that the problem of ore supply will greatly restrict the future development of this steel works. 4. Overall industrial aspect a. SHANSI Province turned its attention to industrial development since the establishment of the prewar YEN Hsi-shan (STC 7051/6932/1472) Government, and in 1922, it distinguished itself as a model province among the provinces of CHINA under the so-called Shansi version of the Monroe Doctrine. Thereafter, for a period of several years, the domestic industries did not show smooth development owing to the wars between the warlords and peoples? revolutions. However, taking advantage of the Ten-Year Economic Construction Plan of SHANSI* Province devised in 192$ and the establishment of the North- west Industrial Company in 1932, an epoch-making expansion of each department in industrial mining was started. The in plants that were either constructed or under construction as affiliated plants of the Northwest Industrial Company before the outbreak of the Japan-China Incident in 1937 were as follows: I__SPECIAL HANDLING REOLIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 % SE'.'1k E Doc No 90225 (10) (PB) (7) Northwest Motor Vehicle Repair Plant ($) Northwest Electrical Plant (9) Northwest Chemmlcal Plant (10) Northwest Coal Mine Plant No 1 (u) Northwest Cement Factory (12) Northwest Ceramic Plant (13) Northwest Leather Factory (14) Northwest Match Factory 0 (15) Northwest Paper Mill (16) Northwest Woolen Fabtic Mill These plants were divided into the fields of light heavy and chemical industries. After the outbreak of the Japan-China Incident, these factories and about 20 affiliated factories of the former Pao-chin Company were placed under the Management of the Hsing-chung Company. With the succeeding establishment of the Shansi Industrial Co, Ltd in 1942, the 36 factories were placed under its administration. b. In general, these factories were concentrated in T'AI-YUAN and its durrounding districts. This indicates that T'AI-YUAN was being developed as an integrated industrial center, although on a small scale, from before the war. Particularly the fact that the machinery industry was developed to some extent in thi s district from before the war made this location a favorable site for the T'ai-yuan Iron and Steel Works. After the end of the war and throughout the Chinese Nationalist period, there were hardly any noteworthy develop- ments on these factories. However, after it came under the control of the Chinese Communists and particularly since the commencement of the First Five-Year Plan, the expansion of the machinery industry in the T'ai-yuan District became very conspicuous. It is important to note, however, that although the new machinery plants that were constructed or were under construction during this period were of great importance and priority from the National standpoint, plans for the basic con- struction of steel works which formed the foundation for the former, were of comparatively small scale. At presant, the reasons for this situation is not definitely known, but it appears that one of the reasons was the limitation caused by the raw material situation which had been mentioned previously. 5. Other aspects It is observed that since the T'ai-yuan Iron and Steel Works is situated within the second line (west of the Ching-han Line) of the so-called national defense zone of Communist CHINA, it commands a relatively favorable position as a national defense industry as compared to the other iron and steel centers presently located on the continent of CHINA. 29 t REQLIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) N. History 1. Outline Civil wars occurred in succession from the latter part of the Ch'ing Dynasty. Each area was controlled by a war lord and the situa- tion was such that only the fittest (strongest) survived. SHANSI Province during 1920 was controlled by General YENi-shan, General HAN Fu-eh'u (STC 3352/1788/3255) controlled SHANTUNG Province beyond NIANG-TZU-KUALA (37?59'N 113o54'E). General YEN advocated the Shansi version of the Monroe Doctrine and strove to expand the provincial power under the banner of "Save the country through construction and production". First of all, YEN aimed at developing the rich underground resources within the province and devised a plan to construct 36 various types of factories with the T'ai-yuan District as the nucleus. This plan was inaugurated in 192$ as a Ten=Year Economic Construction Plan through technical cooperation with GERMANY. The Northwest (T'AI-YUAN) Steel Mill, the predecessor of the present steel works, was constructed in 1935 as a part of this plan and it was a provincially-operated ironworks engaged in the Integrated process of steel manufacture. In November 1937, the T'ai Yuan Steel Mill was taken over by the Japanese Army in the midst of its construction. Thereafter, its construction was continued by the Japanese and by late 1941 the mill commenced full-scale operation on 'olling, steel manufacturing and pig-iron manufacturing. After the end of World War II, the mill was taken over by the Chinese Nationalist Government and the administration of the mill again return to the YEN Shi-shan Government (Shansi Provincial Govern- ment). However, on 19 Apr 49, the mill was taken over by the Chinese Communist Army. With the establishment of the Chinese Peoples' Republic on 1 Oct 49, the mill commenced operation as a state-operated enterprise under the direct jurisdiction of the Iron and Steel Industry Control Bureau of the Ministry of Heavy Industry, the state in which it still remains today. 2. Administrative transformation a. Before the war (1935 to November 1937) (1) Name of enterprise: Northwest (T'ai-yuan) Steel Mill (2) Form of enterprise: operated by SHANSI Province (3) Affiliation: Northwest Industrial Company (1i) Capital: Started with a capital of 2,500,000 yuan (5) Managing executive: P'ENG T'u-hung (STC 1756/ 0960/1738), general manager of the company (6) Operation: facilities under construction; not in operation 30 L SPECIAL HANDLING BEQLIREP DoT BELEASABLE TO FOREIGN ' ATIO' . LS Sc.( Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) b. During the war (November 1937 to August 1945) (1) Japanese Army controlled era (November 1937 to September 1942) (a) Name of enterprise: Shansi Iron Mining Industry Plant No b of the North China Army. (b) Form of enterprise: Army controlled plant (c) Affiliation' Japanese Army; managed by the Hsing-Chung Company. (d) Managing executive: OTA Fuunio ,(~ r L / L president; TAKAHASHI Tetsuzo (s'1 plant superintendent (e) Operation: construction of facilities coin- pleted; integrated process of steel manu- facture (including mining) established (2) Japanese controlled era (October 1942 to August 1945) (a) Name of enterprise: Taiyuan Ironworks (b) Form of enterprise: private corporation (c) (e) (f) Affiliation: Shansi Industrial Co, Ltd (under the control of the North China Development Co, Ltd) Capital: capital of the Shansi Industrial Co, Ltd in October 1942, $0,000,000 yen Managing executive: first president of the company, OTA Fumio; second resident, KAWAMOTO Dai saku (/~J ? 1 "f ) ; ma 11 superintendent, TAKAHASHI Tetsuzo. Operation: integrated process of steel manufacture; commenced small section rolling operation C. After the end of the war (August 1945 to April 1949) (1) Name of enterprise: Tsai-yuan Steel Mill (2) Form of enterprise: operated by SHANSI Province . (3) Affiliation: Northwest Industrial Company (4) Managing executive: P'ENG Ttu-hung, general manager of the company; LIANG Hai-chiao (STC 2733%31$9/4.255), mill superintendent ( 5) Operation: Same as before the war Note: 1. The seizure of the mill by the Chinese Nationalist Government after the end of the war was conducted very smoothly and the 31 -- ----- -- ------ SPECIAL HANDLING REQI; I L ED NOT RELEASABLE TO FOREIGN NATIONALS i SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECFEi Doc No 90225 (10) (PB) administration after the seizure was aimost similar to that of the Japanese era. 2. General manager P'ENG T'u-hu,ng is a graduate of the Waseda University of JAPAN, and was reinstated to the prewar position (general manager). Nearly all of the executives in the various affiliated enterprises of the Northwest Industrial Company during this period were confidents of P' ENG Vu-hung. 3. There were about 130 Japanese (of whom 30 came from the Ching-chin District) detained at this mill after the end of the war and these Japanese were accorded good treatment as technicians. 4. It is claimed that throughout the period before and after the end of World War II, TAKAHASHI Tetsuzo, mill superintendent during Japanese control, had been the outstanding person of the mill from the standpoint of technical, managerial and guiding abilities. At the beginning of the Japan-China Incident, he was despatched from the Pen~cht i-hu Coal and Iron Company whi ch was affiliated to the Okura concern at that tine. In 1937, he took charge of the seizure of this mill. Since then, despite the changes in managerial organization and personnel, he remained as mill superintendent until the end of the war.. Even after the war, he participated in important internal affairs of the mill during the period of Chinese Nationalist Management as well as the early period of the Chinese Communist management. Thereafter, he was relieved of his position as a result of the antirevolu- tionary suppression movement and was sent to YUNG-MIEN (36?42'N 114?43'E) in June 1951. On 28 Oct 52, he passed away as a result of illness. (c) Affiliation: Affiliated with the North China Iron and Steel Company under the jurisdiction of the North China People's Government State-operated Enterprise Department. (d) Managing executives: LAI Chi-fa (STC 6351/ 7139/4099), person in charge of the seizure and control of the company; CHANG P' el-hung (STC 1728/1014/3163), person in charge of the seizure and control of the mill. ( e) Operation: Same as before the war. 32 L aP~CI -L ;AI~DL t~ BEQIA BED NOT BELEAS ABLE TO FOREIGN NATIONALS SECRET d. Period of Chinese Communist control (since April 1949) (1) North China People's Government era (April to September 1949) (a) Name of enterprise: T'ai-yuan Steel Mill (b) Form of enterprise: Public enterprise of Communist CHINA. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) (2) After the establishment of the Central Peoples Government (since October 1949) (a) Name of enterprise: Tsai-yuan Iron and Steel Works (b) Form of enterprise: State-operated enterprise (c) Affiliation: Iron and Steel Industry Control Bureau of the Ministry of Heavy Industry (d) Managing executives: LI Fei-p-ing (STC 2621/2!31/1627), first superintendent (appointed October 1949); PAI Hao (STC 4101/31$1), second superintendent (appointed. October 1952) (e) Operation: Integrated process of steel manufacture (Excluding mining); commenced operation on sheet rolling, electric furnace steel manufacturing and forging Note: 1. In April 1949, the Northwest Industrial Company was seized and placed under the control of the Light and Heavy Industry Seizure and Control Team (headed by LAI Chi-fa) of the T'ai-yuan City Military Control Committee. At that time, the T'ai-yuan Iron and Steel Works was seized and controlled by CW NG P' el-hung, representative of the Army, KUO Chii-ying (STC 6753/1142/2019), deputy representative, and some 10-odd persons. 2. After the seizure by the Chinese Communists; the steel works, as a North China People's Government public enterprise, came under the Affiliation of the North China Iron and Steel Company which was directly controlled by the North China People's Government Public Enterprise Department. 3. With the establishment of the Central Peoplets Government in October 1949, the steel works came under the jurisdiction of the Iron and Steel Industry Control Bureau of the Ministry of Heavy Industry and was renamed the State-operated Ttai- man Iron and Steel Works. 4. The managing staff during Chinese Nationalist control remained in its position even after the Chinese Communists took control, but the actual guiding power was taken away. Thereafter, through purges and antirevolutionary suppression movements the managing staff was either gradually removed or arrested and subjected to thought indoctrination. 3. Alteration of facilities a. In November 1937 when the steel mill was taken over by the Japanese Army, the productive facilities of the steel mill were still incomplete with the exception of the workshop and a part of the power plant. On the whole, 60 to 90 per cent of the steel mill was in the process of construction. 33 ESPECIAL HANDLING BEQLI ED NOT PELEASABLE TO EOPEIGN NATIONALS SECRET 11 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 b. In 1938, after the arrival of Japanese technicians, workers of the steel mill were assembled arid their efforts were concenN traced in the various construction projects. As a result, the power plant facilities (two 5,000 kilowatt generators) within the steel mill was completed in summer 1939. In November of the same year, bla st furnace No 1 (rated capacity, 40 tons) was completed and fired. In July 1940, operation of the coking plant commenced and in August, the - by-product plant was established. Furthermore, in November 1940, blast furnace No 2 (rated capacity, 120 tons) was fired and the manufacture of pig iron went into full operation. Moreover, in September 1941, the open-hearth furnace plant and the medium bar mill commenced operation to bring about the establishment of an integrated process of steel manufac- ture. In late 1943, a small bar mill was constructed as an affiliated plant of the medium bar mill. At about the same time, con- struction of blast furnaces No 3 and No 4 commenced (both were small types with a rated capacity of 40tons).. Owing to the progress of war, steps were taken to meet the sudden increase in the local iron and steel demands, but in late 1944, the furnaces were bombed by the US Air Force stationed in CHINA. As a result, the small furnaces were destroyed by the bombing and the operational efficiency throughout the other depart- ments dropped conspicuously. C. Since the end of the war, there has been no big change in the faciliti es and on the departments of the steel mill throughout the Chinese Nationalist era (operated by SHANSI Province). During this period, the managing authorities adopted measures for improving and in- creasing various facilities in view of strengthening 'the domestic iron and steel self-sustenance standard. However, the supply of necessary materials became difficult following the intensification of the civil war between the Chinese Nationalists and the Chinese Communists, and the work on large-scale projects either did not commence or ceased soon after it commenced. The planning or partial work that had commenced on the main projects were renovations of the blast furnaces and open-hearth furnaces and the construction of a new foundry. d. After seizure by the Chinese Communists, the plan to fully equip and expand the steel works was given priority with the objective of making the steel works the largest integrated iron and steel enterprise in CHINA proper. This steel works was favored by the fact that it was an inland iron manufacturing site. First of all, the pig- iron manufacturing facilities were mechanized in 1951, and in 1952, steel manufacturing plant (open-hearth furnaces and electric furnaces), small bar mill, sheet mill, coke plant, by-products plant, workshops, and refractory material plant were newly constructed or renovated. After 1953, the preparation for the First Five-Year Plan was undertaken. Furthermore, in spring 1953, basic constructions for the electric fur- nace and foundry were in progress. During the foregoing procedure, the coastal iron manufac- turing facilities from SHANGHAI and TANG-SHAN were gradually being transferred to this works with the intensification of the Korean War. This move by the Chinese Communists can be said to be worthy of atten- tion in that it reveals the importance of this steel works from the standpoint of its location and a part of the Chinese Communist policy trend toward the construction of inland based iron and steel industry. 34 SECRET S'ECIALANILING REQLIRED NOT RELEASABLE TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) 4. Production changes a. Prior to the outbreak of the Japan-China Incident, this steel mill was not in operation. b. In August 1911, around the time the integrated pro- cess of steel manufacture was established, the production capacities of the facilities were as follows: (1) Pig iron: 60,000 tons a year (2) Steel ingot: 50,000 tons a year (3) Steel stock: 45,000 tons a year In 1942 and 1943, each department was operating in full under normal conditions. The peak production year before the end of the war was 1942. C. Since the seizure of the steel mill by the Chinese Nationalist authorities was conducted in an orderly manner after the war's end, the transfer of control of each department was made while normal operation was continued, except for the coking furnace which stopped operating for several days. However, after the wheat harvest operation of spring 194, the pressure of the Chinese Communist Army suddenly increased. In autumn of the same.year, blast furnace No 2 ceased operating because of the lack of raw materials and only blast furnace No 1 was barely able to continue its operation. d. After the seizure by the Chinese Communists, the new management was busily occupied for a time with familiarizing itself with the operation of the steel works and with recalling of the workers to the works, reorganizing the workers, and giving political and ideological training to the workers. In the meantime, an irregular operation was carried on for training purposes. However, since the raw material situation turned favorable thereafter, efforts were directed toward a full scale rehabilitation of facilities and normalization of operation from August to September 1949? It seemed that the production activities in the early stage was mainly aimed at the restoration of production to the level of the past peak and at the technical training of workers. However, with the improvement of production thereafter, preparations were made for the First Five-Year Plan commencing from 1953 by unfolding various forms of socialistic production struggles and by gradually adopting the opera- tional system of the USSR. II. Coke and By-products Department A. History 1. From the beginning of the construction of the Tt ai-yuan Steel Mill before the war, plans had already been drawn up for the con- struction of the coking plant as a priority had for establishing an integrated process of steel manufacture. Orders for the blueprint of coke oven No 1 and for the coking plant had ready been placed with a German trading company before the outbreak of the Japan-China Incident. 35 SPECIAL HANDLING BEOLIBED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) 2. By the time of the occupation by the Japanese Army, the construction of facilities had progressed to the fallowing extent: a. Coking unit: 90 per cent completed. b. By-products plant: 60 to $0 per cent completed, with the exception of the gas suction facilities. 3. Facilities under construction consisted of coal washing, coke manufacturing, suction and distribution of gas, gas liquid treating, and by-product recovery facilities. As for the scale, these facilities were capable of handling 360 tons of raw rterial a day that were charged into the 36 ovens of the coking unit. 4. With the firing of blast furnace No 1 about that time, the completion of the coking unit was an urgent matter. For the time being, coke produced by the heap carbonization method at HSIEN-KANG-CHEN (3$"53tN 112?32'E) (130 kilometers north of T'AI-YUAN) can the North Tungpu Line was used in blast furnace No 1-. However, since the raw material for this coke consisted of unwashed coal, the ash content was high and affected the output of pig iron. Therefore, raising the quality of coke through the use of mechanical oven became an urgent matter. 5. Thus, the construction of the coke plant progressed on a priority basis. The plants completed in 1940 and placed in operation were as follows: a. Coke oven No 1; Completed in July b. Ammonium sulphate plant and tar plant: Completed in August C. Benzol plant: Completed in September 6. The superior coking coal produced in WU-TA'I H sien (130 kilometers NNE of T'AI-YUAN) seemed to have been anticipated for use as raw material in to the prewar plan. However, owing to the aggravation of the lack of public peace and order since coming under Japanese control? and moreover to the lack of inconvenient transportation, the use of raw coal produced in HSIEN-KANG-CHEN was decided upon and large-scale mining was conducted. But, this coal was easily weathered and at the same time, even the bony coal (mostly clay shale) became pulverized after about one month of storage. As a result of operations, it became clear that the lowering of ash content could not be easily accomplished even though the coal,was washed with the facilities of this plant. Therefore, the use of Hsien-kang-chen. Coal was suspended after wasting a tremendous amount of labor and expense. After making a survey of the coal to be used as raw material, the coking coal produced throughout the area along the South Tungpu Line was selected. The main source of supply was the Fu-Chia-t' an coal mine (130 kilometers southwest of T'AI-YUAN) operated by the Shansi Coal Mining Co, Ltd. At the same time coal mined privately at CHIEH- HSIU (36?5$'N 111?54'E), HUNG-TUNG (36?15'N 111?42'E), HSIAO-I (37?05'N 111?47'E) and NAN-KUAN-CHEN (STC 05$9/7070/6966) (all these areas are located along the South Tungpu Line) were also purchased and used. Under Japanese management, the actual production of superior coke commenced after spring 1941. 36 SPECIAL HANDLING HEQLAHEB NOT }ELEASAELE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (1C) (PB) 7. At the beginning of the operation, there was a shortage of skilled workers particularly in heating work, and a great turnover in workers was caused by strifes among workers of different plants. As a result, normal operation began after late 1941. Thereafter, pro- duction gradually increased because of the gradual increase of Japanese employees and as a result of their guidance. In 1942, the highest pro- duction result was attained. $. In 1944, when two srnafl blast furnaces (rated capacity of one furnace, 40 tons) were additionally installed, the installation of mechanical ovens was postponed and 50 clamp burning ovens were in- stalled instead in the open area within the steel works (later, the number of clamp burning ovens were increased to 90). Due to the shortage of coal-washing facilities at that time, unwashed coal was used. There- fore, the ash content was high and the coke extraction rate was poor, and the operational result of the small blast furnaces was unsatisfactory. In the latter part of 1944, these furnaces were bombed by the US Air Force stationed in CHINA and their operation ceased. 9. Aside from the above construction projects, plans were drawn up for the construction of coal washing plant No 2 and coke oven No 2, and the expansion of the by-products plant. However, the project hardly progressed owing to material shortages caused by the .war and the deterioration of public peace and order. Immediately before the end of the war, only the foundations for the coal tower and coke oven No 2 had been completed. The new construction plan called for the construc- tion of one battery of coke ovens (daily capacity of lump coke, 200 tons) and one coal washer (daily capacity of clean coal, 1,000 tons). 10.. During the beginning of Chinese Nationalist control at the war's end, the operation result was very poor because of the re- patriation of a large number of Japanese workers and because of the ill- feeling expressed toward the Japanese technicians who remained behind. Thereafter, owing to instructions from higher authorities and increased confidence in the technical skill of the Japanese, production gradually began to recover. However, with the intensification of the civil war between the Chinese Nationalists and Chinese Communists which broke out soon thereafter, production again started to decline. During this period plans for the construction of facilities which had been drawn up during the Japanese management were put into execution. However, only the upper slab of the base for coke oven No 2 had been constructed when the entire construction operation ceased following the final attack by the Chinese Communist Army on 19 Apr 49. 11. Rehabilitation work commenced inmiediately after the Chinese Communists came into control and in October 1949 operation of the entire plant was achieved. In February 1950, the Construction Engineering Office was newly established and the production department and the construction department were set up separately. The coking department was entrusted with the construction work on the unfinished coal washing plant No 2 (daily capacity of clean coal, 1,200 tons), the coking plant No 2 (daily capacity of lump coke, 400 tons) and the attached gas washing facilities. In April of the same year, brick- laying of the coke oven commenced and was completed in October. In late 1950, engineering work for the foundation of the coal washing plant was stressed, but the progress of the project slowed down because of the effect of the Korean War. The construction of both plants was finally completed in September 1952? 37 SPECIAL HANDLING REQLIRER NOT BELEASABLE TO FOBEIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECFent of the ash specification. Lowering of the recovery rate through the washing process, however, is prevented by perfecting the facilities for the recovery of the coal slurry. b. Consideration is being given to raise the dryness of the processed coal and at the same time the difficulty in completely extracting moisture contents is being covered by increasing the charg- ing quantity of coal (11 tons of coal for the normal 10 tons). c a Gas pressure and re gulat ion r o f temperature in the coke oven (1) Pressure for supplying the heating gas: 60 to 100 millimeters on the water column (2) The temperature of combustion chamber: about 1,250 degrees Centigrade ( 3) The temperature of the carbonization chamber: 1,000 to 1,100 degrees Centigrade (4) The temperature of gas which passed through the regenerator is about 300 degrees Centigrade and the gas is sucked into the chimney flue at a pressure of about five millimeters on the water column. (5) 10. Raw materials a. Consumption of raw coal -- see Table No 10-10. b. Supply sources of raw coal (1) The temperature of waste gas in the chimney is about 230 degrees Centigrade and the absorption pressure is about 15 millimeters on the water column. Japanese era Fu-chia-t'an Coal and Hsi-shan Coal of the Shansi Coal Mining Office were mainly used. Also, coal from private mines such as the Chieh-hs iu, Hung-tung, Hs iao-i, and Nan-kuan- chen mines along the South T'ung-p'u Line was occasionally used. (2) Chinese Communist era Fu-chia-t' an Coal, which is a superior coking coal, and Hsi-shan Coal, which is a semicoking coal, are mixed and used.. Calculating from the planned output of coke for 1953, the amount of raw coal needed for that year was about 44 i__SPECIAL HANDLING EEQLI BE0 NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) 4$0 OQO tons. Of this amount, the consumption of 'u-chia-t' an Coal and Hsi-shan Coal is estimated to have been 216,000 tons and 264,000..ton5, respectively. Note : Ta-'t'ung Coal is widely used for general purposes such as for power generation and for the gas producers. c. Supply and demand of raw coal , At the end of the first quarter of 1953, the supply and demand of raw coal was generally balanced and there was no particular shortage. d. Transportation of raw coal (1) Hsi-shan Coal is transported from PAI-CHIA- CHUANG to this iron and steel works over the standard gauge railroad for a distance of about 20 kilometers by way of the Hsin-ch'eng Railroad Station. (2) Fu-chia-t'an Coal is transported to this iron and steel works over the South Tung-p'u Line (narrow gauge) for a distance of about 200 kilomete rs by way of the T' ai-Yuan North St at ion . e. Proportion of raw coal (1) Hsi-span Coal (semicoking coal): 55 per cent (2) Fu-chia-t'an Coal (superior coking coal): 45 per cent f. Amount of raw coal charged During the Japanese era, the amount of raw coal charged into each oven was 10 tons, in accordance with the rated capacity. After the Chinese Communists took control, it was gradually increased for the purpose of higher production. In 1951 It was increased 10.5 tons and after 1952, it was increased to 11 tons, which became the standard amount to be charged. 11. Output of washed coal a. Annual output -- see Table No 10-10. From September 1952, coal washer No 2 was put into operation and the output of washed coal was remarkably increased. Coal washer No 1 has not been in operation since then. b. Destination of washed coal It is mostly used for coke ovens within this iron washer steel works. Since coal washer No 1 was out of operation, coal No 2 has been taking care of the washed coal for both coke ovens No 1 and No 2. A very limited amount of surplus washed coal is being pro- cessed by heap carbonization at the by-products plant for outside sales. 45 LSPECIAL HANDLING REQLIREB NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) Japanese era The daily output of lump coke from coke oven No 1 was about 230 tons. mlxe l the workers as fuel for domestic use. However, most of the bony coal has been thrown away. C. Composition of washed coal -- see Table No 10-9. d. Recovery rate of washed coal Prior to Chinese Communist control, the recovery rate of washed coal was about $0 per cent because the sp ecifications were low. SEC~;~ r for boiler No 2 and has also been distributed to d into the fue After late 1951 following Chinese Communist control. the specifications were raised and as a result, the recovery rate temporarily dropped to 65 to 70 per cent. However, with the raising of the quality of raw coal and recovery of the coal slurry, the recovery rate soon jumped to about $5 per cent. 12. Coke production a. Daily output (1) 10 tons x 0.6~ - 0.70 x 36 x24 hrs x 90 per cent 22$ to 237 tons Amount ' Coke Number Coking \ Yield rate of charged yield of frequency lump coke to each ovens in one oven day (2) Chinese Communist era The planned daily output for 1953 is 450 tons from coke oven No 1 and 37~ tons from coke oven No 2, making a total of 82~ tons. (a) Coke oven No 1 . 11 tons x~. $ x 36 x 24 hours x 0.95 1+50 tons .- ?" 1s Amount Recovery / charged rate Number Coking N. Yield rate to each of ovens frequency in lump coke oven a day (b) Coke oven No 2 11 tons x 0.7~ x 30 x Amount Recovery charged to rate each oven 24 hrs 1 Number of ovens 24 hours x 0.92 37C tons 15 hours N. Coking Yield rate of frequency lump coke in a day SPECIAL HANDLING REQu I RED NOT RELEASABLE TO FOREIGN NATIONALS I l SECRET From the Japanese era, a part of the bony coal has been Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 .Doc No 90225 (10) (PB) ~ L 4' b. Annual output (1) Mechanical ovens -- see Table Na 10-10. In considering the output of coke oven No 1 which has been in operation from the Japanese era, its planned output for 1953 was about twice (159,726 tons) the output of the peak year ($2,530 tons of lump coke in 1942) in prewar days. The planned output for 1953 was a total of 290,000 tons of lump coke for coke ovens No 1 and No 2. The breakdown had been computed as follows: (a) Coke oven No 1 11 tons x 36 x24 hours x 365 x 99 per cent x ($0 per cent - 5 per cent) 16 ours Amount Number Coking Number Operation Recovery Rate of fine charged of fre- of efficiency rate coke ovens quency days ma in the day calendar year s. 159,726 tons (b) Coke oven No 2 11 tons x 30 x 24 hours x 365 x 99.2 per cent x (77 per cent 8 per cent) 15 hours Amount Number Coking Number Operation Recovery rate Rate of charged of fre- of efficiency fine coke ovens quency days ma in the day calendar year 131,4 tons Note: To be exact, the final figures shown above should be multiplied by the percentage of the products meeting specifications. (2) C lamp burning ovens Since there was a shortage of lump coke before the war's end, about 15,000 tons of clamp coke was produced from unwashed coal every year. However, following Chinese Communist control, a very limited amount of clamp coke is being produced from washed coal at the by-'products plant. The actual output of clamp coke in 1952 was about 2,400 tons. C. Destination of coke (1) Throughout the Japanese era and the early phase of Chinese Communist control, coke output was generally insufficient. The entire coke pro- duced here was therefore used within this iron and steel works. 47 4 SPECIAL HANDLING REQLIBED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 "d '- E K - ~ Doc No 90225 (10) (PB) (2) During the period from 1950 to 1951 a part of the coke was occasionally shipped to SHIH- CHING-SHAI't and SHANGHAI. However, this was only for a short period and it was soon dis- continued. (:3) (4) Following the comn>encement of operation of coke oven No 2 in September 1952, there was a surplus in the coke supply and a certain amount of coke was sold to the outside. After September of that year coke was shipped to the outside at a rate of one train a day, composed of ten 30-ton freight cars. During the period from September to December of that year, the amount of coke sold to the outside reached 30,000 to 40,000 tons and it was mainly sent to the Hsuan-hua Pig-iron Manufacturing Plant. The amount of coke sold to the outside in 1953 was about 100,000 tons and it was reported that coke was shipped to the pig-iron manufac- turing plants in HSUAN-HUA and YANG-CH' UAN and also to various mills in T' AI-YUAN. It seems that a certain amount of coke was also shipped to the Shih-thing-shan Iron and Steel Works . Coke breeze is consumed at this steel works as f ue 1 for sintering fine ore. d. Quality of coke -- see Table No 10-11. (1) After the Chinese Communists took control, both composition and strength of coke have been greatly improved. The ash content has been particularly low and in 1953, the ash content of coke used for blast furnaces was less than 13 pe r ce nt . Owing to h igh-tempe rature d is- tillation, the coke strength has been raised and its hardness has been sornwhat increased. However, the porosity has been somewhat lessened. The size of coke produced is generally 100 to 150 millims to rs. (2) Poor quality coke which was produced during the Japanese era and the Chinese Nationalist era was dumped in piles about four to five resters high within this steel works and until the end of the first quarter of 1953 it was distributed to the employees as domestic fuel. e. Percentage of products meeting specification (1) Prior to Chinese Communist control, there was a considerable amount of lump coke which was rejected as fuel for blast furnaces. The reason why the pig iron output of blast fur- naces was not standardized at that time and was generally poor is believed to be largely because of the fact that poor quality coke was used. 48 SPECIAL HANDLING REQI I RED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) (2) Since the specifications of coke were strictly adhered to since Chinese Communist control, the percentage of rejects was greatly lowered. All the products of ovens which produced re- jected coke are discarded and are not used as fuel for blast furnaces. f. Coking time (from charging to drawing) Prior to Chinese Communist control, the coking time re- quired 24 hours. However, since Chinese Corrnnunist control) it has been considerably shortened. (1) In 1952 (actual result) (a) Coke oven No 1: 17 hours (b) Coke oven No 2: 15 to 16 hours (2) In 1953 (planned) ( a ) Coke oven No 1: 16 hours (b) Coke oven No 2: 15 hours g. Operating rate Prior to Chinese Communist control, there were three inefficient ovens but there were no inefficient ovens under Chinese Communist control. The planned operation rate for 1953 was 99 per cent for coke oven No 1 and 99h2 per cent for coke oven No 2. h. Percentage of coke breeze The planned percentage of coke breeze for 1953 was five per cent for coke oven No 1 and eight per cent for coke oven No 2. is Recovery rate (yield rate) In the 1953 plan, the recovery rate of coke for the amount of coal charged was $0 per cent for coke oven No 1 and 77 per cent for coke oven No 2. Compared to the 66.5 per cent recovery rate (lump coke) prior to Chinese Communist control, the recovery rate for 1953 is a considerable improvenent even when the percentage of coke breeze is subtracted. 13. Repair of coke ovens a. Life span of a coke oven The life span of a coke oven varies according to its type. Under normal operation (about 90 per cent of the rated capacity) it is possible for a coke oven to be used for 15 years. Coke oven No 1 was initially fired in July 1940 and had been in use for 15 years by mid-1955? By spring 1953, this oven had considerably deteriorated. 49 SPE~I A . HANDLING REQt1 HEO NO x RELEASABLE TO F0?EI GAT N TIONA L SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET .Doc No 90225 (10) (PB) b. Repair of cold coke oven Repairs after ovens have cooled differ with the degree of damages. Past repairs made at this steel works are as follows (1) At the end of World War II Since shipment of coal was cut off at the end of World War II, the ovens were deliberately cooled. However, the number of cracks on the walls caused by contraction was very limited. Three ovens were operating poorly even before the ovens were cooled; therefore, it was de- cided that they would be repaired on this oc- casion. The time required for coating all the furnace walls and re lining the bricks of the three ovens (carbonization chambers and re- generators) was one month during which period a total of about 450 workers was used. (2) At the time of seizure by the Chinese ComMUnists Since this plant was located directly in the center of the fighting during the Chinese civil war, and also because of the fleeing of the employees, the plant was forced to shut down operation, which resulted in the rapid cooling of the ovens. However, since rehabi- litation work was carried out even before the ovens were completely cooled, there were no serious damages. Note : The three poorly operating ovens, which existed from the eapane~ due era, initially produced a larger amount of coke breeze the poor quality coal used as raw material. Consequently, the coke could not be withdrawn by means of a coke pusher. A coke pusher was used after about 1.5 to two meters of coke were dug out from both sides of the ovens by manpower (known as "oven digging"), Since this was frequently repeated, the oven walls on both sides became cool and created cracks. The central por- d tion became concave because of the great resistance confronts while coke was being withdrawn by means of a coke pusher e of the also caused ovens on both sides to bend. An above case is shown on Chart No 10-11. Chemical Plant 1. Affiliation and number of plants a. Affiliation The Chemical Plant is affiliated with the Coking Depart- ment of the Production Office of the Ttai-yuan Iron and Steel Works b. Number of plants: four (end of the first quarter of 1953) (1) Suction plant (2) Ammonium sulphate plant S ~ECI A . HANDLING REQU FEO NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) Tar plant (includes extraction of naphthalene) Benzol plant These four plants are set up in such a way that an inte- grated chemical synthesis operation can be carried out. 2. Operations Suction plant It draws the gas from the coke ovens and extracts water and tar contents from the gas. Then after the by-products are re- covered, the gas is distributed to the coke ovens, rolling mills, and boilers for heating purposes. b. Ammonium sulphate plant The water content which was obtained by cooling the gas from the coke ovens is fractionated and made into condensed. liquid- ammonia which is passed through chemical reactions and made into ammonium sulphate . C. Tar plant Tar is distilled and separated into liquid-ammonia, light oil, middle oil, heavy oil, crude naphthalene, crude anthracene, pitch and others, d. Benzol plant Benzol is drawn out from the gas in light oil. This light oil is then fractionally distilled to yield benzol. 3. Equipment a. Disposition of plant facilities -- see Chart No 10-6. b. Equipment at the suction plant -- see Table No 10-12. c. Equiprr~nt at the ammonium sulphate plant -- see Table No 10-13. d. Equipment at the tar plant -- see Table No 10-14. e. Equiprr~nt at the Benzol plant -- see Table No 10-15. 4, Improvements and increase in facilities a. Gas suction and gas scrubbing equipment for coke oven No 2 The gas suction and gas scrubbing equipmnt are of the same design as those for coke oven No 1.. One set of these facilities was additionally installed. Of these facilities, the 2.5-inch gas pipe was replaced by a three-inch pipe to increase the cooling volume of the gas coolers. At the same time, large pumps for gas suction were installed in order to supply gas to the rolling mill? 51 SPECIAL HANDLING REQIIHEO NOT BELEASAELE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) The 250-horsepower motors for the gas suction machines were unused motors which were brought from the Pen-ch'i-hu C oaal ofdthe Iron Company during the Japanese era. Along with this transfer motors, the 41-horsepower motor of the gas suction machine for coke oven No 1 was replaced by a 150-horsepower motor. Consideration is being given for increasing the capacity of other facilities in com- parison with the capacity of auxiliary facilities for coke oven No 1 and to cope with the demand for higher production. b. By-products plant Since September 1952, the by-products from coke oven No 2 were tentatively sent and processed at the existing by-products nplan . However, owing to its limited capaclof, buildings additionally were under installing co eight tion in spring 1953 for the purpose crystallization tanks at the tar plant. Also, two or three additional oil coolers (spray system) were then under construction at the bentol plant. 5. Coordination of facilities The by-products processing facilities under Japanese manage- ment were designed to cope with an output of 70,000 tons of pig iron a year and 360 tons of raw materials charged into coke ovens dur fgc,oal the period of 24 hours.. On the assumption that, for the amount charged, the standard production rate of armmonium sulphate is one per cent, tar is five per cant, benzol is 0.7 per cent and crude naphtha- lene is six per cent of the production rate of tar, (refined products are 65 per cent of crude products), it seems that the facilities capable of a certain amount of surplus production. However, following the additional installation of coke oven No 2 in September 1952, the facilities were no longer capable of pro- cessing all the by-products and moreover existing facilities in general were in a deteriorated condition. Consequently, the lack of balance in the facilities became conspicuous. To compensate for this short-- coming, an expansion of the byproducts plant was planned in spring - 1953? However, the execution of this plan was then expected to take place during the period of the second basic construction phase (the, second half of the First Five-Year Plan) of this iron and steel works. 6. Operational methods a. Suction plant -- see Chart No 10-9. (1) Condensation and separation of water and tar The gas produced in the coke ovens has a considerably high temperature and also con- tains a large amount of water and tar. This gas is accumulated in the dry main, cooled by liquid ammonia, and then indirectly cooled by gas coolers after passing through the suction main. During this process, liquids are re- moved by means of seal pots and the gas is condensed and separated by means of coolers and other apparatus, 52 SPECIAL HANDLING REQLIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SE{~IZ CT Doc No 90225 (10) (PB) (2) Secondary recovery of tar The gas, which was condensed and separated, is cooled by the coolers. It is passed through tar extractor by means of a gas exhauster and is again sent to a tar extractor where the re- maining tar is removed, (3) Recovery of ammonia and benzol The gas which has been passed through the tar extractor twice is sent to the ammoniascrub- bers where the ammonia content is recovered then sent to the benzol scrubbers where the benzol content is recovered. (4) Regeneration of the gas for heating purposes After recovering all the by-products, most of the gas is used as heating gas for ovens, coke for heating furnaces of the rolling ll, for tar distillation, and for chemical analysis. (5) Recirculation of liquid ammonia of the dry maul The liquid ammonia from the dry main is passed to the separating tank where it is separated from the tar. It is then sent back to the dry main by pumps and reused. (6) Recovered water of the gas coolers Water which was used in the gas coolers is sprayed and cooled at the cooling tower and recirculated into the gas coolers. b. Ammonium sulphate plant -- see Chart No 10-12. (1) Processing n~ thod This is the only plant utilizing the "gypsum method" in the Orient. The semidirect method has been adopted in JAPAN and the sulphurous acid method is used at the plant of the former Manchut' ia Chemical Co, Ltd in DAIREN. The method now adopted in JAPAN should be regarded as the saturation method and must use sul- phuric acid. It is reported that in SHANSI Province there is a comparatively limited amount of sulphuric acid resources (although surveys on natural re- sources are still inadequate) but there is an inexhaustible deposit of gypsum, which can be used as substitute for sulphuric acid. There- fore, it is conceivable that this plant adopted the gypsum method as in the case of RM.ANY. 53 SPECIAL HANDLING REQI I RED NOT nELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SC t_ ~ "s _ 1 Doc No 90225 (10) (PB) The finished product based on this method is definitely neutral. Therefore, there is no necessity for neutralization and its purity is more than 99 per cent. Compared with the saturation method, the facilities used in this method seem to be fairly complicated but the containers do not have to be made entirely acid proof. (2) Condensation and separation by coolers The gas produced in coke ovens is passed through the suction main to the gas coolers. When the temperature of the gas is reduced to about 35 degrees centigrade, most of the tar and water contained in the gas are condensed. On this occasion, the water absorbs about 30 per cent of the ammonia in the gas and thereby forms liquid ammonia. The condensed tar and liquid ammonia are se- parated by specific gravity (tar, 1.2; liquid ammonia, 1.0). Subsequently, tar is sent to the tar plant and liquid ammonia is distilled by ammonia stills at the ammonium sulphate plant. (3) (4) Recovery by ammonia scrubbers After recovering the tar and liquid a:imonia by means of coolers, the gas is passed to the gas exhauster, then to the tar extractor and finally to the cooler. Here, the remaining tar which was not extracted during the initial process through the primary coolers and the tar extractor installed in front of the gas exhauster is removed. Subsequently, the gas is led to the ammonia scrubbers where the gas is scrubbed through the cold water sprinkling system. Thus, the remaining ammonia in the gas is recovered and naphthalene is also re- moved at the same time. Formation of concentrated liquid ammonia The above liquid ammonia merely contains about 0.5 per cent of ammonia. Therefore, a limited amount of this liquid ammonia is charged into the still and the still temperature is main- tained at 100 degrees Centigrade by forcing steam into the still from its bottom. (Prior to Chinese Communist control, both liquid lime and steam were used) . The water is removed and concentrated liquid ammonia is formed. The concentration of liquid ammonia is con- sidered most suitable when it is at 10 to 12 per cent for the purpose of the following pro- ces3ing operation. 54 i__SPECIAL HANDLING REQI;IRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) (5) Reaction by reactor The reactor is a container which is equipped with an agitator inside and which has a conical top and a cylindrical bottom. The upper por- tion consists of two layers The concentrated liquid ammonia is charged into this reactor and a reaction is obtained by forcing carbon dioxide into the reactor from its bottom and charging powdered gypsum from the top while the concentrated liquid ammonia is being stirred. As the reaction progresses, the temperature rises somewhat, therefore the reactor must be cooled and regulated to maintain a constant temperature of 45 to 50 degrees Centigrade. It is believed that during this proce ss, arrr- monium sulphate is not formulated directly, but that ammonium carbonate is first formed from which ammonium sulphate is then formulated. Expressed in equation form, the reaction is believed to be as follows: 2NH3 - H2O + CO2 -(42 2 CO3 ( NHS,) 2C03 -I- CaSO4 --* (CN4) 2SO4 Y CaCO3 (b) Separation by filter In this react1o_7, the degree of solubility of ammonium sulphate is high but the degree of solubility of calcium carbonate is extremely low. Consequently, the ammonium sulphate re- mains liquefied while calcium carbonate forms a precipitate. This mixture is passed through a vacuum filter and the calcium carbonate pre- cipitate is filtered out from the ammonium sulphate solution. (7) Crystallization of ammonium sulphate The filtered ammonium sulphate solution is sent through the preheater to the vacuum still where the ammonium sulphate is crystallized. The crystalline ammonium sulphate is accumulated in the ammonium sulphate collector, then placed in the centrifugal separator which completely separates the crystals from the basic liquid. Crystals of anuTionium sulphate. are dried in the drying room. C. Ter plant-- see Chart No 10-13. (1) Preheating by heat exchanger The tar withdrawn from tar tanks is first sent to the primary heat exchanger. A hose tube is installed in the tank of the heat exchanger and warm distilled gas from the intermittent 55 SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PP) (2) The Cold stills flows through this hose tube. tar which is to be distilled in the following tube process flows on the outside of the hose and is thus preheated. Since the distilled gas from the stills has been heated to a ter pe rature of 100 to 300 degrees Centigrade, the tar is automatica:ay heated to over 100 de- grees Centigrade. Consequently, the liquid ammonia and a part of the light oil is eva- porated and anhydrous tar is formed Distillation method and temperature The anhydrous tar is charged into the inter- mittent still which is gas-heated (handofiring of coal is also possible) from the b The tar is gradually heated to remove its oil content, leavint, only pitch at the end. In the latter phase of distillation, steam is blown into the still to aid the distillation o~ lows The as distillation temperature is (a) Liquid ammonia: up to 100 degrees Centi- grade (b) Light oil: 100 to 170 degrees Centigrade (c) Middle oilo 170 to 270 degrees Centigradh (d) Heavy oil: over 270 degrees Centigrade It takes about 30 hours to distill a 20-ton t (3) (4) (5) ion still. Consequently, the dally distilla output of two intermittent stills is 30 tons. Regulation of distillation period The period of distillation is regulated according to the melting point of pitch. In the event that soft pitch is desired, dis- tillation is shortened to leave a certtainhis amount of oil content in the pitch. plant, there is a very limited demand for soft pitch and hard pitch is mainly produced to in- crease the output of oil (creosote oil) e for recovering benzol. Pitch production After distillation, the remaining pitch is cooled placed in the pitch cooler. rthen it has somewhat, it is drawn into the pitch bayand? naturally cooled and hardened. When it i be sold to other enterprises, it is dug and loaded onto freight cars. Extraction of middle oil and heavy oil The light oil, midc.le oil, and heavy oil from stills are somewhat cooled by the secondary 56 ` --- SPECIAL HANDLING BEGS IRED NOT RELEASABLE TO FOREIGN NATIONALS ' .---- SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) %.7 4. J i\ _ heat exchanger and again cooled by coolers. These oils are liquefied, accumulated in re- ceivers`, and sent to their respective crys- tallization tanks. These oils, are naturally cooled for several days at their respective crystallization tanks. Naphthalene is ex- tracted from the middle oil and crystallized anthracene is extracted from the heavy oil. The oil content is sent back to their respec- tive tanks. In separating crystals, the simple sublimation oven is used and the crystals are indirectly sublimated (a phenomenon to directly evaporate solid elements) by steam. Following separation of crystals, the heavy oil is further processed by the filter press to remove the residue anthracene and is then sent to tanks. (b) Separation of liquid ammonia and light oil The liquid ammonia and light oil, which were evaporated in the stills and the primary heat exchanger, are cooled and separated by their own separators. d. Benzol plant see Chart No 10-13. (1) Recovery method In recovering benzol, there are the t'ga_s cooling method", "absorption method by creosote oil", and "absorption method". At this plant, the oil scrubbing method with creosote oil is adopted. That is, the gas which had passed through the ammonia scrubbers is sent to the benzol scrubbers and 90 per cent of the benzol in the gas is absorbed through the creosote-oil spray system. This oil which is called rich of contains two to five per cent benzol, therefore it is distilled to ex- tract the benzol. (2) Extraction of crude benzol The rich oil is first heated at the heat ex- changer by the waste oil returned from the light-oil still. Then, it is led to the pre- heater, indirectly heated to over 125 degrees Centigrade by steam, and led to the light-oil still. In the light-oil still, if the tenr- perature of waste oil at its outlet is main- tained at more than 105 degrees Centigrade, the benzol evaporates from the top of the still together with the steam. The compound of ben- zol and water which had evaporated from the light-oil still is passed to the dephlegn~ter where the oil and water are separated. Subse- quently, it is sent to the seiniproces ping still 57 LSPECIAL HANDLING REQLIDED NOT 1ELEASAFLE TO FOREIGN NATIONALS SECRET 1 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PH) (3) and further distilled to extract the crude benzol. In the semiprocessing still, it is indirectly distilled by steam to a temperature of about 11+0 degrees Centigrade and the formu- lated distillate is tentatively sent through the cooler to the tank. This crude benzol is a compound of benzene, toluene, and. xylolhydro'- carbon n contains carbon disulphide, unsaturated of pyridine and other chemical op unds. Extraction of refined benzol In purifying crude benzol, the common method was to remove the impurities by washing crude benzol with concentrated sulphuric acid and sodium hydroxide. This plant is equipped with facilities to carry out the above process but the facilities have not been used to this date from the Japanese era. This plant is merely engaged in producing motor benzol which is used as a substitute fuel. Operation o the refining s bll is the same as that of the s~miprocessing still. Howev?r, before the distillation s,s completed, steam is directly blown into the still merely to aid the distillation. (4) Extraction of toluene Fractional distillation of toluene was once commenced in the latter phase of the Japanese era because of the need for TNT. However, pure toluenc2 could not be recovered and only crude toluene of about 7J per cent purity was extracted. Following Chinese Communist con- trol, fractional distillation of toluene has not been conducted. (5) Disposition of remaining oil The remaining oil is mixed with the residue of the semiprocessing still and sent to the naphthalene crystallization tank. Following separation of crystals, it is either mixed with the creosote oil or shipped to the rub- ber plant as solvent oil. (6) Regeneration of waste creosote oil The waste oil which is drained from the bottom of the light-oil still is creosote oil which does not contain any water or benzol. It is sent through the h:;at exchanger to the . of cooler. After the temperature of the waste oil is reduced to about 25 degrees Centigrade it is returned to the benzol scrubbers and again used for absorbing benzol. Thus, the creosote oil is repeatedly used but it even- tuafy becomes viscous and loses its benzol absorption power. Therefore, it is either re- distilled or used as an antiseptic. 58 I nr?rT At lJt.L.i. rtL HANDLING BEQL.IRED NOT RELEASABLE TO FOREIGN NATIONALS t SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 S C 4 Doc No 90225 (10) (PB) 7. Raw materials a. Vclume of gas produced by coke ovens The volume of gas produced is uncertain since there is n~ gas flow meter. However, considering the volatile content of coal, it is believed that about 260 to 2$0 cubic raters of gas is produced for each ton of coal charged. Therefore, it is conceivable that the volume of gas produced in 1953 reached about 106,600,000 to 114,800,000 cubic meters. Note: According to the 1953 plan, the amount of clean coal to be charged was 410,000 tons. b. Supply and demand of gas All the coke-oven gas is sent to the by-products plant. However, only 12 or 13 per cent of this gas is used as by-products raw material. The volume of escaped gas is unknown. After the by- products were recovered the gas was distributed in the following pro- portions in 1953. (1) Heating fuel of coke ovens: about 55 per cent (2) Heating furnaces at the rolling mill: { (3) Tar stills at the by-products plant: about 45 (4) Boilers: I per cent (5) Assay room: ' However, gas distribution to the rolling mill was often sut off because of the insufficient capacity of the gas exhauster. 8. Production a. Annual output by items -- see Table No 10-16. Production of carbolic acid was commenced with makeshift facilities as a countermeasure for the so-called bacteriological warfare in spring 1952. Consequently, it is not proper to estimate the sub- sequent annual output of carbolic acid based on its production in 1952? In addition, there was a plan to produce carbon black but it was never carried out. b. Destination and usage of by-products Of the by-products, nearly all of the a; ~monium sulphate, pitch, and crude naphthalene (including industrial naphthalene), $0 to 90 per cent of benzol, and 10 to 15 per cent of tar are sold to the out- side. Ten to twenty per cent of benzol (substitute automobile fuel), $5 to 90 per cent of tar (distilled to extract creosote oil used for recovering benzol) and crude anthracene (fuel) are domestically consumed. 59 LSPECIAL HANDLING REQLIBEB NOT BELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 60 Doc No 90225 (10) (PB Note: Light, middle, and heavy oils are mixed and used as creosote oil for recovering benzol. Crude anthracene is used na converters. for gas producers at the open-hearth furnace plant C. Distillation ratio The distillation ratio at the tar plant is as follows: 1 Light, middle, and heavy oils: 23 per cent (2) Crude naphthalene: 6 per cent ( 3) Crude anthrace ne : 2 per cent (4) Pitch (soft and hard): 65 per cent (5) Loss: 4 per cent Note: Figures in Table No 10-16 are based on this ratio. S~'#CIAL HANDLING REOLIRED NOT RELEASABLE TO FOREIGN NATIONALS , ~_____ _.~..._._.. ____._. ,__ - SECRET 11 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 er- %; L Doc No 90225 (10) (PB) III. Pig-iron Manufacturing Department A. Affiliation and Number of Plants 1. Affiliation Pig-iron Manufacturing Department of the Production Office, T'ai-yuan Iron and Steel Works It is under the supervision of the assistant superintendent for production. 2. Number of plants There was one blast furnace plant which was divided into the following three small plants (shops). a. Blast Furnace No 1 Plant Blast Furnace No 2 Plant C. Raw Material Plant B. History 1, In 1931, YEN Hsi-shan contemplated the construction of both the pig-iron manufacturing and the coking departments on a priority basis when the Ttai-yuan Steel Mill, the predecessor of the present works, was established. When the Japanese troops occupied the mill in November 1937., ninety per cent of blast furnace No 1 (rated capacity, 40 tons) and about 60 to 70 per cent of blast furnace No 2 (rated capacity, 120 tons) were already completed, 2. From January 1938, the construction of plants was resumed by Japanese technicians under the supervision of the Japanese Army. In November 1939, blast furnace No 1 was completed and fired, and in November 1940, blast furnace No 2 was completed and fired. Thus the pig-iron manufacturing department commenced full operation, 3. As the war progr.issed, the demands for steel increased. In order to meet this demand the construction of blast furnaces (small furnaces with rated capacity, 40 tons -each) No 3 and No 4 started from mid-1943 based on the plan of the Japanese government, and their corn ple tion and initial firing were realized in October 1943. Normal pro- duction, however, could not be attained because of the worsening con- ditions in local peace and order and the intensification of bombing raids by the US Air Force. Since then, for a period of a little over a year, only 5,163 tons of pig-iron were produced. Two small blast fur- naces were destroyed in the bombing raid in late 1944. At that time, blast furnace s No 1 and No 2 did not suffer immediate damage s, but due to difficulties in obtaining raw materials and shortages of workers, blast furnace No 1 was forced to suspend operation. in spring 1915. 4. Before the end of the war, the pig-iron manufacturing department was at its peak in 1942, and the total pig-iron output during that year was 44,201 tons. At that time, blast furnace No 1 mainly pro- duced foundry pig iron, and blast furnace No 2 produced open-hearth pig iron. 61 Ls)EcL&LIJANDLING REQLIREO NOT BELEASABLE TO FOREIGN NATIONALS I _ SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doe No 90225 (10) (PB) 5? After the end of the war, the seizure of the plants by the Chinese Nationalist Government was carried out fairly smoothly; therefore, there was no disruption in the operation of blast fa naace No 2. ? Blast furnace No 2 re sunsd operation in spring 1946, an awhile, it was operated satisfactorily, but with the subsequent in- tensification of the Chinese civil war, shortages in raw materials s- occurred. After the wheat harvesting operations in spring 1945, pres- sure by Chinese Communist troops became intense. In autumnhe94o, blast if furnace No 2 was finally forced to suspend furnae operation No 1 was barely able the Fu-Chia-ttan Coal Mine. Only blast to maintain its operation. . 6. Under Chinese Nationalist control after the end of the war, the actual output of pig iron was comparable to about 60 per cent of that during Japanese control. During this period, steel plates, pipes, and furnace wall bricks of the two small blast furnaces and their attached hot-blast stoves which were damaged by bomtingraids before the war's end were all removed by the ChineseNationalidifferent authorities because of the shortages of materials and used for purposes, leaving no trace of these facilities behind. 7. On 19 April 49, the plant was taken over by the Chinese Communist troops. There was no damage to the plant facilities during the civil war. There was no let up in production even for one day after the plant was seized. Blast furnace No 2 resumed operation in autumn 1949? Blast furnace No 1 resumed operation for the third time in 1950. C. Facilities 1. Principal facilities 10-1$. a. b . C. Layout of plant facilities -- see Chart No 10-14. Blast furnace facilities -- see Chart No 10-17. Hoisting device for blast furnace -- see Chart No d. Hot-blast stove -- see Chart No 10-19. er -- see Chart No 10-20. Blo e. f. w Gas-cleaning apparatus me Theisen di s inte grate r-type gas scrubber equipped with combined gas purification apparatus was installed to absorb dust from blast-furnace gas. (1) Type: Theisen disintegrator-type (2) Gas purification capacity: 20,000 cubic meters an hour Amount of water used: unknown Amount of electric power used: 150 horsepower Dust removal ratio: 0.5 gram per cubic meter 0 62 SECRET. psr;i HANDLING REGUBEB NOT BELEASABLE TO FOREIGN N'ATIO':\ALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) 2. Accessory equipment . a. Ore storage yard This is an open-air storage yard with an area of 200 meters by 300 meters b. Two crushers For the purpose of spalling iron ore and limestone, two new crushers were installed. Each crusher was capable of spalling 25 tons an hour. These crushers were capable of spalling 375,000 tons of ore which is sufficient for the production of 150,000 tons of pig iron a :tire ar. 150,000 tons x (1.76 t 0.74) _ 375,000 tons Pig-iron output Iron Limestone Amount of ore needed ore to be spalled However, the actual working hours of the crushers are reduced somewhat because the fine ore requires no crushing. The maxi- mum size of the crushed ore is about 90 millimeters. Note : Before this equipment was installed, the ore was crushed by hand and transported on dollies. C. Belt conveyor The belt conveyor was established in 1951 to transport raw materials from the ore storage yard to the ore bins. d. Ore-screening apparatus It was installed in 1951 to screen crushed ore. e. Ore-storage bin It was installed in 1951 as an ore--charging apparatus. It was equipped with a hopper to supply ore to scale cars. f. Coke bin It was newly installed in 1952 as a coke supply facility and is equipped with a hopper to supply coke to scale cars. g. Scale car It was made in GERMANY and can weigh up to about four tons. h. Roasting furnace There were four simple clamp-type roasting furnaces. Each furnace was capable of roasting 10 to 20 tons of iron ore at a time. i. Sintering furnace A There were two 4-ton and two 6-ton sintering furnaces . The daily productive capacity was about 50 tons.. 63 I__SPECIAL HANDLING REQLIREO NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 rrtr 1`t.. n~ g Doc No 90225 (10) (PB) j. Ladles for hot-metal car There were two ladles. The capacity was 25 tons each. 3. Removal and destruction of equipment During the second bombing raid on T'AI-YUAN by the US Air Force stationed in CHINA in late 1944, eight 250-kg bombs scored near hits and damaged the small blast furnaces No 3 and No 4. Therefore, the mill was forced to abandon these furnaces. After the end of the war, since the attached equipment was removed and diverted for other uses during both the Chinese Nationalist era and the Chinese Communist era, their original form was practically gone. The columns (six) of the blast furnaces were used as supports for the ore belt conveyor which was installed in late 1951 and the iron plates of the hot-blast stoves were diverted for use as building materials. 4. Increase and improvement of equipment a. Improvement of raw material facilities In the past, the ore was crushed by hand and transported on dollies. However, the complete rr~chanization of raw material faci- lities was realized in 1951; such as the installation of belt conveyors, crushers, screening apparatuses and ore bins. Since the crushed ore is also sintered and charged into the furnace, the screen is standardized at 50 mm. In addition, the information concerning the mechanization of the coke supplying equipment is as previously mentioned. b. Enlargement of furnace capacity After the Chinese Conu_nists took control, the thickness of the brick wall of the furnace was educed to increase its working volume. The increase in working volume of the furnace due to remodel- ling is shown on Table No 1,0-17. Along with this remodelling, the capacity of the hot-well section was also increased conspicuously. The working volume ofblast f\irnace No 2 is also being enlarged under a similar method, but it was impossible to ascertain the true figure of the en- larged working volume of the furnace. The second repair work on blast furnace No 2 since the Chinese Communists took control was expected to be conducted after May 1953. However, during the course of this repair work, there were no plans to increase the working volume furnace. It can thus be construed that the inner capacity had already been enlarged to the limit during the initial repair of the said blast furnace. C. Enlargement of the tuye re After the Chinese Communists Came into control, it be- came possible to increase the blast volume by enlarging the diameter of the tuye re . d. Increase in blower capacity After the Chinese Cor~munists came into control, the pig- iron output of blast furnace No 2 was increased by 20 to 30 per cent with the use of blower No 4 (1, 500 hp) . Blower No 3 (B00 hp) was used in place of blower No 4 while the latter underwent routine repairs (for six days a month). During this period, the daily output of pig iron decreased from an average of 300 tons (when blower No 4 is used) to about 50 to O tons. 64 IGN NATION\ R ' .4 E DLING RECL I BED NOT RELEASABLE TO FO S LIAL IIAN SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SE~:T'_I Doc No 90225 (10) (PB) 5. Defects in layout of equipment The site area of the blast furnace plant is very limited, i then fore there is no room for expansion. The power plant is located on the western side, and the area to the west of this power pl ntf the an unusable depressed area. The area south of the forrr>er s ite small blast furnace is a lowland that cannot be used except as atrub- bish dump. There are plants established to the north and east, fore the only space for additional facilities is limited to the former site of the small blast furnaces and its vicinity. 6. Coordination of equipment capacity in relation to other affiliated departments a. Coordination with the coke department (1) In the latter part of the first quarter of 1953, the capacity of the coking equipment was 290,000 tons. Taking the coke ratio of 1.13 as the standard, it is sufficient for the production of 250,000 tons of pig iron. Con- sequently, the production of 151,250 tons of pig iron planned in 1953, and even the pro- duction of 200,000 tons of pig iron planned for the future clearly indicates the relative- ly low pig iron production capacity. (2) The coefficient of effective utilization of the working volume of the blast furnaces in the lat to r part o f the fir st qua rte r of 1953 was 1.0 to 0.9. In the near future, there is a possibility of improving it to 0.7. In such case, the pig-iron output will reach the 230,000-ton level. At the same time, however, the coke ratio will also be sure to drop so that the imbalance in equipmnent capacity in re lat ion to the coke de partme nt will probably continue for some time. (3) The pig-iron manufacturing goal of the iron and steel works in the latter part of the First Five-Year Plan was said to be 300,000 tons. Even on the part of the coke departn;ent, the ne1-T construction of coke oven No 3 is said to have been contemplated during this period. . Therefore, an imr~alance in the output of coke and pig iron would probably continue for quite some time . The fact that the plan for the outside sale of coke by this iron and steel works is reported to have permanency can be said to confirm the situation of this period. b. Coordination with the steel manufacturing department (1) The steel output of this iron and steel works under the first plan of 1953 was 130,000 Mons. This planned amount, however, was a conserva- tive estimate because the expected importation of crane equipment was delayed. It can be 65 LSPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONt'..S SECRET i Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) seen definitely that if the crane eqipnent arrives and the attached facilities are im- proved, 170,000 tons f steel can be produced. If tappins can be carried out four times a day, it would be possible to produce 15,000 tons of steel in the future with the three existing open-h.,arth furnaces. The amount of molten pig iron charged in the latter part of the first quarter of 1953 was ~;o0 kg to ;ach ton of steel produced. If this is considered as the standard, then the amount of molten pig iron ne=;ded to make 170,000 tons of steel would be 136,000 toes, and 148,000 tons of molten piiron would be needed to make l5,000 tons of steel. In both cases, it can be assurled that the steel output is roughly balanced with the planned amount of pig iron output for 1953. (2) Around April 1953, ,plans for the con~:truction of an additional two open-hearth frnaces (capacity, 50 tons e,,ch) had already been materialized. The realization of this plan increases the steel manufacturing capacity of this works by 70 r r cent as compared to the production level of 1953. Therefore, the amount of molten pig iron needed within the iron and steel works would be about 230,000 tons, and including the production amount of foundry pig iron and chilled pig iron, about 300,000 tons of pig iron would be required. Since the above figure matches perfectly with the pig-iron production goal of the works for the latter part of the First Five-Year Plan, it can be said that the production of pig iron and steel was woll balanced throughout this period. 66 1 SPECIAL HANDLING REQLIRED NOT RELEASABLE TO FDBEIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 0 t furnaces when the effective i1~ot~, ~ . 1 The anticipated ective capacity utilization . ,~ output of the existing blas f , coefficient 0.7 can bo computed as follows: is Effective Calendar Rate of ?Accept~nace Annual output Effective Utilization capacity operation rate ton coefficient days oiler.,, (m3/ton/day) ni..a+ ri1rr~fe 158 approximately No 1 Blast furnace No 2 Total 231,100 2, The basis for ca tons of tha existin ca (170,000 ~ calculating the steel manufacturing paccte --11 arth furnaces is as follows: open ~ Output Steel output Number of Calendar Rate of Acceptance Number of each t lrt~ times a day days operation rate furnaces ton , ton - approximately $ x 3 ~ 50 x ho r 365 x 0.5 x 0.9 us x 170,000 .4 hours 292 i 0,7 x 365 x 0.99 x 1.00 _ approximately 150,800 0.7 x 365 x 0.99 x 0.99 d 0 n z 0 ~o 0 N V1 r 0 tb rn II- Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 m C) rn the plan f required an 3 The amount of molten pig iron or 1953 is as follows. P v~ !tllI Planned amount of Amount of molten pig Acceptance Amount of molten pig o rate charged per ton of needed ton > steel ton r' steel output ton W $ approximately 106,000 0 s000 $ x 130,000 0.9 2; ? N o Ifl r I21' output in 1953 , iron and chilled pig iron out is as follows: p Computation of found i ro ~' p~ ~ Comu a~ I ~ p v Foundry Pig iron and chilled 1i . ~ Planned amount of Amount of molten pig r ron output ton pig iron ton needed ton pig i o r 151,250 .. 106,000 .. approximately 45,000 r~ Cl) o H O Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) d. Hot-blast stove operation Normally, three hot-blast stoves are attached to one blast furnace, of which one is used for air-blasting and the other two for heating. Blast-furnace gas is used for as fuel for heating. The hot air regenerated by heating is mixed with cold air and blown into the blast furnace. However, when the air temperature drops to a prescribed temperature, the source is switched over to the next regenerated hot-blast stove. The blasting duration of a hot-blast stove is about two hours. 3. Improvements in operational methods There is no particularly new operation method, but from the historic development of production, the following points cart be pointed out. 69 D. Operational Organization of Labor See Chart No 10-15 E. Operational Method 1. Operational process -- see Chart I'Jo 10-16 The operational process shown on Chart No 10-16 was put ~Unti1 force in 1951 after the ore-processing facilities were mechanized. then, the ore was crushed and screened by hand and transported on dol- lies. Even after 1951, the coke-manufacturing process has been gradually improved along with the completion of various facilities. For instance, in regard to the method of conveyance from the coke storage bin to the hoisting apparatus, plans for electrifying the cars was taking shape in spring 1953, but it had not as yet been carried out. 2. Notes on the operational methods a. Roasting f urnace (clamp-burning type ) processing Iron ore produced at WU-AN and LI-KUO is magnetite. Therefore, to simplify the spalling, the lump ores are sorted out at the ore storage yard and roasted in the clamp-burning type roasting furnace. Lump coal is burned on the ground and lumcsof ore are piled around it, then coal is piled on this ore. About 10 to 20 tons of ore is roasted in this manner by natural drought. b. Number of tappings and removal of slag Each blast furnace is tapped eight times a day. Slag is removed one hour after each tapping. C. Processing of pig iron In the case of foundry pig iron, the hot rr~tal is cast in the sand bed in front of the furnace. In the case of open-heath pig iron, the hot metal is first poured into the ladle (25 tons) and then charged into the open-hearth furnace. A portion of the remaining hot metal is made into molded pig iron and is also used in the open-hearth furnace. The open-hearth pig iron used at this iron and steel works mainly consisted of hot metal and partially of chilled pig iron. During the Japanese era, the usage of hot metal was comparatively limited because work coordination between the blast furnace and the open-hearth furnace was not well maintained owing to production conditions on both sides. [SPECIAL TA D NOT !ELEASAELE TO FOREIGN NATIONALS HANDLING REQC,~RE , SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 R? ' _p ?, ' E ' Doc No 90225 (10) (PB) a. Strict sizing of ore To maintain the furnace in good condition, the size of the ore was standardized at 50 millirr ters. Neither excessively large nor excessively small ores were charged into the furnace. For this reason, special care was given to the roasting of hard large ore for easy spalling and to the sintering of fine ore before charging. The original blast furnace No 2 and blast furnace No 2 after its first re- modelling had a tendency of frequently forming scaffolds, but due to the thorough sizing of ore and an increase in the volume of air blast, it became possible to enforce efficient operation from late 1950. b. Increase in the volume. of air blast The $00-hp blower for blast furnace No 2 was used until the early part of the Chinese Communist era, but from about 1951, it was replaced by a 1,500-hp blower. As a result, the draft in blast furnace No 2 has become very effective and production has increased by 20 to 30 per cent. C. Utilization of superior grade ore Until about 1950, low-grade ore (iron content, 40 per cent) produced in SIENSI Province was used, but after 1951 the amount of pig-iron output has increased considerably with the utilization of rich ore obtained from other provinces. It may safely be said that the increase in production after 1952 is mainly due to this rich ore supply. After spring 1952, a movement for qualitative improvement was begun and a strict demand for standard-size ores was made to the mines, which brought about highly effective results. d. Improvement in the quality of coke It is needless to say that the quality of coke has a great effect on the output of pig iron. At this iron and steel works, the ash contest of coke is limited at 11 to 12 per cent. Coke having more than 13 per cent ash content is considered below standard and is prohibited from being used in the charge. The size and structural strength of the coke are also clearly specified and the use of coke not meeting these specifications is not permitted. Note : 1. It is common knowledge that the increase of one per cent in ash content in coke increases the coke consumption by two per cent in the blast furnace and decreases the pig-iron output by three per cent. 2. The ash content of coke during the Japanese era was more than 17 per cent. 3. Since Chinese Commmunist control, coke was expended rather wastefully in an attempt to increase production and rationaliza- tion in heat control was inadequate. e. Measures taken to prevent scaffolding of charges When scaffolding of charges occurred in the blast furnaces, moderate measures were taken during the Japanese era, but under Chinese Communist management, dynamite was used under the guidance of Soviet specialists to facilitate the dropping of materials within the furnace. 70 .._ ____- -- - ----~---` t SPECI AL SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) f. Importance of slag component During each inspection tour, the percentage of slag is the chief concern of the Soviet technicians. The above is believed to indicate that they are paying close attention to the charging of raw materials for the purpose of regulating furnace conditions and to t he ensuring of the quality of the pig iron produced. g. The int~'oducticn of Soviet techniques Soviet techniques were fully adopted after 1952. Wnen Soviet specialists carry to inspect the plant in autumn 1949, they pointed out the fact that blast furnace No 2 must produce 300 tons of pig iron. At that time, only 120 tons of pig iron was being produced, by this furnace and the plant technicians were very much surprised, to say the least, at such an impossible suggestion. However, the effective working volume of the said furnace was 292 cubic meters and in late 1952, 290 to 320 tons of pig iron were produced daily. Therefore, it has been proven that the output of 300 tons was nothing to be so amazed about. Friction arose at times between the Soviet technicians and the Japanese technicians because of divergent technical views. For instance, in late 1951, the scaffolding of charge occurred twice in blast furnace No 2. In regard to this instance, there was a difference of opinion between the Soviet specialists who came from PEKING and the detained Japanese technicians, and sharp disagreements arose. The Soviet specialists severely criticized the Japanese pig-iron manufac- turing technique as belonging to the eighteenth centur4r, but in the end the Japanese views were accepted and the furnace was repaired. The Chinese Communist authorities were highly concerned over this incident, and after late 1951, Japanese technicians were transferred to t he basic construction department or to other factories which were backward in technique. The above is believed to be the step taken before the over all introduction of Soviet techniques after 1952. 71 SPECIAL 1iA U' ING REGI I RED NOT BELEAS! BLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 'I C ' Doc No 90225 (10) (PB) r-i ~ -N ?~ o $.4 U a cd m . rn bCi U ~ ?rl ?rl N N S~ ?ri ,.~:: 0?r-4 C1n -p p O H 0 N a) -PC,) N ?cd U cd O N ,~ U p10 I. _~ . /' ti -zf -p -P -P -P -P a) a) G a) .}) U U U U U c:: ? r a) p g~~ o p1 N F?, a Qi 4-) 4 0 U 4, 0 ~ 0-:t O ~ U U U U U H ~ r i 0 O ?N H f I I O H I I 0 O O - Hz I I O H I I O +) I I I I d ?r- 0 0 ~n Sa 21 0 ~n O ?ri ra L- c-\ ~ ~U) : I ?' H b1 4,0OH d 0 a) -I O~ H H H~U cYr-I l H ~ ?r1 ?H Ul !ti I4 0a) ~ Q H O 0 O U) a) U 0 O I`+ H cd .0 r-1 7? o 0 U) 3 :: L SPECIAL HA? LING REAL I BED NOT 'RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 i,t Sl._4:~&_ i Doc No 90225 (10) (PB) 2) (3) During Chinese Nationalist control The iron ore used during Chinese Nationalist control was much the same as that used during Japanese control, but due to the state of peace and order in the district concerned, ore was obtained only from TING-HSIANG, TUNG-SHAN, HSI-SHAN, and SHOU-YANG. During Chinese Communist control At the beginning, iron ore produced in SHANSI Province was used as in the past, but due to the poor grade and limited output of this ore, the supply source was gradually shifted to the rich ore found in other provinces. In other words, the above change came about be- cause demands created by the sharp increase in pig iron output from late 1950 through 1952 could not be net. In regard to iron ore produced in other pro- vinces, the Lung-yen and Wu-an ores were first obtained in late 1950 and used together with several varieties of iron ore produced within the province. In early 1952, however, the Lung-yen product (hematite) was mainly used together with the ore produced at WU-AN (magnetite), LI-KUO (magnetite), and TLJNGr- SHAN ( iron ore found in SHANSI Province). Under the 1953 plan, the supply of raw material depended almost entirely on ores from other provinces. Under the initial phase of this plan, the entire amount was supposed to con from LUNG--N, WU-AN, and LI-KUO, but later from the standpoint of regulating th3 demand and supply throughout the country, the plan was revised so that iron ore produced within the province would be used at the same time, although the amount was very limited. In this case, Tung-sham ore seems to be the only locally-produced ore that can be utilized. The said ore was mined by hand at the begin- ning of 1952, and the daily output was about 100 tons. Horse carts were used to transport the ore from the mine. At one time, iron ore produced at TING-HSIANG in SHA:aI Province was widely used. However, since the ore contained mica; it flattened out when crushed and lowered the pig-iron production efficiency by cutting down the draft within the furnace. In addition, due to some errors in digging, the redevelopment plan which was expected to be carried out during 1950 and 1951 also was abandoned in the midst of operations. 73 RECTAL HANDLING REQIJBEL) NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 S r ~,. ~ K _ t Doc No 90225 (10) (PB) The amount of ore supplied by LUG-YEN had already reached one hundred and several ten thousand tons in 1952, and this iron and stl works is the largest eonsurr r of this ore. The proposed purchasing amount of iron ore in 1953 is shown on Table No 10-21. b. Coke This works has attained full self-sufficiency by using the coke manufactured in its own coke plant. At the beginning of Chinese Communist control, a partial supply of h3ap carbonized coke was received from CHING-HSING and LU-AN, but it was not long before this purchase was halted. c. 1ecovered pig iron Rejected pig iron is at t Imes recharged into the blast furnace as recovered pig iron, but since the acceptance rate of pig iron is more than 90 per cent, the volume of rejected pig iron is very small. d. Limestone Inexhaustible deposits of good quality limestone are found in the Tung-shan and Hsi-shan areas. The source of supply is con- sistent and has remained unchanged since Japanese control. Limestone produced at hSI-3HAN is transported by rail, whereas limestone from the Tung-span Mine is transported by horse-drawn wagons. e. Manganese (1) During Japanese control Manganese ore from the Ching-lo Mine ($0 km northwest of T'AI-YUAN) was used, and occasicnal- ly iron ore (Manganese content, seven to 10 per cent) from the Chou-yang Mine was mixed with the above ore. High-grade ore from INDIA was used before the Pacific War. The manganese ore from the Ching-lo Mine was of good grade and contained more than 40 per cent manganese, but the highest amount of ore dug during one year was about 2,000 tons. (2) Under Chinese Communist control Just as was done during the Japanese era, efforts have been made to obtain manganese by using ore produced at the Ching-lo Mine, by mixing this ore with iron ore produced at 3 OU-YANG, or by mixing this ore with specular iron manufactured at the Yang-chtuan Pig-iron Manufacturing Plant or ferromanganese from the Northeast Area. However, from 1952 through 1953, it seems that manganese ore (L'langanese content, 32 to 35 per cent) frora LO-P I I:JG in KIA1uG3i Province was mostly in use. The amount of ore dug at the Ching-lo Mine was about five tons a day in 1950, but this ore appeared to be very near to being exhausted. 74 SPECIAL HANDLING REAL I RED NOT BELEASABLE TO FOREIGN NATION=ALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 n 4 41 F1 Doc No 90225 (10) (PB) f. Fluorite Prior to Chinese Communist control, fluorite produced at WU-CH'i NG-CN (37?251i~ 111?26'B) (halfway between FEN-YANG L37?16'N 111?47';7 and LI-$IIH /37?29 'N 111?04 ') in the southern part of SHANSI Province was initially used, but later it was replaced by fluorite from the Tsingtao district. However, under Chinese Communist control, digging of fluorite from the Wu--ch'eng-chan mine was resumed. Fluorite in this district is a reticulate ore of inferior quality. The mining method was primitive, and the daily output in August 1949 was about 200 tons. Later, it was replaced. by fluorite from the Tsingtao district. 2. Volume of various raw mat?rials consumed a. Consumption rate of raw materials (1) Iron ore At the beginning of 1950, the ore ratio was about 2.5, but with subsequent improvement in the ore quality, the ore ratio was expected to be 1.76 under the 1953 plan. 2) Coke The coke ratio under the 1953 plan was set at 1.13. (3) Limestone In spring 1952, about 500 kilograms of lime- stone were consumed for each ton of pig iron produced. With the subsequent use of iron ore (magnetite; p~iosphorus ore) from WU-AN and LI-KUO, the consumption rate of limestone has increased to X00 kilogram for each ton of pig iron produced under the 1953 plan. (1) Iron ore 75 SPECIAL HANDLING REAL I BEn NOT BELEASABLE TO FOREIGN NATIONALS --- - SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 The planned consumption volume in 1953 is the sum of the planned purchase amount of ore (264,000 tons) from other provinces shown on Table No 10-21 and the planned consumption volume of the ,r3ry small amount of provincial ore. However, since an accurate figure of the planned amount of consumption of provincial ore is unknown, it is impossible to point out ac- curately the proposed gross amount of the said year. Note: 1. Since it is said that only a relatively small amount of pro- vincial ore is consumed, it would probably be safe to assume that the proposed amount of purchase of ore from other provinces is the planned consumption volume for the said year. Volume consumed Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB ) 2. With Table No 10-21 as the basis, the average quality of ore from other provinces can be computed as follows: a. Lung-yen ore 147,000 tons x 0.55 (Fe) (Fa) 8C,B50 tons b. Diu-an ore 71,000 tons x 0.58 (Fe) ` (Fe) 42,920 tons c. d. Li-kuo ore 43,000 tons x 0.59 (Fe) Total (Fe) 149,140 tons (Fe) 25,370 tons 149,140 tons 264,000 tons . about 0.565 (Fe) (Fe) (Gross tonnage of ore) On the other hand, the equation will be 1. Qu = 0.56 (Fe) if the l.7~ ore ratio (1.76) under the 1953 plan is used in the calculation. It is believed that the resulting difference in the above two calculations may be attributed to the following conditions: a. Although a very small amount, low-grade provincial ore is included in the planned consumption. b. About 93 per cent of iron, four per cent of calcium, one per cent of silicon, and some amounts of manganese and other elements are contained in the pig iron. A small quantity of the iron content in the ore is mixed with the slag and dust and is lost (2) Coke If the planned amo~int of coke consumption for 1953 is calculated from the abovementioned coke ratio, it would be as follows: 151,250 tons x 1.13 171,000 tons Amount of pig Coke Amount of coke consumed iron accepted ratio Note: Lump coke of less than 13 per cent in ash content is used. (3) Limestone When computing from he planned consumption rate (800 kg per ton of pig iron produced will be 0.8) for 1953, the planned amount of consumption of limestone for the same year is as follows: 151,250 tons x 0.8 w 121,000 tons Amount of pig Limestone Amount of limestone iron accented consumption consumed rate (4) SPECIAL HANDLING REQUBED NOT EELEASABLE TO FOREIGN N,\TIQNALS I SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Manganese ore About 30 to 40 kilograms (Consumption rate, 3 to 4 per cent) of manganese ore from LO- P'ING are needed to produce one ton of pig iron. Therefore, the consumption volume of manganese or during 1953 is estimated to be about 5,000 tons. Z~ Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PH) 0 3. Charging of raw materials a. Volume of a single charge -- see Table No 10-22 Volume of a single charge is based on the amount of coke and the amount of iron ore and limestone charged are calculated in proportionate to the amount of coke. The amount charged and the type of raw materials charged depends upon the condition of the furnace. b. Number of charges per day -- see Table No 10-22 C. Charging order iron ore is charged simultaneously with coke and lime- stone, and according to the condition of furnace, a suitable amount of manganese is charged at thright time. G. Production 1. Daily output a. During Japanese control In the most productive years of 1912 and 1943, the daily output nearly equaled the rated capacity. On the whole, however, the daily output was about $0 to 90 per cent of the rated capacity. In other words, the daily output of blast furnace No 1 was 35 to 40 tons and that of blast furnace Not was about 100 tons, After October 1940 when both blast furnaces No 1 and No 2 were in operation, blast furnace No 1 produced foundry pig iron, and blast furnace No 2 produced open--hearth pig iron. However, in 1945, blast furnace No 1 was blown out, and thereafter, the t~-pe of draft pig iron to be produced was decided by the conditions at the time. Under the previously mentioned conditions, small blast furnaces No 3 and No 4 were incapable of much production until they were bombed and blown out in late 1944? b. During Chinese Nationalist control Both blast furnaces No 1 and No .2 were in operation, but their daily output seldom exceedCd that during Japanese control. Fol- lowing the "Wheat-harvest Operations' in spring 194E, the Chinese Commu- nist Army intensified its pressure and blast furnace No 2 which was the main production cog had to suspend operation because of the shortages of raw materials in autumn 194E. C. Under Chinese Coimnunist control During the period between autumn 1949 and early 1950, blast furnace No 1 produced about 40 tons of pig iron daily and blast furnace No 2 produced about 120 tons of pig iron daily. This amount did not differ much from the output during Japanese management. Scaffolding of charges occurred frequently during the operation of the original and first remodelled blast furnace No 2. Particularly frgm the early part to the middle of the first remodelled blast furnace No 2 period (Autumn 1949 to May 1953), the efficiency dropped a little due to scaffolding of the charges. In winter 1950, due to damages to the hearth, the furnace was banked for more than a week because of damages to the hearth. However, 77 SIeIJiTANDLJT REQLIBED NOT BELFASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) from late. 1950 through 1952, the production of pig iron became favorable, and thereafter, production started to increase. The charges in daily output during the foregoing period is shown on Table No 10-23. 2. Annual output -- see Table No 10--24 a. During Japanese control The peak production was in 1942 when 44,201 tons were produced (Blast furnaces No 1 and No 2 were in operation). b. During Chinese Conmiunist control Production increased rapidly during the Antirevolution- ary Suppression Movement of 1951, and the Three--anti arid Five-anti movements of 1952. The total output of blast furnaces No 1 and No 2 in 1952 was more than 130,000 tons. The output consisted mainly of open-hearth pig iron with 30 per cant foundry pig iron. The planned production for 1953 was 151,250 tons. This amount can be computed as follows: (1) Blast furnace No 1 (Normal operation) Effective capacity (i11)) Utilization Calendar coefficient days (m3/ton/day) Operating Acceptance Annual rate rate output (ton) 158 0119 x 365 x 0.99 x 0.99 = 62,300 (2) Blast furnace No 2 (Blow out was planned) Blown out LirLited produc- da;rs t ion days 292 1.0 x (365 - 52 - 30) 0.99 x 1.0,E = $1, X00 Limited ;hisnber of Annual out- produc- days pi eu during n9n-produc- tion iron not tion period days produced (ton) 292 - 1.25 x (30 - 0.5) x 0.99 x 1.00. 6,650 Distribution of pia iron . a. During Japanese control Under the integrated proces.. of steel manufacture, the greater part of the pig iron output was supplied to the steel maufac- turing department of the works, but a portion was sent to the central plant (the present Trai-yuan Machinery and Tool Plant). b. During Chinese Communist control Considering the actual output of 91,000 tons of steel in 1952, the amount of molten pig sent to the steel manufacturing SPECIAL HANDLING REAL IBED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) department of the works is estimated to be 72,000 tors. Therefore, it can be surmised that approximately 60,000 tons are principally sold outside as chilled pig for open-hearth use and foundry pig iron. Foun- dY-y pig iron is sent to the machiner:?plants in T'AI-YUAN, TIEicTSIN, and SHA GHAI. It has been said that the output of foundry pig iron in 1952 is 30 per cent (about 40,000 tons) of the total pig iron output of more than 130,000 tons. The planned steel output of the works in 1953 is 130,000 tons. The amount of molten pig iron required for this output is ti- mated to be i0b,000 tons (see Note 3 under III, C, E, b in this chap- ter). The amount of chilled pig iron that can be sold outside is about 50,000 tons (mostly foundry pig iron). The amount of outside sale is slightly below the figure of the previous year. The planned amount of steel manufacture for 1953 is said to have been reduced by 15,000 tons due to delay in the rebuilding of facilities attached to the open- hearth furnace. Therefore, it can be imagined that the amount of out- side sales of pig iron has almost r~ach~d the same level as that of 1952. 4. Grade and specifications After the Chinese Communists took control, the specifications for open-hearth pig iron ranged from No 1 open-hearth pig iron (Silicon content, less than 1.0 per cent; Manganese, 0.$ to 1.5 per cent; Sulphur, less than 0.05 per cent; and Phosphorus, less than 0.5 per cent) to No 3 open-hearth pig iron (Silicon content, 1.25 to 1.50 per cent; other elements are the same as that of No 1 pig iron). Until spring 1952, the No 2 open-hearth pig iron constituted most of the pig iron produced and there were some that fell short of the specifications. However, from the latter half of 1952, the quality was improved considerably, and the pig iron produced contained 0.7 to 1.2 per cent silicon, about 1.0 per cent manganese, and a very small quantity of sulphur. Thus, No 1 open-hearth pig iron constituted he bulk of the pig-iron output. The foundry pig iron is also graded from No 1 foundry pig iron to the No 3 foundry pig iron. The No 1 foundry pig iron contains 2.75 to 3.5 per cent silicon, 0.5 to 1.0 per cent manganese, and 0.05 per cent sulphur; whereas the No 3 foundry pig iron contains 1.5 to 2.25 per cent silicon, 0.5 to 1.0 per cent manganese, and 0.06 per cent sulphur. Based on the silicon content, it ca. be said teat these spe- cifications are intermediate between the specifications used in the UN1T~D STr:TES and the li $SR. Moreover, for details, refer to a list of temporary specifications of products under XI of this chapter. 5. Percentage of products meeting specifications The percentage of products n eting specifications in the 1953 plan was as follows: a. Blast furnace No 1: 99 per cent b. Blast furnace No 2: 100 per cent It can be 'construed that the above figures include the flexibility of applying other standards to tiose goods of poor quality 79 t SPECIAL HAN'IrLINO BEQLI BELL NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) SECRET which occasionally appear. Blast furnace No 1 produces both foundry and open-:learth pig iron. During its conversion period, however, pig iron that was intermediate in composition between foundry and open- hearth pig iron was at times produced. It is said that even this pig iron can be used in most cases. 6. Effective working volume utilization coefficient of blast furnace. a. The results of 1952 (1) Blast furnace No 1: about 0.9 (2) Blast furnace No 2: about 1.0 be The plan for 1953 The Iron and Steel Industry Control Bureau of the Ministry of Heavy Industry has called upon the works to rain the planned effective utilization coefficient of blast furnace No 2 to 0.9. As a result of studies made, the works established the coefficient of blast furnace No 1 at 0.9 and that of blast furnace No 2 at 1.0 by using the results of the preceding year as the basis. Note: In 1952, the coefficient of the small blast furnace at YANG- CH'IJAN was 0.5, and the one at P ;N-CH'f, was honored as the national model. However, it was reported that the best monthly average in 1952 was 0.6715 and the best record was 0.613. 7. Ope rat in_ g rate The operating rate of both blast furnaces No 1 and No 2 as planed for 1953 is 99 per cent. The suspension of operation of one per cent is due to barking of a furnace. The cleaning of bloytirs is the principal factor for the suspension of operation. Since blast furnaces No 1 and No 2 are both equipped with reserve blowers, the actual barking of furnace takes only about six to seven hours even during the regular monthly repair (f'or six days). However, there is a difference in capacity between the regular blower and he reserve blower. Therefore, the efficiency of pig-iron manufacture decreases while the reserve blower is in use. For instance, in the case of blast furnace No 2 the average pig-iron output was 300 tons a day when the regular blower was used, but when the reserve blower was used, it decreased to 220 to 250 tons a day (in early 1953)? Note: In JAPAN, it seems that the average number of work days for the year is calculated by the following method: the number of days .required for major repairs during the life of the furnace is divided by the number of durable years of the furnace to arrive at t he average number of days annually required for major repairs. This number is used in calculating the average number of annual work days of the blast furnace. However, in Communist CHINA, the foregoing method was not used. Calculation of the number of annual working days is based on the actual nu_rrd er of working days Tox each year. Therefore, the total number of days required for 80 SPECIAL HANDLING BEQLJBED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (io) (PS) nwnber of calendar days of major repairs is subtracted from the the year in which the repair was carried out or the specified year in which the repair work is expected to be carried out. It is believed that such a method is only logical In the carry- ing out of a planned economy. See under III, G, 2, b of this chapter for an example of this calculation. $. Slag SPECIAL HANDLING BEQLIBED NOT BELEASABLE TO FOREIGN NATIONALS SECRET a. Composition The composition of the slag is about the same as that of the Hsuan-hua Pig-iron Manufacturing Plant mentioned in Chapter Six. Its only charact ~ r;.st is is the large amount of limestone used in h he charge . The iron content in the slag is about one per cent of amount tapped. b. Disposal The slag is placed in the slag ladle, and almost all ofon it is discarded. It was used to fill in depressions and for re clamat purposes. In the early part of 1953, however, a part of it was dis- solved in water and made into liquid slag. This liquid slag was sent t:) the T' ai-yuan Cement Factory and was being tested as a raw material for cement. 9. Blast furnace gas a. Composition It is composed of carbon monoxide, carbon dioxide, hy- droge.~ gas, nitrogen gas, methane, and an extrer.Ely small amount of iron. It contains a large volume of carbon monoxide. b. Uses Since its principal component is carbon monoxide which is poiso:ous, it cannot be used in :comes. After being passed through hurdle-type Teissens gas scrubbers, it is sent to the hot-blast stove and burned. A part of the gas is also used by the boilers attached to the power plant. In the past, large volumes of gas escaped from bhe throat of the furnace, and it was not used completely. In spring 1953, a plan was set up to use a mixture r'f coke gas and producer gas in the heating furnace of the rolling mill. However, since blast furnace gas contains only 900 kilocalories per cubic meter as compared to the 4,500 kilocalories per cubic meter of coke gas and the 1,200 kilocalories per cubic meter of producer gas, it cannot be denied that the efficiency of the heat output is low. Life span and repairing of blast furnaces a. The expected life span of a blast furnace blast furnace No 1 had undergone its - In early 1953 , second remodelling and blast furnace No 2, its first remodelling. Throughout Japanese managerrLent, the expected life spans of both blast furnaces No 1 and No 2 were about six to eight years. Even during the Chinese Nationalist period after the war's end, the expected life span of blast furnace No 2 was the same as that during the Japanese period. 10. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Uoc iVo 90225 (10) (PH) However, due to shortages of raw materials after the war's end, blast furnace No 1 was not operated regalarly with long banking and blown- out periods. Thus, the expected life span of the first remodelled blast furnace No 1 was very short. After the Chinese Communists took control, the intensive use of blast furnaces and their facilities has become very conspicuous. Since blast furnaces No 1 and No 2 are constantly operated at close to . their full capacities, their life-expectancy was limited to only about 32 years. For instance, the first remodelled blast furnace No 2 was fired in autumn 1949 and it was expected to be blown out for major re- pairs in May 1953? Also, the second remodelled blast furnace No 1 was fired in 1950 and it was already stated in spring 1953 that this fur- nace was expected to be blown out for major` repair in 1954. b. Time required for repair of blast furnace It took six months to repair blast furnace No 2 in 1949. It took four months to repair blast furnace No 1 in 1950. However, the repair plan for the second remodelled blast furnace No 2 which was expected to be blown out in May 1953 called for 52 days from the blow-out time, through cooling, dismantling, building, drying, and blowing in. The period is shortened considerably compared to the pre- vious time required for repairs during the Chinese Communist era. On the whole, however, it can be said that this indicates an unusually high efficiency even when compared to the logical time required in re- pair. Such high efficiency was said to have bn atuained as a result of the adoption of Soviet furnace-repair rr thod. In JAPAN, due to economic reasons, the repair of furnaces after it is blown out seldom seem to be conducted at such speed. Therefore, accurate data that can be compared to the Chinese Cornrriunlst method are rarely found. Techni- cally speaking, however, it is said that it normally required 90 to 100 days. C. Time required in drying the furnace body The time required to dry the furnace body- during the pla_Yr ned repair in 1953 is unknown, but it took three to four weeks when blast furnace No 2 was repaired in 1949. d. The time required from blow in to initial tapping It took 24 hours at the time that blast furnace No 2 was fired in 1949, but under the production plan of the said furnace in 1953, it was shortened to 12 hours. e. Time required from blow in to normal operation The operticn is not normal for about three to four weeks after the blow in. Under the production plan of blast furnace No 2 for 1953, an allowance of a 25 per cent drop in the pig-iron output for the period of one month after the blow in was made. Since this reduced rate is the average value for the .entire period, it was le s by 50 per cent in the early part of the blow in. After that, it was gradually increased to regain normalcy by the latter part of the period of restriction. 82 I__SPECIAL HANDLING BEQUIBEO NOT RELEASABLE TO FOREIGN NATIONALS ' j _......._-._-a._. SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 50X1 -HUM Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) Iv. Steel Manufacturing Department A. Affiliation and Number of Plants 1. Affiliation The department is affiliated with the Production Office of the Tai-yuan Iron and Steel Works and is under the jurisdiction of the assistant superintendent for production. The department is divided into the steel manufacturing department and the electric furnace steel department. 2. Number of plants a. There are the following four small plants (workshops) under the steel manufacturing department. Open-hearth furnace plant Ingot casting plant Gas producer plant Dolomite plant b. There are the following two small plants (workshops) under the electric furna cc steel department. . (1) Ele ctrl c furnace plant (2) Pattern plant B. History 1. History of the steel manufacturing department . a. The open-hearth furnace plant was designed by a German prim to the Japan-China incident, and part of the work got underway. However, the greater portion of the construction and the installation of machinery were done after the Japanese technicians arrived in January 193g. b. Difficulties in raw material and transportation were overcome at the time, and the commencement of operations was rushed. As a result, the furnaces were fired and tapped for thet first ttt time time opera- tions Sep 41. Listed below are the principal facilities P ra- tions began: (1) Open-hearth furnace (rated capacity, 30 tons; fixed type) : two (2) Gas producers (13 tons) : five (3) Ingot bed (three plates each): two r- -S ..._ SpEGjL HANDLING REOL I RED NOT RELEASABLE TO FORE! GN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 EL ,+ i~ r -~ Doc No 90225 (10) (PB) C. Of the two open-hearth furnaces only one was worked and operation was confined to about two heats a day. However, in February 1942, steel was tapped three times a day, and the stage for the full scale operation of the two open-hearth furnaces was reached. The peak production year before the end of the war was 1942, in which year the output was approximately 40,000 tons. d'. At first, there were 185 employees (65 Japanese and 120 Chinese), but the nwnber reached 313 (65 Japanese and 248 Chinese) in 1942. e. Under Chinese Nationalist control following. the end of the war, the two existing 30-ton open-hearth furnaces were converted into 40-ton furnaces, and one gas producer (13 tons a day) was newly built. The output, however, never matched that of the Japanese era. f. In 1952, after the Chinese Communists had taken over control, plans were drawn up to increase the various types of facilities, and the basis for a planned stee:L output of 130,000 tons for 1953 was set up. During the first half of 1952 the two 40-ton open-hearth furnaces were each converted into 50-ton furnaces. In autumn 1952, one 50-ton open- hearth furnace was added. Also in 1952, two gas producers (30 tons a day each) and one ingot pit were newly built, while three other ingot pits were enlarged. The addition of ladle crane had not been carried out even by spring 1953. This formed the production bottleneck of the department. 2. History of the electric furnace steel department a. The iron and steel works had no electric furnace facilities during Japanese control before the war's end. The manufacture of electric furnace steel was entirely dependent on the adjacent Yu-ts ' ai Machinery and Tool Plant (presently, the T'ai-yuan Machinery and Tool Plant). b. The works started manufacturing electric furnace steel in 1952. Electric furnaces were brought in from the coastal area in 1952, and in autumn two 3-ton electric furnaces were in operation. Also, efforts were being made to have the two $-ton electric furnaces that were then being brought in from TANG-SHAH in operation by the end of 1953. C. The transfer of these electric furnaces was at first motivated by the policy for the dispersal of the coastal iron and steel industry to the interior because of the Korean War. Thereafter, from the general standpoint of constructing iron and steel centers in CHINA, the transfer was made under independent plans. C . Open-hearth Furnace Steel Manufacture 1. Facilities a. Layout of facilities for open-hearth furnace steel manufacture -- see Chart No 10-17. b. Size of the plant buildings -- see Table No 10-25 84 SHANDLING REQL I BED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) C. Cross-section of the open-hearth furnace plant buildings -- see Chart No 10-1$. d. Table No 10-26 Data on open-hearth furnace facilities -- see e. Structure of the open-hearth furnace -- see Chart No 10-19 f. Structure of gas and air ports -- see Chart No 10-20 . g. Chart No 10-21 Brick-laying prodedure for the regenerator -- see h. see Table No 10-27 Refractory materials used in the open-hearth furnace --- is Gas producer facilities -- see Table No 10-28 j. Structure of the ladle car -- see Chart No 10-22 k. see Chart No 10-23 Structure of the ladle used for molten steel -- 1. Shape of the ingot cases used for rimmed steel see Chart No 10-24 2. The removal and destruction of facilities No facilities have been affected. The US air raid just before the end of the war and the Chinese Nationalist air raid directly follow- ing the seizure of this plant by the Chinese Communists inflicted virtually no damage upon the open-hearth furnace plant. 3. Improvement of facilities The open-hearth furnace facilities were mainly improved since 1952. The main improvements are as shown on Table No 10-30. Note: Three technicians took part in improving the construction plans. One was a detained Japanese, another was an assistant superinten- dent of the works, and the third was a Chinese engineer (graduate of the Kuramae Higher Technical School in JAPAN). 4. Increasing of facilities The job of increasing open-hearth facilities lagged somewhat behind that for the pig-iron manufacturing department. The first-phase basic construction plan was put into effect from 1952? In spring 1953, plans for the second-phase basic construction (from 1954) took shape. Table No 10-31 shows the increase in open-hearth furnace faciliti es at the end of the first quarter of 1953. Note: In the second phase of basic construction, plans called for the addition of two 50-ton open-hearth furnaces (and two $-ton electric furnaces). Information on this matter is covered under section on "Basic Construction". SPECIAL HANDLING BEQI.IBEP NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) 5. Defects in facilities from the standpoint of capacity and layout. a. Defects a:n capacity (1) Shortage in the capacity of ladle crane In September 1952, the capacity of the open- hearth furnace was increased to 50 tons, but that of the ladle crane remained the same. This was the major factor restricting the steel output at the time. According to the load coefficient, there should be a surplus of 20 to 30 per cent in the capa- city of the existing 50-ton crane. However, since it is already superannuated, the crane and its crag were re-enforced. In spite of this fact, the steel output was restricted to 33.5 tons as a result of the load tests by Russian specialists in early 1953. This is a much stronger restriction than the 38 tons of early 1952. For a time, both the 40-ton ladle and the 10-ton ladle used on the electric furnaces were utilized, and the ladle crane and ingot cranes were also mobilized, but operations did not run smoothly owing to a shortage of cranes. The 70-ton crane that was proposed to be newly built at the time was scheduled to arrive from the USSR in late 1952? But since it had not arrived by late April 1953, it was inevitable that the 1953 plans for steel production had to be extensively revised. The operations of the three open-hearth furnaces were greatly hampered, since the number of cranes remained the same. Painstaking efforts were made in regulating the progress of the operational process. Note: It seems at the time, however, that the 70-ton crane was sure to arrive soon. (2) Open-hearth furnace combustion method The present firing method by means of gas producers is an old combustion method; hence, the heating efficiency is necessarily poor. (3) Lack of mixers Since there are no mixers, the hot metal is carried by ladle cars. The ladle is covered while awaiting charging. The lowering of heating efficiency .s unavoidable. When a mixer is used, the temperature of the hot metal drops only five degrees Centigrade an hour, but under the present conditions where 86 SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECE1 Doc No 90225 (10) (PB) there are no mixers, the temperature drops 10 degrees Centigrade an hour. It is also impossible to satisfactorily obtain unifor- mity in the quality of the pro ducts. (4) Method of laying bricks in the regenerator The bricks in the regenerator are lain in a cylindrical manner. In this method the con- sumption of bricks for each ton of steel manufactured is greater than in other methods. (5) shortage of charging cranes and ingot cranes 'here are two charging cranes and two ingot cranes for the three open-hearth furnaces. Since a high degree of operating efficiency is demanded, and there are miscellaneous uses and periods of waiting, these facilities cannot be considered as being adequate, b, Defects in the layout Since there is not much space at the plant site, the plant will become very crowded if the two proposed 50-ton open-hearth furnaces and the one 300-ton mixer are newly built. There will not be any room to even move around. The most difficult problem is that there is no extra space in the raw materials yard. Consequently, the present smoke- stack used by the open-hearth furnaces and the gas producers may have to be moved. When the five open-hearth furnaces are lined up in a row, the idea of setting up the raw materials yard at one end, as is the case now, will prove inefficient. It will probably be necessary to have the raw materials yard directly connected with each open-hearth furnace from the side. 6. Balancing of facilities a. Coordination with the pig iron manufacturing facilities Coordination between the pig-iron manufacturing and steel. manufacturing facilities will not be re-explained here since it has already been d escribed in III, C, 6, b of this chapter. Preference was given to the construction of new steel manufacturing facilities. There- fore it seems that when the pig-iron manufacturing capacity temporarily fell behind, consideration was given to the idea of supplying pig iron from the Yang-ch~uan Pig-iron anufacturing Plant. b. Coordination with rolling facilities The medium rolling plans for 1953 called for 125,000 tons of billets, sheet bars, end steel stocks. Originally, the planned operating rate for rolling in 1953 (decided at the end of 1952) was 75 per cent. However, the rolling operation rate of the advanced enterprises in CHINA (laN-SHtiN, for example) had already reached $5 per cent at the time. It seems that the realiza- tion of this advanced operating rate thereafter became the target f this works, too. Therefore, based on this advanced operating rate of $5 per cent, the maximum amount of steel that can be roled would be roughly 140,000 tons. g7 L SPECIAL HANDLING REQ1JIBED NOT RELEASABLE TO FOBEICN NATIONALS .SE.CRET. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) Planned anent of Planned amount of steel Planned amount of bloom rolling manufactured in open- steel manufactured in hearth furnaces electric furnaces 125,000 tons s (130,000 tons 4 $,100 tons) _ 0.9 141,250 tons Since the recovery rate (yield rate) in rolling for 1953 is believed to have been roughly 90 per cent (see Note below) and the acceptance rate of steel bloom is 99.5 per cent, approximately 160,000 tons of steel ingots were needed for the medium rolling of 140,000 tons. 140,000 tons f 0.9 t 0.995. 160,000 tons Note: The basis for estimating the yield rate for rolling is as shown below: The original planned steel output for 1953 was 138,000 tons from the open-hearth furnaces (three 50-ton furnaces) and electric furnaces (two 3-ton furnaces) combined. But later (spring 1953), owing to the delay in improving the open-hearth furnace accessory equipment, the planned output was somewhat lowered. However, there were prospects that the improvements in the open-hearth furnace accessory equipment would be .ccomplished in a very short time. Therefore, it was believed that when these improvements are made and the abovementioned steel tr nufacturing facilities begin to show high efficiency in production, steel output of 170,000 to 1$0,000 tons during the year would be achieved. With just these conditions as a basis, it can be said that rolling and steel manu- facturing facilities were in a virtual equilibrium even when the rolling department attains the earlier mentioned advanced operating rate (that is, when the amount of steel needed is 160,000 tons). It was believed, however, that this balance would be upset after 1954 or 1955? This is because in spring 1953, concrete steps were being taken to construct two new 50-ton open-hearth furnaces and two $-.ton electric furnaces and it was believed that they would be completed in 1954 or 1955? Therefore, it can be said that the balance between steel manufacturing and rolling facilities at that time was destined to be upset by the rolling department unless rolling facilities were in- creased proportionately during this same period. It is reported that to cope with the expansion in the steel manufacturing department, transfer of the small bar mill was being studied for the purpose of strengthening the medium bar rolling facilities. 125,000 tons x 0.$5 0.75 7. Operational methods a. Operational process -- see Chart No 10-25 b. Operation of the open-hearth furnaces (1) Raw materials charging method Before the Chinese Communists took control, blast furnaces No 1 and No 2 had operated simultaneously for only a short period of time; therefore, the ?8 ' SPECIAL HANDLING REQI IRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) supply of rwlten pig was irregular and generally the "chilled pig and scrap" . method had to be used, After the Chinese Communists took control, they temporarily followed the method that had been in use. But from about 1950, they switched to the "hot metal and ore" ;~ethod, which they have continued up to the' present day. (2) Raw material charging order After the heat is tapped, remnant slag is scraped out and the hearth is readied; then pre-charging begins. First of all, small type teeI scrap is charged followed by large type steel scrap. This is then followed by the charging of ingot pig ( chilled pig) and iron ore. About half of the limestone is charged at the same time as the steel scrap. Since there are no mixers, the hot metal is kept ready on hot-metal cars. During this period small broken up iron ore is put into the hot metal, and compressed air is blown in to speed up deoxidation, decarburization, and desilicification. The idea in mind is to shorten the time needed for refining. (3) Charging procedure (a) Charging cold material The cold material is loaded into charging boxes (capacity, 2.5 tons) in the raw materials yard located at one end. Then it is hoisted onto the deck of the open- hearth furnaces by dollies and distributed to the side of each furnace. SECRET There was a rather smooth supply of scrap iron during the Japanese era, but during the Chinese Nationalist era following the war, the supply became rather stringent.. When the temperature of the above charge reaches the stage where it is about to melt, the after-charging starts, in which the hot metal is charged by means of the hot metal charging trough. When the melting is over, limestone is put in. When the refining is completed, the ferroalloy is put in immediately before the heat is tapped. When it is time for charging, the charging box is suspended on the tip of the ram by a charging crane. It is then carried to the front of the open-hearth furnace and charged into the furnace from the charging door in front. L SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) (b) Charging time One charging operation takes a minute to a minute and a half, but the overall time is about two minutes. (There are times when only 500 kilograms can be put into the charging box when the scrap is thin. This affects the charging time.) How the charging time has been reduced in the single operation of an open-hearth furnace is shown below. (4) (c) SECRET 1 2 Under Japanese ar1d Chinese Nationalist management (30-ton open-hearth furnaces used): three to three-and-a-half hours. Under Chinese Corri..nunist management (last- half of 1952; 50-ton open-hearth furnaces used): two hours. Hot metal charging The hit metal is hauled by a ladle car to the place where the ingots are made. It is charged from the charging door on the back wall of the open-hearth furnace by a ladle crane. The hot metal in the ladle was weighed previously at the entrance of the open-hearth furnace plant. At this time, allowances are made for hot metal sticking to the ladle. Blowing in of air arid gas (a) The flow of air and gas through regenerators on both sides is reversed every 15 to 20 minutes. (b) At the flue entrance the gas is 500 to 600 degrees Centigrade; at the entrance of the combustion chamber, 1,200 degrees Centigrade; and when mixed with air inside the combustion chamber, 1,2$0, degree Centigrade. The gas pressure at the water column is $0 to 120 millimeters. (c) When the air is blown in, it is 1,000 degrees Centigrade in the flue, and this air is heated up to 1,200 degrees Centigrade after it enters the regenerative chamber. The blowing in of air is regulated by a winch that opens and closes a value (lid) at the air inlet (completely open during melting process, slightly open during refining process). 90 SPECIAL HANDLING REOEIREO NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 r I_ ? 7 tt.,:: s Doc No 90225 (10) (PB) (5) (d) The Soviet method of steel manufacture has had its influence since the last half of 1952, and the method of blowing in air by a compressor has been adopted. A record of the air blown in is determined from the readings on the CO2 meter. (e) Also in use experimentally is the so-called oxygen steel process whereby oxygen is run into the open-hearth furnace by a tube from a gas cylinder. Use of the Bessemerizing method This method has been used since 1950 under the supervision of Soviet technicians. This is the method in which a one-inch pipe of five meters in length is immersed in the molten steel and compressed air is blown in. This speeds up decarburization and desilicification (method of shortening the oxidation time). The pipe is made by rolling up thin iron plates. But since the tips of the pipes melt quickly because of the heat, an open-hearth furnace is equipped with ten pipes for each operation. There is nothing especially new about this method, but it should be noted that it points out cha- racteristics of the Soviet method of steel manu- facturing whereby emphasis is placed on oxidation time which had heretofore been disregarded. (6) Temperature of the steel bath (7) The temperature of the steel bath is 1,650 degrees Centigrade. The temperature of the molten steel when tapped is 1,620 degrees Centigrade. Temperature of the regenerator The temperature of the regenerator reaches 1,450 degrees Centigrade. The temperature is measured by a pyrometer. ($) Discharging of waste gas Waste gas is discharged through a small flue in . the regenerator and then out through the snake stack. It is dischargedand replaced with fresh gas and fresh air by the gas reversing valve and air reversing valve. Note: Recently, a sensitive pressure regulator (a device which regulates pressure by electric currents transmitted from the pyrometer) has come into use. This regulator automatically regulates the pressure of the reversing valves and the adjustments on the large damper. However, in T'AI-YUAN in spring 1953, it was not as yet being used. [__SPECIAL HA DUNG REQLIBEO NOT BELEASABLE TO FOREIGN NATiONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) (9) High speed assays Materials are assayed twice to judge the quality of the steel, once immediately after the steel melts and once near the end of the refining process. The main purpose of the first assay is to assay the material to see how much ferro- alloy, etc is to be added, and the second assay is to determine the tapping period. In order to report the results of the high speed assay promptly to the shop, a signal light is installed in front of the furnace so as to eliminate SHISETSUJI (TN Presumably "time loss~r) iY refining time. Thai s signal light i.s designed in such a manner that it can show the percentage of components in figures from 0 to 9 and the names of such elements as silicon, manganese, carbon, sulphur and phosphorus. (10) At the time of tapping, the molten steel (bath) is poured in a ladle, but the slag immediately floats to the top of the bath. This slag is run off into a slag receptacle, but it immediately solidifies. The slag, since its iron content has no useful value, is disposed of in an open space outside the plant. Normrlly, the chemical composition of the slag was as shown below, but the Ca0/Si02 (basicity) of 2.5 to 3.0 was regarded as ideal. (a) 5102 -- 17 to 1$ per cent (b) CaO -- 40 to 50 per cent (c) A1203-- 5 to 6 per cent (d) FeO -- S to 9 per cent (e) Fe203 -- 5 to 6 per cent (f) MnO -- 5 to 6 per cent lapping is called "opening a hole". A hole is dug from the tap hole into the hearth and tapping is carried out. The tapped molten steel is received in a ladle and after the slag has been removed, it is sent to the ingot casting yard. With skill, the hole-opening operation generally takes five to six minutes, and the bath starts flowing. Sometimes the operation takes as long as ten minutes, I2 SPECIAL HANDLING BEQL IBED NOT RELEASABLE TO FQBE1GN NATCNALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) C. Controlling the heat (1) Calorific value of the producer gas -- see Table No 10-32. The calorific value is above normal, since the excel)ent coal produced at TA-T'UNG is used. (2) Calories consumed In the plans for 1953, for each ton of steel manufactured, 1,400,000 to 1,600,000 kilocalories of producer gas were consumed. The basis for this calculation is as shown below. Amount of gas Coal for manu- Amount of producer gas produced by one factoring one needed for manufacturing kilogram of coal ton of steel one ton of steel 3 to 3.5 cubic meters x 330 kilograms . about 990 to 1,155 cubic meters Calories to one Calories consumed for mane cubic meter factoring one ton of steel 990 to 1,155 x 1,400 kilogram calories about 1,400,000 to 1,60,000 cubic meters kilogram calories From the standpoint of thermal efficiency, it can probably be said that this amount of con- sumption is far below the present international standard ($00,000 kilogram calories when hot metal is the main constituent, and 1,200,000 kilo calories when the rain constituents are scrap steel and cold pig) Note: 1. According to the plans for supply and demand of raw materials in manufacturing steel at this works in 1953, $00 kilograms of hot metal and 275 kilograms of scrap steel were used to make one ton of steel, 2. As reference, shown below is the amount of calories needed to manufacture a ton of steel at the Yawata Steel Works. a. During the war: 1,300,000 kilocalories b, Latter half of 1953: 990,000 kilocalories c. First half of 1954: $40,000 kilocalories Dispersion of heat -- see Table No 10-33. Focal point in improving thermal efficiency The USSR is reported to be presently consuming $00,000 to 1,000,000 kilocalories of heat for the manufacturing of one ton of steel. Conse- quently it can be said that there is much room 93 LSPECIAL E1ANDLING BEQLIRED NOT RELEASABLE TO FOREIGN NATION, SECRET SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECFET Doc No 90225 (10) (PB) for improving the thermal efficiency in the present setup in Communist CHINA. Noting this point, Communist CHINA has taken up the subject of raising the thermal efficiency. Since the crux of the matter is found in the imperfect combustion of the producer gas inside the meltirg chamber of the open-hearth furnaces, one of the main problems is to stop the escape of imperfect combustion gas to the regenerator. The temperature of regenerators is set at 1,250 to 1,300 degrees Centigrade. At T'AI-YUAN in spring 1953, the regenerator temperature was 1,4+50 degrees Centigrade, and the heat loss was very great. As a result, the bricks in the regenerator quickly disintegrated. This brought on the inconvenience of necessitating an earlier cold repair. For this reason, a university graduate technician is permanently assigned at the plant to measure the temperature of the regenerator. In this way the plant authorities are trying to find a means of improving the thermal efficiency. d. Ingot casting operation (1) The dispnsitir~n rf plates, central runners, and molds (a) Number of plates (casting pits) 1 During the Japanese and Chinese Nationalist eras: three 2 During the Chinese Communist era: four (b) Number of central runners 1 During the Japanese and Chinese Nationalist eras: three 2 During the Chinese Communist era: four (c) Number of molds: 1$ (2) Molds There are various types of ingot cases depending on the sizes of the ingots and the quality of the steel. The two following types were usually used at this plant. (a) For ordinary steel ingots: Top thickness, 250 millimeters; bottom thickness, 270 millimeters; height, 1,500 millimeters; weight of the steel ingots, 680 kilograms; square-shaped with the large-end down. SPECIAL HANDLING REQL I BED NOT a LJ SP.ELE SECRET 1:1 _.:_; Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SE CS El Doc No 9225 (10) (PB ) (b) For killed steel ingots The cubical content is the same as those of the molds used for ordinary steel ingots. They are square--shaped with the large-end up and with riser heads attached. Before the Chinese Communists took control, the ordinary ingot cases weighed about 500 kilograms and they measured 20 millimeters less than those mentioned above. (3) Teeming method Bottom-pouring method is used and the molten steel is poured directly from the ladle into the central runner. (4) Care of molds and life expectancy After the molds are used, materials such as brick dust that are stuck to it are removed. Then the mold is coated with graphite and put aside. The molds are used about 120 times. (5) Preheating of the ladles The ladles are heated by coke-rven gas before they receive the molten steel. (6) Procedure for stripping opereti~n (a) Time to start stripping -- 40 to 60 minutes after the molten steel is pured (b) Temperature at time of stripping -- tem- perature of the steel ingot, about X50 degrees Centigrade; temperature of the case, about 150 degrees Centigrade Generally speaking, the ideal temperature ()f the cases at the time ref stripping is 90 to 100 degrees Centigrade and the stripping operation is withheld until the cases cool naturally to that temperature. At this plant, however, the ingots are stripped sooner than normal because of the frequoncy of use of the cases and because of plate replacing operations. (c) Methcd of removing the molds The case is removed by lifting it with an ingot crane. 95 0 SPECIAL HANDLING fEQUIRED NOT , :EP}ALE TO FC~'r ,;C SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) e. Operations of the gas producers (1) Since there is no directly attached boiler, steam is brought in from the coke-oven boiler through an asbestos-wrapped pipe. It is important that the steam intake be regulated in order to make the combustion inside the furnace uniform. (2) Air is blown in by blower. When this is done, attention is given so that a large volume of air is blown in to increase the gas calories. The foreman measures air pressure with a pressure gauge and regulates it. (The air pressure is 1.0 to 1.5 kilogram). (3) Coal is lifted by a 2-ton hoist to the top of each furnace and it is dumped in the hoppers on each furnace. Care is taken to see that the coal (coking coal) does not stick together. Coal of poor coking property is best. (4) The gas generated in each producer is run to a main pipe, from which the gas is then sent to the open-hearth furnace by a pipe five meters above the surface. Gasification point The gasification point is $00 degrees Oentigrade. The gas is of three colors: black, white, and pink. The gas, when it is pink is at its best. The gasification point is $00 degrees Centi- grade, but gas temperature drops to 500 to 600 degrees Centigrade at the entrance to the flue. At the entrance to the combustion chamber in the open-hearth furnace, the gas temperature rises to 1,200 degrees Centigrade. The gas is then mixed with air and the tem- perature rises to 1,280 degrees Centigrade, $. Improvements in operational technique Technical improvements achieved as a result of the introduction of Soviet techniques. a. Increase in the amount of air blown in (put into effect in the first half of 1952) By adopting the so-called Soviet-type steel manufacturing - method, it was possible to increase the amount of air blown in and to speed up decarburization. The air is fed in by a compressor. 96 0 I__SPECIAL HANDLING REOL I RED NOT SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) b. Putting into practice the Bessemerizing method (used since 1950) It was put into effect under the practical guidance of Soviet technicians. This is the method whereby a pipe, five meters long and one inch in diameter, is inserted into the molten steel when the steel is being refined. This is for the purpose of speeding up decarburization and desilicification. c. Adoption of the oxygen steel manufacturing method In 1951, an oxygen supplying apparatus was connected with the air reversing valve apparatus on a test basis. The idea was to raise the temperature in the furnace at melting time and to shorten the steel manufacturing ti ue. 0 ygen was brought in in oxygen cylinders from an oxygen plant outside the works. The apparatus is a simple one in which oxygen is run through a tube from the oxygen cylinder to the air insertion hole. This apparatus is depicted on Chart No 10-27. Note: The oxygen steel manufacturing method is one of the methods that the USSR has been boasting about to the whole world. when the air pressure is increased to realize a perfect combustion inside the open-hearth furnace, there is the disadvantage of lowering the regenerator temperature. However, if the oxygen is supplied as it is in this method, it not only eliminates this disadvantage but it also reportedly lowers gas consumption, which is a desirable effect. d. Regulating the opera.ticns of the gas producer The gas calories can be increased by blowing in more air than steam. Consequently, the foreman (a skilled worker) regulates the amount of air and steam blown in. 9. Labor a. Distribution of workers engaged in open-hearth furnace steel manufacture -- see Table No 10-34. b. Changes in the number of shifts (1) Japanese era (a) In 1941: single shift system (b) After the end of 1942: two-shift system (2) Chinese Nationalist era after August 1945: two-shift system (3) Chinese Communist era after July 1949: . three-shift system Note It is reported that by the adoption of the three-shift system, the workers are not as tired as they had previously been, and that their will to produce has risen tremendously. 97 SPECIAL HANDLING REQUIRED NOT BLLEt SJ BLL TO F ri G~, SECRET _-.~ ,~r # Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECFE1 Doc No 90225 (10) (PB) C. Working hours After the three-waft system was adopted, each work shift lasted eight hours, or nine portal-to-portal working hours. However, since there are two hours of study each day, the actual portal-to-portal time is 11 hours. d. Degree of workers? skill (1) Japanese era In 1941 (two open-hearth furnaces, one generally in operation), the workers were unaccustomed to steel r?~.nufacturing operations. Consequently, a lot of time was required to n nufacture steel. There were only about two heats turned out every 24 hours, Note: This inefficiency was also due to the fact that Hsi-span coal (poor gas content) was used. The practical training given to workers thereafter gradually began to show, and by February 1942, turnover was about three heats every 24 hours. (2) Chinese Communist era -There were five or aix ekilled workers ;j. the open-hearth furna ee plant. They supervised and pushed the operations of the entire plant. In 1952, turnover was 3.4 to 3.$ heats every 24 hours. 10. Raw materials a. Source of principal raw materials (1) Pig iron Pig iron is supplied entirely by the pig-iron manufacturing department within the works. During Japanese control, the operation of blast furnaces was irregular, therefore, mostly cold pig iron was used. With the simultaneous operation of the blast furnaces No 1 and No 2 after the Chinese Conpnunists took control, molten pig iron came to be mostly used. Cold pig iron is used at times but the amount is very small. (2) Steel scrap In 1953 steel scraps consisted of those widely collected from throughout SHANSI Province, and the Tientsin and Shanghai Areas, and those re- covered from the ingot casting and rolling mills within the works (scraps from ingot casting, rejected steel, rolling scraps and miss-rolled products), t seems that the ratio of these two groups of scrap sources was about half and half, 98 SPECIAL HANDLING REQUIRED NOT BELEj SII.BLE TO FGHEiC~ N SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) During Japanese control, this mill was de- pendent on the army for the supply of steel scraps; therefore, no shortage was felt. During the early period of Chinese Communist control steel output was small and the steel scrap mixing ratio was only about 10 per cent. Therefore, the requirement in itself was not too great. However, the supply of scrap steel was very difficult due to faulty transporta- tion, poorly organized system of collection and the lack of permeation of political influence. In 1951 raw steel was produced by converters as a substitute for steel scrap, but this was soon discontinued due to unsatis- factory results. After 1952 the demand for steel scrap suddenly increased due to the increase in steel output and especially due to the improvement in the mixing ratio. Insurance of the necessary absolute amount of steel scrap, however, is becoming more difficult in spite of the fact that remarkable improvements have been nide in transportation, in the collection system and in the permeation of political influence. It is presumable that this situation still prevails today. b. Supply of secondary raw materials (1) Limestone (flux) Limestones produced in HSI-SEAN and TUNG-SEAN in the vicinity of T'AI-YUAN are being used. Limestone having more than 50 per cent lime content and less than one per cent silicon dioxide content is said to be desirable. This limestone also contributes to deoxidation, desulphurization and desilicification , The amount of limestone charged, including quick- lime, is about seven per cent of the steel out put . (2) Quicklime (flux) Quicklime produced by the roasting furnace of the ammonium sulphate plant within the works is being used. (3) Fluorite (flux) During Japanese control, fluorite produced in WU-CH'ENG-CHEN (located 100 kilometers south- west of T' AI-YUAN between FEN-YANG and LI- SHIH on the South T'ungp'u Line) was used, but since the quality was poor, it was replaced by fluorite produced in TSINGTAO. 99 SPECIAL HANDLING BEQL I BED NOT BEY EASABLE TO FOREIGN NAT . .., SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) (4) The Tsingtao fluorite was used even after Othe Chinese Communist took control. It has to 60 per cent calcium diflu0tiused every time not This fluorite, however, is steel is manufactured. It is salso?used in lating the slags. Fluorite was claybricks. Iron ore (oxidizing agent) Iron ore equivalent to about five per cent of the steel output is charged asideoxi deoxidizing agent. Iron ore used at present LI-KUO . Of produced in LUNG-YEN, WU-AN the above, the ore from WU-AN is considered the best because it contains a large used of ferrous-oxide. Lump ore is specially us to accelerate deoxi.dation. (5) Scale (oxidizing agent) The oxide coating on steel materials which appear at the time of rolling is call battetura in Communist CHINA. It was dis- carded during the Japanese era but it is reported that the Chinese Communists began to use it from around 1952. (6) Manganese (oxidizing agent) Under Japanese control, this mill was mainly dependent upon the rnganese imported from INDIA, but when sea transpo rta~~ of the war, difficult during the latter pa manganese produced in CHING-LO (75 kiloers northwest of T t AI_YUAN) of SHANSI Province ? to was used, or iron ore (~ pUeYANG of SHANSI 10 per cent) produced in SH Province was used as a substitute. After coming under Chinese Commmunist control, manganese ore produced in CHING LO (50 to 60 first per cent nr~ngane se content) was used , but this source has been mined out. There- after, after, the ferro-manganese (Mn Fe) produced in AN-SHAH and TIENTSIN, or spiegeleiSen in YANG-CHUAN has been used. manganese is not used too much because its cost is high. It seems that manganese ore ( 32 to 35 per cent manganese content) produced in LO-P'fliG of HUNAN Province is mainly used at present. (7) Silicon (addition agent) In auturi 1952 some ferrosilicon (Fe-Si) was manufactured at the electric furnace plan within the works, but at present Tientsin products are being used. 1Co SPECIAL HANDLING BEQL I BED NOT RELEASABLE TO FOREIGN NA'. SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 1 ; Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) ($) Phosphorus (addition agent) The supply source of f errophosphorus for sheet metal is unknown. C. Mixing ratio of raw materials After coring under Chinese Communist control, a mixing ratio of 90 per cent pig iron and 10 per cent steel scrap was adopted because of the difficulty in securing steel scrap. In early 1952 the mixing ratio was changed to 75 per cent pig iron and 25 per cent steel scrap by order of the Ministry of Heavy Industry of the Central Govern- ment in conformity with the national pig iron supply and demand plan. Thereafter 800 kilograms of pig iron and 275 kilograms of steel scrap were charged for each ton of steel produced. The change in the mixing ratio since the Japanese era is as shown on Table No 10-35. d. Amount of raw materials charged The total amount of charge is 120 to 121 per cent of the steel output. A rough estimate of the yield rate of iron content is 93 per cent. The amount of charge in e any 1953 was as shown in Table No 10-36 and the order of charge is as shown on Table No 10-37. e, Amount of raw materials required The amount ,rf raw materials required in the steel manu- facturing plan of 1953 (annual output, 130,000 tons) which was decided upon in late 1952 was as shown in Table No 10-3$. According to the revised plan of spring 1953, the planned amount of steel manufacture was lowered to 114,2$0 tens. It is presumable, therefore, that the amount of raw materials required also decreased abut 10 per cent. f. Supply and demand of raw materials for gas producers (1) Supply source Ta-t-ung coal was used in 1953? The quality of this coal is excellent. Stun was supplied from boiler room Tao 2 of the asking plant within the works. (2) Calorific heating power The calorific value of producer gas is about 1,450 kilocalories per cubic meter. This is (3) 200 kilocalories more than ordinarily obtained. Amount of consumption The amount of coal consumpti'n in the 1953 plan was 300 to 330 kilograms per ton of steel output. The amount of coal needed for the gas producers to meet the initial steel manufacturing plan of 1953 was 39,795 to 43,775 tons. 101 F_SPECIAL HANDLING REQUIRED NOT AELEr SABLE TO FOREIGN ' SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Dr~c No 90225 (10) (PB) This figure can be substantiated from the gas- producing facilities. The method of computa- tion is as follows: Daily coal Daily coal Daily total consumption by consumption by coal the old facilities the new facilities consuinpti~n (13 tons x 6 gas producers) 4- (30 tons x 2 gas producer= 138 tins a day 138 tons x 365 calendar days x 0.85 operating rate = 42,7$0 tons a year Computation with the daily steel output as the standard would be as follows: 425 tons (daily steel output) x 03 to 0.33 ton (coal consumption per ton of steel output) - 127.5 to 140.25 tons a day (daily coal consumption) Note: The amount of coal consumption by the old facilities (five producers) during Japanese control was 35 to 40 tons a day because each producer consumed seven to eight tens. g. Motive power Power is received from the thermal power plant located within this works. The consumption rate is unknown. 11. Production a. Daily (1) (2) There were tw^ 40-ton open hearth furnaces during Chinese Nationalist control. As regards the daily output, there was not too much dif- ference from that during Japanese control. Especially after summer 19L$, the output suddenly decreased because of the difficulty in obtaining raw materials. Finally production became impossible. 102 SPECIAL HANDLING BzQ I Btu? NOT RELEASABLE TO FOBEI GN SEcRE1 output Japanese control There were two 30-ton open-harth furnaces during Japanese control. One steel manufacturing opc ratiCn required about eight h'.urs. The daily output during 1942 to 1943, the most active period, was about 150 tons. Due to furnace re- pairs and difficulty in obtaining raw materials, the period in which the two furnaces were in full operation was short, and the steel output rarely attained the rated capacity. Throughout Japanese control, the maximum output was 170 to 180 tons when the two furnaces were in operation at the same time. Chinese Nationalist control Lkl Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Dcc No 90225 (10) (PB) (3) Chinese Communist control Efficiency in production improved yearly after 1951. In spring 1953, the daily production reached 425 tons. Facilities at that time consisted of three 50 ton open-hearth furnaces. Even with the operational technique of that time, the actual daily output capacity must have been about 560 tons, but due to the super- annuated attached facilities (ladle crane), the actual operati^1n was limited to the 425-ton level. b. Annual output The annual output of products meeting specifications was as follows: (1) Peak before the end of the war (1912) (a) Two 30-ton open-hearth furnaces: about 36,000 tons (b) Maximum monthly production: 4,000 tons (c) Average monthly production: 3,000 tens (2) In 1949 (the year in which the Chinese Communists confiscated this works) -- two 40-.ton open-hearth furnaces: 20,000 to 30,000 tons (3) In 1952 There were two 50-ton open-hearth furnaces since spring and three 50-ton open-hearth furnaces since Septe nber . The steel output for the year was 91,200 tons, (4) In the 1953 plan (a) There were three 50-ton open-hearth furnaces (b) Controlled figure of the Ministry of H'avy Industry in August 1952: 134,000 tons . (c) Planned figure decided in December 1952: 130,000 tons. (d) Planned figure revised in spring 1953: 114,280 tons 103 r SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NA 'T `'" ~L SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Dac No 90225 (10) (PB) C. Computation of the planned amount for 1953 26 square 5.44 tons (1) Computation of the figure decided in December 1952 meters (effective hearth area) x per square meter a day (effective utilization coefficient) x 3 (number of furnaces in operation) 425 tons a day ( daily output). hearth area 425 tons (daily output) x 365 (calendar days) x 0.$5 (operating rate) x 0.99 (hot metal recovery 0.99 (percentage accepted & 129,200 tons a year steel output) rate) (annual Note: This computation shows a shortage of $00 tons, but details are unknown. (2) Computation of the figure revised in spring 1953 33.5 tons (steel output per furnace per operation) x 24 hours 6.4 hours (frequency of tapping a day) x 365 ( lendar days) x 0.85 (operating rate) x hot metal recove 'ae x 0.9 percentage accep d) 14,5$6 tons a year (annual output of accepted steel) Note: This computation shows an error of 360 tons but details are unknown. d. Itemized production The planned output by items for 1953 (fixed in December 1952) is as follows: (1) Rimmed steel: 9$,700 tons (2) Killed steel: $,$00 tons (3) Sheet steel: 22,500 tons (4) Total: 130,000 tons Note: Besides the above, a small amount of cast steel is produced the purposes of making rollers. for It is believed that under the revised plan of spring of 1953, the production of rimmed steel was reduced by about 16,000 tons. The reason for this is that this portion consists of billets for out- side sales. C. Specifications For details see the "List of Provisional Specifications for Products" entered under section XI of this chapter. 104 L SPECIAL HANDLING BEQUIBED NOT RELEASABLE TO FOREIGN NATC'i-':..3 SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) (1) Classification of steel (a) No CO -- steel that do not meet specifications; mostly steel with high phosphorus content. (b) No Cl (c) No 02 These are called rimmed steel, and are of MC specifications; (d) No C3 carbon content, 0.10 to 0.35 per cent. (e) No 04 (f) (g) No C5 No C6 ` Killed steel of AC specifi- I cation No Cl to No C3 steels are mainly used as con- struction materials. Sheet steel is mild steel and is classified by its phosphorus content. No 04 to No 06 steels are used for shafts and structural purposes. The specifications differ from those of JAPAN in that they are somewhat more flexible, but otherwise they are generally the same. (2) Size (seven different sizes) (a) Medium size -- three sizes (680 kilograms, $oo kilograms and 1,000 kilograms) (b) Small size -- four sizes ($0 kilograms, 130 kilograms, 180 kilograms and 250 kilo- grams) The 680-kg wide-bottom rimmed steel ingot and the 650-kg, wide-top killed steel ingot with riser are the two sizes most commonly used. These sizes will probably not change for a while because they are for mass production of ingots for medium size rolling. Sizes and shapes of commonly used steel are as shown in Chart No 10-28. f e Distribution of products All the rimmed steel, killed steel ar.d sheet steel pro- duced under the 1953 plan were to be delivered to the medium bar rolling department within the works. Steel for casting rollers are delivered to the roller plant. g. Disposition of recovered scraps Scraps (steel scraps sticking to ladles, gits and plates) obtained from ingot casting and rejected steel are charged into the open- hearth furnace and regenerated. 145 __SPECIAL HANDLING BEAU I BED NOT BELEASABLE TO FOREIGN e?'Tr Ft I LL _`A SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) ii. i-i1.?J1JtJ ai t) f t__ ags Slags are thrown away into a depression which is located outside the plant but within the compound of the works. 12. Production data of open-hearth furnace steel manufacture a. Effective utilization coefficient of equipment (1) In the 1953 plan Equipment utilization coefficient for each furnace was generally 5.44 tons per square meter per day in late 1952 At first this coefficient was the basis for computing the planned output for 1953. .The average steel output per furnace computed inversely from this coefficient would be as follows: 26 square meters (effective hearth area) x 5.44 tons per square meter a day ( utilization coefficient} + Steel output of 37.73 tons is much too small a figure for a 50-ton open-hearth furnace, but as previously related, this is due to the limitation arising from the superannuated ladle crane. This figure was further reduced to 33.5 tons in spring 1953 as a result of the load test of the ladle cane conducted by Soviet specialists. The effective utilization coefficient in the revised plan, therefore, was further lowered. Computation of this coefficient is as follows: hours (frequency of tap = ing) 37.73 tons (steel output ;-. for each heat) 33.5 tons 2 hours 6.4 hours 26 square 4.45 tons (steel output for each heat) x (frequency of tapping per day) t meters (effective hearth area) 1 per coefficient) HANDLING ` EQL BED NOT f ELLA. ABLE O FOBEIGN NAT1'{iL. SECRCE i (2) square meter a day (effective utilization The effective utilization coefficient after the improvement of attached facilities In spring 1953, an order had already been placed with the USSR for a 70-ton ladle crane which was expected to be newly established. After its arrival, installation, and operation, it is obvious that the effective utilization coefficient will have immediately risen. It is presumed that the steel output per day per fur- nace in this case would attain 1$7.5 tons and the coefficient is computed as follows: 106 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 hour Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) i SECRE I 50 tons x 2 hours _ 1$75 tons t 26 square meters 6 . t, hours . . ? 7.21 tons per square meter per day b. Stee1-making time (1) During Japanese control During Japanese control, it required eight to nine hours to manufacture steel with a 30-ton open-hearth furnace. This was pro- bably because the cold pig and scrap iron method (35 per cent cold pig and 65 per cent scrap iron) was then being carried out. Due to repairs and time loss, the frequency of tapping in 1941 was generally twice a day, but in 1942 (the peak year before the war's end) tapping was generally carried out 3.0 to 3.5 times a day. (2) Chinese Communist control The hot metal method (molten pig iron 75 per cent; scrap iron, 25 per cent) is enforced. In 1952 the production of steel by the 50-ton open-hearth furnace ordinarUy required six hours and 20 minutes to seven hours. The shortest time on record was about five hours and 40 minutes. In the 1953 plan, the time required for manufacturing steel was determined to be an average of six hours and 24 minutes. (3.75 heats a day). This figure is presumed to be equal to the international standard, but Soviet specialists claim that it can be re- duced to about six hours and 10 minutes by the "quick steel refining method" which they advocate. It is believed that four charges a day will be realized in the near future. Breakdown of the average time required in manufacturing steel in the 1953 plan is as follows: (a) Tapping time: 5 minutes (b) Inspection, cleaning and minor hot repair Preliminary charging: about 2 hours Melting time: a little over 2 hours Refining time: 1.5 to 2 hours Preparations for tapping: 10 minutes 107 r._.. - ._ _. __._.. ... _._ ----- -- _ _ _ _- S HANDLING BE+0LIREB NOT RELEASABLE TO FOREIGN` NATIONALS I ~'ECIAL inside the furnace: 15 to 20 minutes Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) C. Operating rate (period of operation in one year) The operating rate has developed into a high rate incomparable to that under Japanese control. The actual output of 1952 was $4 to $6 per cent, and in the 1953 plan the average of each furnace was $5 per cent. This is equivalent to 310 operational days in a year. With each furnace being charged 3.75 times a day, each furnace would be tapped an average of 1,163 times a year. Results of 1952 showed that open-hearth furnaces No 1 and No 2 both exceeded 1,000 tap- pings during the year. d. Recovery rate (1) Recovery rate of raw materials (steel output against amount of charge) Recovery rate under the 1953 plan was 93 per- cent because the steel output was one ton.. for $00 kilograms of pig iron and 275 kilograms of steel scrap, or a total of 1,075 kilograms charged. Note; The raw material recovery rate is covered in the raw material supply and demand plan but not in the steel manufacturing plan. (2) Recovery rate of steel ingots (amount of steel ingot against the total steel output) In the 1953 plan the steel ingot recovery rate was fixed at 99 per cent on the basis of the results attained during the latter half of 1952. In this case the remaining one per cent (unre- covered portion) consists of steel sticking to the ladle and that spilt in teeming. e. Percentage of products meeting specifications The percentage of products meeting specifications is the yield rate of accepted ingot for the amount of steel ingot cast from molten steel. The percentage of products meeting specifications under the 1953 plan was fixed at 99 per cent. on the basis of the results attained in 1952. Of the other one per cent (rate of rejection), 0.5 per cent is made up of steel ingots on whose surfaces patterns have appeared, those that are imbedded with sand and those which had not completely filled the ingot case, while the remaining 0.5 per cent is made up of those which are rejected in the pickling test. 13. Repair of open-hearth furnaces a. Classification of repair Furnace repairs are classified into hot and cold repairs. The number of days required for repair work in both cases is counted as the number of days that furnace operation was suspended. Therefore the reduction in furnace repair time becomes an important factor in the improvement of the open-hearth furnace rate of operation, (de facto extension of the life of open-hearth furnaces). Minor repair works such as throwing in magnesia clinkers or dolomite clinkers are not considered as hot repair work defined by the operational regulations. These repairs were woven into the steel manufacturing time as part of its process, and` therefore was not included in the time of operational suspension. 1o SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) b. Hot repair (1) (2) (3) (4) Hot repairs consist of emergency repairs for such damages as to the hearth and other places. They are divided into major and minor hot re- pairs. This classification is clearly defined in the operational regulations according to the size and depth of the damaged parts. Minor hot repairs are ordinarily carried out after every 12 or 15 tappings. Scores of shovel-fulls of magnesia clinkers or dolomite clinkers are thrown into the damaged part and pressed with soldering iron to fuse them. The time required for this repair work is about two hours. During Japanese control it was necessary to carry out a minor hot repair after every seven or eight tappings. Under Chinese Communist control, the quality of raw materials, quality of refractory materials and consideration given from the operational s tandprint have contri- buted much to increasing the number of tap- pings before each repair. Major h~Dt repairs are carried out after every three minor hot repairs. The damages become worse after every 40 or 50 tappings; therefore, repair work is done over again. Time required for a major hat repair is 14 to 16 h~?urs. In the 1953 plan the number of days required for hot repair works over a period of 1,160 tappings was about 15 days. Sometimes hot and cold repairs were carried out at the same time. This was carried out after 50 to 60 minor hot repairs and about 20 major hot repairs. C. Cold repair :1) Repair work other than Jr the hearth -- namely. inside the f urrlac e and regenerator -- is acf:omnl.shed during cold repairs. Cold repairs n.ra classified into major, medium and :iinor repairs depending on the extent of the repair and the place requiring the repair. (2) Minor cold repairs were mostly done when the cooling box of the nozzle leaked or collapsed. When the furnace temperature drops dawn enough for people to enter the furnace, the repairman steps inside, removes the damaged part, puts in new bricks, and stamps the magnesia clinkers and dolomite clinkers. In this case various necessary bricks were lined up in the order of the pnsitians they were going to be used. This is done to facilitate the progress of the work. 109 r~- LSPECIAL HANDLING REQLIRED NOT RELEASABLE TO FOREIGN NATIONALS SECRET 11 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) (3) After the repair is completed it is necessary that heat expansion of bricks be carried out by gradually raising the furnace temperature for about three days. Since the temperature curve should be raised in accordance with the degree of expansion of the bricks at the time of heating, it is carefully illustrated in the operational regulations in detail. Heat- ing is first started by burning firewood in the furnace. The number of days required for a minor cold repair was more than fire days, which included two days and two nights for pure repair, three days for heating and cooling. Medium cold repairs were mostly those of the roof, nozzle and regenerator. The roof is replaced when it becomes like a. stalactite cave, and the regenerator was cleaned when slags accumulated. When replacing the roof, the mold frame is supported from underneath and new bricks are laid on top. During Japanese control a rock drill was used when slags solidified, but after the Chinese Communists took control dynamite was used for rapid removal to save time. The time required from the previous tapping until the start of the next charging of raw materials is about 10 days. Of course this ten days include the time required for cool- ing, repairing, and heating. These repairs were carried out after every 210 to 300 tappings. Repairs are carried out three or four times a year. (4) Major old repairs are carried out when hearth bricks are replaced or when the checkerwork of the regenerator is replaced. During Japanese control, part of the medium cold repairs was classified as major cold repairs. After the Chinese Communists honk control a strict dis- tinction has been established between the medium"and major cold repairs. Hearth bricks were replaced when molten steel leaked from the hearth, and checkerwork bricks were replaced when their surface became tile- like and the absorption of heat became poor. During Japanese control, major cold repairs were conducted about once every three months, but in the 1953 plan they were scheduled for about once every six months or about once every 500 tappings, 110 SRECI AL FIANDLANG REQI; I RED NOT REL EASARLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) SEA The time required from the previous tapping until the next charging of raw materials ranged from two o three weeks. In this case heating required about one week. (5) Periods of the foregoing major, medium and minor repairs frequently coincided with each other, and therefore the actual number of days required was about 40 days a year. Furnace sidewall was replaced about once every five years. D. Electric Furnace Steel Manufacture This works started steel manufacturing operations by electric fur- naces immediately after the first transfer-project (transfer of facili- ties from the coastal area) was completed in autumn 1952. At the end of the first quarter of 1953 the secr~nd transfer-project was in progress. Steel manufacturing by electric furnaces at this works, stands on an equal footing with steel manufacturing by open-hearth furnaces in all aspects including plant organization, facilities, and work processes, therefore it has become a specialty of this mill. 1. Facilities a. b. Facilities layout -- see Chart No 10-29. Data on facilities -- see Table No 10-40 2. Operational method a. In the first quarter of 1953, there were no out- standing characteristics in the way ref operational method because only a short period had elapsed since operation started. b. This mill still had a long way to go befor< it would be able to produce such high quality steel as tool steel, and high-speed steel. C. In the charging of raw n~terials, cold materials were of course charged. 3. Raw materials a. Principal raw materials (1) Supply source P.aw material consisted mainly of billet scraps, but miss-rolled products and other small steel scraps were also used. Control of steel scrap is strictly carried out from the standpoint of refining. There is no definite information concerning the supply source of such ferroalloy as ferro- silicon. 111 SPECIAL HANDLING REQUIBED NO'S RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc Nn 90225 (10) (PB) (2) Amount required In the production plan for 1953, the production of good ingot (raw steel) by electric furnaces was fixed at $,100 tons. It was estimated that the amount of steel scrap needed would be around 9,000 tons when computing from th?: rates of recovery (steel manufacturing and ingot casting) and acceptance. b. Electric power (1) Supply source Electric power was supplied by the thermal power plant established within the works. No fuel other than electric power was used. (2) Amount required Although details are unknown, it is said that about 1,500 kilowatt-hours of electri- city ie needed to produce a ton of steel. When computing with this figure as the basis, more than 12,000,000 kilowatt-hours of electricity should have been consumed to attain the steel production goal for 1953 ($,100 tons of steel meeting the specifi- cations) Note: The calorie input for the 1,500 kilowatt-hours of electricity required to produce a ton of steel would be as follows when calculated by the Japanese system; 1,500 KWH x $60 kcal/KWH (unit calorific value) 1,290,000 kilocalories (electric power calorific value) t 7$.4 per cent (percentage of calorie input) e approximately 1,650,000 kilo- calories (total calorific value) The percentage of calorie input is equal to the percentage of the electric power supply calorific value for the total calo- rific value produced by electric power, oxidizing agent and flux. The figure 1,650,000 kilocalories seems to be appropriate judging from the presDnt thermal efficiency of open-hearth furnaces in Cotmnuni st CHINA. However, further study is necessary because we have an empirical impression that it ?was about 2,000,000 kilocalories in the early stage of opera- tion by open-hearth furnaces. 4. Production a. Output -- see Table Nn 10-41 The plan for the first quarter of 1953 c~11ed for the production of 1,$00 tans of.good ingot (raw steel) and the planned total production for that year was $,l00 tons by electric furnaces No 1 and No 2 (rated capacity, three tons each). It was reported that 112 SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONAL 3 SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECnEi Doc No 90225 (10) (PB) electric furnace No 3 , (rated capacity, $ tons), expected to be completed in autumn of the same year, would be used to supplement the foregoing two furnaces in case it becomes difficult to attain the planned output. The amount of production by electric furnace No 3, however, was not included into the plan of the same year. For reference, Table No 10-41 shows the estimated production for 1954. The figures, however, cannot be expected to be accurate, b. Products Steel ingots for structural purposes were all .. killed steel, and consisted mainly of good qua Uty carbon steel for general structural purposes (for use as rails). C. Specifications wring the first quarter of 1953, workers from the workshop department made castings (gears and other items) for machine- tools at this plant. A large quanity was not produced because the molding shop was inadequately equipped. It seems that this shop was used for the sake of expediency only. The sizes of ingots conform to those of open-hearth furnace steel manufacture. The quality of steel, as far as carbon steel is concerned, is as previously related in the paragraph dealing with open-hearth furnace steel manufacture. d. Distribution of products Products are distributed throughout the nation, espcially to the state-operated mills in CHINA proper. However, silicon steel is shipped to the various mills under the Blectric Industry Control Bureau. 313 . In the fourth quarter of 1952, carbon steel for structural purposes was mainly refined. Besides the above steel, this mill temporarily produced special steel for gun barrels in be- half of the T'ai-yuan Machinery and Tool Plant which had electric furnace troubles. In manufacturing special steel, ingot cases were borrowed from the Tsai-yuan Machinery and Tool Plant to cast ingots. The production plan for 1953 was as follows: Products First quarter Annual Steel ingot (good ingot) 1,300 tons 3,600 tons for structural purposes Silicon steel ingot 500 tons 4,500 tons (good ingot) Silicon steel ingots were to be rolled into sheets for use in electric motors and transformers. Production was low in the first quarter of 1953 because operation was suspended during January for technical reasons. I__SPECiAL HANDLING REQUIRED NOT BLLEASJtBLC TO FOREIGN NAT1ONAL3 SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) e. Data on production (1) Effective utilization coefficient (a) Actual results at the end of 1953 1 Furnace No 1: 11.67 tons per 1,000 kilovolt-amperes per day 2 Furnace No 2: 9.$3 tons per 1,000 kilovolt-amperes per day Calculation of the coefficient is as follows: 1 2 Furnace No 1: 3.3 tons (each tapping) x 2 hours 6.5 hours (frequency of tapping a day) i- 1,050 kilovolt-amperes = approximately 11.67 tons per 1,000 kilovolt amperes per day Furnace No 2: 3.6 tons (each tapping) x 2 hours 6.5 . hours (frequency of tapping a day) + 1,200 kilovolt-amperes = approximately 9.$3 tons per 1,000 kilovolt '.mperes a day (b) Plan for 1953 1 furnace No 1: 13.69 tons per 1,000 kilovolt-amperes per day (each tapping 3.7 tons) 2 Furnace No 2: 12.00 tons per 1,000 kilovolt-amperes per day (each tap- ping 4.0 tons) Calculation of the coefficient is as follows: 1 Furnace No 1: 3.7 tons x 2. hours 5 hours x 1,050 kilovolt-amperes = approximately 13.69 tons per 1,000 kilovolt-amperes per day 2 Furnace No 2: 4.0 tons x 2 hour's - $ hours x 1,200 kilovolt-amperes = approximately 14.00 tons per 1,000 kilovolt-amperes per day (2) Recovery rate The recovery rate (yield rate) of ingot from molten steel was fixed at 9$ per cent in the 1953 plan based on the actual results of 1952. (3) Percentage of products meeting specifications In the 1953 plan, the rate of acceptance of steel ingot was fixed at 96 per cent based on the actual results of 1952. 114 SPECIAL HANDLING REQLI ED NOT flELEASARLE TO FOREIGN NATIONAL 5 i __ SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 (4) (5) SECFET Operating rate The actual result of 1952 was $0 per cent. The 1953 plan called for $2 to $3 per cent (300 days of operation) Reason and number of days of work suspension As in the case of open-hearth furnaces, opera- tion is suspended whenever cold or hot repair is carried out. The number of days that operation was suspended during the 1953 plan amounts to 65 days (including holidays) when inversely calculated from the operating rate. V. Rolling Department A. Affiliation and Number of Plants 1. Affiliation The rolling department is affiliated with the Production Office of the T'ai-yuan Iron and Steel Works and is under the super- vision of the assistant superintendent for production (also holds the position of Chief of the Production Office), It is divided intot he bloom-rolling and sheet rolling departments, he 2. Number of plants sheet mill a. Plants affiliated with the rolling department (1) Medium bar mill (2) Small bar mill b. Plan affiliated with the sheet rolling department; B. History 1. When the T+ai-yuan Steel Mill, the predecessor of the present works, was first established before the war, YEN Hsi-shan requested a German engineer to draw up a plan for a medium bar mill and imported a mill from GIlKANy as a part of the facilities for es- tablishi.ng an integrated process of steel manufacture. 2. While this plant was still under construction, it was occupied by the Japanese Army in November 1937. With the operation of the Pig-iron and steel manufacturing departments the estab' a rolling department became urgent . ' llshment of pleted in August 191]. and operation staus the medium bar mill, was com- rted from September. 3. Later, with the intensification of the Pacific War, the for an inPrease in local output of steel materials x demand of a small bar mill was started in ~. ncre~sed. Constrt,etio from 1914 as an annex plant of the medium Tbar his mill started operation small bar mill, however, were those which were o mill. Equipment of the out North CHINA. These equipment Were rebuilt andeusedtatrth~. d?shmough- mill . 115 LCIAL HANDLING REQLIREO NOT RELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Itr was the policy to use the power source jointly with the medium bar mill, and it was set up so that the small bar mill would be operated when the medium bar mill suspended operation. 4. After the war, this mill came under the management of the Chinese Nationalists, and operation was continued with the prewar facilities. The production of this mill during the most active period was equivalent to several ten per cent of that under Japanese control. Pressure of the Chinese Communist Army, however, became intense after the "Wheat-harvest Operation" which took place in spring 1948. Opera- tion, therefore, was barely maintained. Construction of the roller plant was started during this period. 5. Immediately after this plant came under the management of the Chinese Communists in May 1949 the rolling mill office was bombed and damaged by the Chinese Nationalist air raids. There was no immediate damage, however, to the productive facilities of the mill. 6. Construction of a sheet mill started from late 1951. Progress of the construction was hampered somewhat due to the fact that it coincided with the Three-anti and Five-anti movements which were at their height. For necessary facilities, the sheet rolling facilities laying idle in SHANGHAI were to be collected and transferred here, parts that were lacking were ordered from the various mills with- in the country, and thus part of the transfer of facilities was com- pleted in November 1952. Operation with one set (TN Presumably rolling facilities) started from February 1953? At that time there were two sets of sheet rolling facilities at this rill. Great hopes were en- tertained of this mill because this was the only regular sheet mill under the Chinese Communist administration. 7. In the meantime, the roller plant was completed and the production of small rollers started after 1952? . E. In preparation for the enforcement of the First Five- year Plan, the Chinese Communists carried out remodeling and construc- tion work from summer through autumn 1952. This work involved the addition of a 100-ton heating furnace and other equipment to the medium bar mill for the purpose of doubling the capaicity of facilities. It also involved the separation of the small bar miu from the medium bar mill for the purpose of effecting full scale simultane?ua operation of these mulls from winter 1952? C. Plant Building Layout and Structure See Chart No 10-30 and Table No 10-42 D. Medium Bar Mill Due to reasons connected with the power source, the medium bar mill was jointly operated with the s-r11 bar mill until autumn 1952. Inde- pendent operation became possible from winter of that year because the small bar mill was separated. This mill, however, has clearly indicated that it carries out bloom rolling as its main operation and addition- ally carries out steel material rolling. 116 SPECIAL HANDLING REQLIRED NOT RELEASABLE TO FOREIGN NATIONALS . SECRET WA Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET 117 Doc No 90225 (10) (PB) 1. E quipment No 1O-A4 a. b. C. d Layout of mill equipment -- see Chart No 10-31 Medium bar rolling equipment -- see Table No 10-43 Heating furnace and gas producers -- .see Table ment of medium bar mill -- see ui Attached e Table No 10-45 . e. f. q p Shape of medium-size rollers -- see Chart No 10-32 New heating furnace and preheating apparatus see Chart No 10-33 g. -- Old preheating apparatus for the heating furnace see Chart No 10-34 h. Structural outline of the lateral conveyor -- see Chart No 10-35 i. Structural outline of the pressure straightener see Chart No 10-36 j. Structural outline of the roller straightener -- see Chart No 10-37 [i;'E:cI;iT HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATTONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Dc c No 90225 (10) (PB) 2. Imprroven~nt of equipment a. During the period from autumn to winter 1952, the small bar mill was separated from the medium bar mill and made indepen- dent. Thus, the restriction to the productive capacity of the plants, which was heretofore caused by joint usage of equipment, was eliminated. b. During the period from summer to autumn 1952, a 400-ton heating furnace and a 30-ton gas producer for medium rolling purposes were newly installed. This doubled the medium rolling capaci- ty and made possible the full operation of existing ,rolling facilities. At t_re same time, paralleling with this, expansion and augmentation of steel ingot and finished products transporting facilities were com- pleted. Also at the same time, auxiliary facilities such as the cooling pit and steel ingot yard were enlarged. In spring 1953, the 400-ton heating furnace was mainly used and the 200-ton heating furnace was merely used for heating special products such as silicon steel and special structural steel. C . Following Chinese Communist control, a special repair shop was established for each project and machinery was quickly and com- pletely installed. 3. shortcomings in capacity and layout of equipment a. Shortcomings in capacity Following Chinese Communist control, the workload for the motors becare overloaded because of the adoption of the 24-hour operation system and tee increase in the rolling workload. Particular- ly, during the summer season, motors were liable to becorr overheated and there was a necc ity of suspending operations for the sake of safety. Therefore, in spring 1953, there was a plan to replace the existing motors by large-type motors. b. Shortcomings in the layout The plant area is extremaly limited and this has been causing much inconvenience in handling stel billets at the cooling pit. O;;ing to the disposition of the existing facilities of the small bar mill, transportation of steel billets to the small bar mill has been a great hindrance in the overall operation of the medium bar mill. Therefore , in spring 1953, it was reported that the small bar mill will be moved for the purpose ?f incr.asing the r~edium rolling capacity. 4. Coordination of facilities a. Coordination between the n ilium rolling facilities and tie steel ir~anufacturing facilities Since information concerning this matter has been given under tee steel manufacturing department, it will not be repeated here. b. Balance between the bJ.o3riina capacitor and the steel rolling capacity Plans for 1953 called for the total output of 119,000 tons -- 100,000 tons of billets and 19,000 tons of sheet bars. Of this total, 60,000 tons of billets and the 19,000 tons of sheet bars were for use within the works and the remaining 40,000 tons of billets were to be sold to the outside. 11$ SPECIAL HANDLING BEOL I BED NOT BELEASABLE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECFET Doc No 90225 (10) (PB) The output of s1ral1 bar material made from the billets within the works is 54,000 tons and the output of sheet metal made from the sheet bars is 14,500 tons. The medium blooming capacity is 40,000 tons more than the demand for raw material for small bar and sheet metal. In the said plan, however, since the output of medium bar material was fixed at e 000 tons it is quite certain that the above surplus output for outside sale was not the result of limitations in facilities but was rather because of a policy to adjust the demand and supply of commodities. . Originally, the rated rolling capacity of ui dium bar material was 45,000 tons (nearly 50,000 tons in billets), and including the 60,000 tons of billets for small bar material and the 19,000 tons of sheet bars for sheet metal, the blooming capacity reached about 130,000 tons. Therefore, if the irdiur rolling process is smoothly carried out without any interruption in the blooming and finishing pro- cess it can be regard3d that the blooming capacity (medium bar roughing mill) and the output capacity of steel stocks (medium and small bar material and sheet metal) are in balance. 5. Operational method a. 1''edium bar rolling process -- see Chart :.0 10-3?. b. Transportation of steel ingots Steel ingots are transported from she ingot casting yard to the mediui-: bar mill by the railways within this iron and steel works, and are c:.arged into a heating furnace by :mans of a 10-ton crane (15-ton crane before Chinese Conrcunist control). C. Operation of the old heating furnace (Following the installation of a parallel-type continuous haating furnace after the Chinese Communists took control, the old heating furnace was used for the heating of special steel ingots such as steel ingots for the electric furnaces). (1) During Japanese control and Chinese Nationalist eLfll.L?u L, 1Q 0 0 o. w 0 N N 0 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 ,1 I. ' I Ii I I ~. - Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Chart No 1x37 l+~ dium Bar Mil Roller Straightener (End of the. first quarter of 1953) Side View ('___? 1 i Ground Plan __I> M #I?4 i., fl7J+J.T[ 9 -r , I ; i , !' High-speed gear Li_i_I i I l i 11 I [ !~_ I I. 4 I QUO--hp motor 292 SPECIAL !ANBtLTNG REOL IBEO NOT RELEASABLE TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 - ` f rri t I -h?-~ -~ ! i-. r----?'-j f~IJ'H a Reduction gear Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Medium Bar Rolling Process (End of the first quarter of 1953) Steel ingot yard jj Freight car Crane 400-ton ' heating furnace (For billets) ~` Lshearing machine l ______L__Crane Cooling bed Crane ii_Small bar mill 200-ton -~ heating furnace Rollgang j ..- J Roughing roll] . I Conveyor ____j i__No 1 finishing mill j Conveyor (For steel No 2 finishing mill (For sheet material) bar) Rollgang i S wing machine .1 Crane L-'g bed IP or duct ,processing !-and straightening f_ _....? I Crane L2 L. Freight car .y ProCu ct storagee 1:j 293 Rollgang ~Sa g machirie Crane Cooling bed J 1 Crane Freight car LSheet mill:ijj SPECIAL 1~ANDLING BEQC IBED NOT FELEASA#3LE TO FOREIGN NATIONALS I Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Chart No 10--39 Layout of Small Bar Mill Facilities (End of the first quarter of 1953) ,1S. ir i'' ! ,it I 1ii I /- itl ;.I 1$Z0q _mm t: --.-----.- *- ? -- ?--......- , ? J l 1 I ~I''Ii !I, I -?,-~fT i I ' .;I ! di i i i I ' t20 ". y ?~ I i \ ' Small bar mill 1 .. l'll iill ( 4) Medium bar mill vi' _I1~iI i Ef2 Ji 1 i i,J 9)j ,i i ; { ~!. p ~I illl n1~ L .~ I ~ ` ; ' '' l l 16,'J I TT ; ' 3 -!" III ~' - I ..i_.~- Oi III 0 o' -- 0 1 ' c: r 1I'I H? LI . n ;''; r1 I l; l f ~)K15 ;c;' ? Note: The thick lines shown on this chart indicate the facilities which were brought in and increased in late 1952? 294 ib m SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONALS o' m H Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 1 9 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Chart No 10-39 (Cont'd) No 1 2 3 4 5 6 7 $ 9 10 ll Designation Medium bar mill motet (Formerly it was used together with small bar mill.) Reduction gear of medium bar mill Medium bar roughing roll Reduction gear for the old small bar mill (2$O rpm) Pulley for the old small bar mill (diameter, 1,200) Flywheel for the old roughing roll (diameter, 3,$00) Cotton rope for the old universal chuck 7 Pinion for roughing roll Roughing roll (three high) Motor (400 hp) for the new roughing roll rpm) for the new roughing roll Reduction gear (120 . 12 12' 13 Universal chuck gear for the old finishing roll Transfer of 12 The old finishing roll pinion 13' Transfer of 13 14 The old finishing roll ( I - VI are roll numbers) 14$ Transfer of 14 15 The old cooling bed 15' Transfer of 15 16 The old reeling machine 16' Transfer of 16 17 Finishing roll motor (1,000 hp) 1$ Finishing roll reduction gear (300 rpm) 19 The old heat Lrng furnace 19' The new heating furnace (Expansion of 19) 20 The old heating furnace charging machine 20' Transfer of 20 21 Motor (15 hp ) for the old charging machine 21' Transfer of 21 22 Suspension lever 23 Rollgang 24 Coke gas pipe (diameter, 10 inches; five meters above the ground; 450 meters to coke plant) 25 Billet yard 26 The new flue (underground) 27 The new chimney 2$ Wire rod yard (outdoor) 29 The medium bar mill ^hirrney 295 SPECIAL HANDLING REQUIRED NOT BELEASADLE TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Shape of the Small Bar Finishing Roll Japanese Roll _ .. 300 - l2 ? SpE~TJITNG REC~t IRED NOT RELEASABLE TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) Chart No 1041 Small. Bar MiU Roll Bearing Upeer Roll Hanger Note: The synthetic resinous metal is widely used in JAPAN as the latest new method. In this new method, oil is not used, water alone is sufficient. Water Water JL11- i Roll shaf~ ..;,' ~? i_. , Gun metal Lower Roll Bearing Wader Bearing Gun metal 297 Oil , .. -..-Hanger / (PoU / \, N shafts %ti' t I ~a !./._.__ ...~_ Babbitts metal --.- Babbit' s metal ' SPECIAL HANDLING REO TREO NOT RELEASA3LE TO FOREIGN NATIONALS SECRET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) Chart No 10-42 Installation of the Small Bar Finishing Roll (End of the first quarter of 1953) St Roll Foundation . ?? '5 .. - \ `' .5. ." , ` ~? ? L ?. - - ?? Processed steel 2Q$ I SPECIAL HADLING REQUIRED NOT PELEASAPLE TO FOREIGN NATIONALS SECRET 950 mm Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Foundation Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 a 0 M C, Chart No 10-43 door Coal Furnace hearth Extraction Dolomite stamp Dolomite is star ed e dth anhydrous coal tar. u ertieal Section of the Heating Furnace) door I, , , ~--~ Cross-section of the furnace A Profile of a __*._ %\\?.\\ .,_Br1 ck ~ v Section of the 11--___- Furnace Hearth ! 1 .. , LIII] (Grate Water Heating Furnace of the Small Bar Mill (end of the first quarter of 1953) 12,00 mm Steel Steel . sleeper bloom (Exchanged once every six months soo flT:. Steel _- Steel sleeper bloom 100 mm Steel sleep er (Ground Plan of the Charging Machine) .Steel bloom .L. FT -s ----- Charging machine Motor ``Worm-gear Jji 15 hp motor Side View of the Charging Machine Steel sleeper ----- Worm gear t~ 0 C) 2 0 0 H 0 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Chart No 10-44 Operation of the Suspension Lever for Small Bar Rolling . (End of the first quarter of 1953) Socket Suspension lever I1 I. 300 Suspension retal From heating furnace to the rollgang of the roughing roll rSPECIAL HANDL TN0 RE iTIRD ~ NGT RELEASABLE TO FOREIGN NATIONALS I Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Pulley 1 Rail \ Suspension t metal Chain Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 cJ~t I- I v ~ Doc No 90225 (10) (PB) Chart No 10-45 Structure of the Rollgang for the Small Bar Roughing Roll (End of the first quarter of 1953) 500 ::I . 500 150 d L1 ' 1 Bevel gear Reduction gear --h Ij1I 7.5 hp motor (Interlocking device is set up underground.) 301 SPECIAL HANDLING REOLIREO NOT RELEASABLE TO FOREIGN NATIONALS SECfET Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Roller Inclined ~- Ij j I 'Runner SPECIAL HANDLING REQUIRED NOT RELEASABLE TO FOREIGN NATIONALS Doc No 90225 (10) (PB) Structure of the Coo Ung Bed of the Small Bar Mill (End of the first quarter of 1953) Motor /!ice (horsepower i unknown) Gear --- 2, 500 , I I -~ Roller ~ liii h 1 --- V I F ? _ ~r 0 ,Q 0 mm T Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 w 0 w Chart No 10-7 Reel Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Winders of the Sma17. Bar Roll /; ., F- I-v-- I 1F "O 800 mm / Reduction gear , :q I Jf Lii ...' Concrete 0 J Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 15 hp n rn '6 rn Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 301 LSPECIAL_FATLINGREQLIRED NOT PELEASABLE TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SE'':.ET Dolly SPECIAL M'!DLING REQUIRED NOT PELEASAI3LE TO FOREIGN NATIONALS Ope rational Proce ss for Small Bar Rolling (End of the first quarter of 19 53 ) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Locomotive crane Heating furnace Roughing mill I+ Finishing mill Cooling bed Finishing stand Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 (tT\ Doc No 90225 (10) . Chart No 10-50 Small Dar Roughing Roll Pass and Operational Process Upper roll 3b0 VI Mid~1e roll ,f .''_ .22 mm ~ ,55 Material (hot steel bloom) thiclmess $0 millimeters 306 SPECIAL HANDLING RECLIBEO NOT RELEASABLE TO FOREIGN NATIONALS j I` Lower roll 10 t0112 per cent Brushed Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 H 4-1 ._ . , rtj N a0 Q) 0 a ~- .-----?--- ti i a H N ._w.._.-_?- 0 ~4 I N tY Ly -i 0 H H 307 SPECIAL 'I!ANDLING REQUIRED NOT PELEASARLE TO FOREIGN NATIONALS i Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 (It is not perfectly round y Roll (Upper) (Lower) roll 3o$ 1 SBECI AL HANDLING REQUIRED NOT RELEASABLE TO FORE IGN NATIONALS "Vacant space Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 r*i H O 2,000 mm 300 rn1tSoo mm -~! I Steel sheet (laid on bottom) f00 degrees ~ Steel sheet laced against A the wall Centigrade Cross-section of the Foil Sheet Furnace of the Sheet Nilll Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 (End of the first quarter of 19$3) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 ^ Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sheet Roll Three-stage Reduction Gear Double helical gears Flywheel 3,000 mm 4 312 LrITNTG BEOiTREB NOT FELEASABLE TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRE Structure of the Sheet Mill's Continuous Annealing Furnace (End of the first quarter of 1953) Brick 1-1 s ~, C1 u 000 c7o; ; C) U -Frame made of cast steel SPECIAL .1!ANDLING REGLIRED NOT RELEASABLE TO FOREIGN NATIONALS Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 x d H O Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Chart No 1O" 59 . '..3'uan Iron and Steel ~~~orlcs T Sheet Roiling Operation at the ai. (Fund of the first quarter of 1 in thickness 1 Rolling ~ 0 millimeter of sheet less than 1. operation Q 1 , Sheet bay.. .n g ahca.gmachine, ~urnaee r rol1 ro hi~ ll. ~. n ~ IPrinry ~ rqu hinb ~ ~. ~~xa,~u. n ~1 Heating crude T , She ~ .~l~ fQ1 ~ ~- roll ro~hi.n m1~.1 Flnishln lnxll ---Ied~ ?1 ShEtfu rou ~ha.nu .~,rnace..... [econdary roll (finishing g i .e Il .~.....~....... -- - _.._..._...._..._ ._. _ . ,.~.. ~., ~ ~. ? c ~s ea~a.n Old 1011., - innealIn n c ~- g anYl g ~~ /fh ~ r~ ~? ~?y~ sheara.n _ machine --~Ro IrY ~.! ~, ~ ?.? A~ zeG.ci. aa~ ~8 U.1 C4t~Qn C7 C7 (L) ? S I...... r --~ Fleet straightener) {Inpectiori multi le~~.~1dl - Product sp 6, ., .-~. 1 ina.shln ~traa. 111ena. p of sheet 1.c,~~~s than a n U millimeter in thickness operation. 2 Rolling ~ 1. 2 _....,.~. .' PrimaryrnL roil roughing mi . --~- Heatan crude furnace -- Sheet a ar ~ shin ~- --~ S 1 sheara.n machnne ~~ 6 - I ng ro11rougha.ng .1].-- Doublz. ru ~ doubling rou ha. r. e a, hcati.~~ foal sheet .Furnao ..~. ~ ~-- ~. ISecondary Pra.mt r,~ g eet fornate -Fa,r~.slunra rola .~ fir a. i1 . g and machine)!-1Seoondary 1ishineb miLl. -. Shearin heating zoa.1 sly . 10 ~ Roughing straightening (cold roll) -..~. IAnnea7ing l annealing furnaco J I- - ? _rp -,.tener .Inspecta.on .-1> Product r e ' n:tlta.le~~~.ndle,sheet stray ~l..~ -~. Fa.na.sha.~ s, traa.-11t na. t~ -.. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 (4) (7) (~) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 m W H 0~. Chart No 10-61 Plant No 1 Pl~nt No 2. Utilized b electric repairing department) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 .Cross Section of the Chilled Casting Plant Building Sm ....;' L' ...~ '. _.._'j ' t:... ' i . bm I,. fl 4 I . i u , i 4 il , _: ; '. 11; m ; $m r 8m 2lm ~_ ..-_.......~ 5 i 20m ..._...__...._. ,I II ~I 1'? ~I r Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 G.L. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Doc No 90225 (10) (PB) S E C R E I Chart No 10-63 Layout of Facilities (End of the first I r 7 I 9 -- - . I -- N 3 ! 6 ^1 0 5 lOm 15m i m LEGEND 1 5,000--kw generator, turbine 2 6,000-kw generator, turbine 3 Blower 4 GIRUJITSUSHU* Boiler 5 Babcock boiler 6 Small boiler 7 Blast furnace gas pipe a New cooling tower 9 Old cooling tower 3l I SPECIAL HANDLING REQU I RED NOT RELEASABLE TO FOREIGN NATIONALS - of Power Plant No 3 quarter of 1953) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 PAI-CHIA- ' :1:. ' To TA-T'UNG To r _. -'. i c} HUANG-HO U-YUAN 1 , North Tungpu -x `. I t , . r ~~~ take 1- CHUANG _!Jw-a \'In- } Airfield I I Railway 4 bridge f ~. HSIN-CH'ENGTs'un Water Intake and Water Supply Facilities (End of the first quarter of 1953) FEN Ho r i _. ! ' ~ j I i t i 1 I ~ 1HSIN-CH' ENG - ;I 1 .:1\\ r 1 I -- - _ I.~ : k E\: A 1 I ~ ,I\ , To T' ai- 1 i' CHAO-CHUANG /I North _ `?'~? ~~ ' i ~ Station Ts :4: ti Worker' s , ; ~--,L : - ` (quarters r - T.. 1 t L. ~' ~ ` , station -- ditch`;,, _ '!\ i.i~- `Deep wells ull1ping i Il -.I -take' ::1T P ,,..I :__ Reservoir ;, towers (2) J I i j f i I . I_;` 1 ~, - - 'Water stations (2) :'i ,~ 'ri l: ).:. : _ .. _ z Water supply Reservoi No 2 Reservoir No l 2i I ? l 4 KU--CH' ENd T'ai-yuan Iron and Steel Mill Ts' uri :Quarters for Japanese 319 SPECIAL HANDLING REQUIED NOT RELEASABLE TO. FOREIGN NATIONALS I T, Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 .c-ii n z N O Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Chart No 10-65 Organization Technica1 Supervision Section End of the first quarter of 1953) of the Technical Supervision Section Chief Physics Team -PhYsical Testing Subsection ---Meta11agraphica1 Team s. -. Heat Treatment Team r- Organic Team ''-Chemical Testing Subsection Iron and Steel Team _. Coke Team '-Special Steel Team Note: Total number of personnel -- 200 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 C, 2 0 O N N H 0 m c`m -f Combined Decision Group rn c~ 7 4p r -3 a z Chart Nn 10-66 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Ericksen Cupping Test Procedure Products ti 1 diameter Plate I Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 N 0 v b 00 rn c~ 7 4p r -3 a z Chart Nn 10-66 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Ericksen Cupping Test Procedure Products ti 1 diameter Plate I Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 N 0 v b 00 rn c~ 7 4p r -3 a z Chart Nn 10-66 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Ericksen Cupping Test Procedure Products ti 1 diameter Plate I Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 N 0 v b 00 x r z n a a 0 r I C, z w N Chart No 10-69 Housing Plan at KU-CH'ENG-TS~UN ('Iwo-family unit) 21 shaku One family Kitchen About 6-mat room About 6-mat room 12 -------- . 7 .\ F3 I Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA- ;u -?-----Storeroom `_____-- Wa shroom -/ Entrance One family \ RDP81 -01 043R00060001 0004-6 0 0 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Housing Facilities at SHIN-LLP1U Layout of quarters (Family quarters) ( Barra ck-type) 1 20 m (Bachelors quarters) (Barra ck-type L_ Cross section of bachelor's quarters f.,~-_y._- :.~~. Ground level f'. yi/y/ %!/E //.T%:! k-- 2 m- ->1 m -. - 2 in -~ 325 r--------~.-... SPECIAL HANDLING REOL I RED NOT PELEASABLE TO FOREIGN NATIONALS I [taom-~ 10 10 m __.i"... m (Divided into 10 households) I.5 rn -J Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 f) rn C) '-TI 0 In.\ !V 0' Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Chart No 10-71 Location of the Yangch uan Ironworks Hi land To Yan -ch'uan Mine Affairs Bureau Housing for the min Ya -ch' uan Ironworks T' AO C h' uan T'AO Chuan is normall Y dry, and sO it can be crossed without a bridge. To THAI-YUAN To WU-THAI iii c e~t Cx YUAN /~n v \ HSING iiiHousing for the iron- works Width of river, about 250m To , 1 YxNG-CH'UAN-GRAN I~ "? SHIN-CHIE1- .i. Unresto~i (Station) High land To PING- CHUfWG ~ as yet.) TING ~ S outh ~ v 'N l1 CH 'ANGCH ' IH Standard gauge Narrow guage 50 0 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 1 a rn . A T ,.\ YAN C~ SHOUW ;, r ' SHIN-CHIA-. ~:... L ~;. ,- - YA CHUANG ~ b NG '' 1 :a YU-TZ'U .kt 1 ails were re-4. moved SHANSI ~_??? r C HING- Provencet x, HOPEH Province 0 100 150 200 lan d 0 C) 0 ~o 0 A) N 0 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 SECRET Doc No 90225 (10) (PB) Chart No 10.72 Facilities Layout of the Yang-ch' uan Ironworks (Summer 1950) Clamp burning coking ovens-- about 60 ovens Ore bin .Qla st -,+--~ ~a c L_ 27,000 tsubo :J I. '1 C J JN N IN - o o o ,power ~~ i_-- 3 2 \ 1 u plant ~ \7cJ6?? PjP Hot-blast stove Blowers _..,_ ,_ ?, 1 4 l o r t~ Ore storage yard . O.01 L _ --____ room Blower room ,1 Front gate % Standard gauge railroad siding Before the end of the. war a ceramic plant was located at this place, but it was removed after the Chinese Communists took over control. 1 32'7 Water supply well SPCREQIJIBEB NOT FELEASABLE TO FOREIGN NATIONALS I SEGE3. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 f--f----1-; ---i -i---+-- __4-- r, Dolly line fi ~ffi^A L shop Living quarters Cast iron pipe plant f- --- Cupola ti Cast iron.,. ~b plant --T - Repair work Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 50X1 -HUM Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 50X1 -HUM Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 50X1 -HUM Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 r- rn a C) z Table No 10-3 Department Item Coke and j Lump coke Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Itemized Output of Products Output during the peak year j Output for 1952 jOutput for 1953 (Planned) before unitthe,nd of war (alt: ton) (unit: ton) (: ton 1942 , by-products n ar -- --- 00 -- 7 4 3 00 U nknown _ i . Ammonium sulphate " -------------- 3 00 230 . Crude benzo _________ ~- 1 ----- 620 t 1'6 80 ___ _ Pitch Creosote ______________ ; 900 1,100 tf ?t- - 3 _-.__...-.-..,...._..__~._........~..... Crude na hthalene ------------ P 20 ! u I 2 - 5 I, rm~do ~n+hrono~~o It r7ca __ Pig iron Steel Pig iron Open-hearth steel n ______________ 17 -_.u~rrrrr $ / 530 91,200 j ~ (In springy 1953 Rolling Casting Electric furnace steel Medium bar mill Small bar mill Sheet mill 11 ------- 2,530 ~ 2,990 ~ 194,280 ~ 290 000 44, zul over 130,000 151,250 , 0 % f this ount ~ ~ Of which about 30% were i for consisted of ~ P~. , . g I , CdStltl for casting 36;000 130,000 i statistic revised to 114, 2~0 Some ' Structural steel , X100 s about 30,000 ~ Unlmown ~ Steel stock 6,000 1944 about 5,000 ! Billet 100,000 Sheet bar 19,000 Unknown ~ Steel stock 54,000 - I Silicon steel plate 3,500 Ordinary steel plate 11,000 Chilled 610 Chilled 1,000 ~ (?) (TN Sic.) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 0 2 0 0 N to cn m m r- rn a C) z Table No 10-3 Department Item Coke and j Lump coke Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Itemized Output of Products Output during the peak year j Output for 1952 jOutput for 1953 (Planned) before unitthe,nd of war (alt: ton) (unit: ton) (: ton 1942 , by-products n ar -- --- 00 -- 7 4 3 00 U nknown _ i . Ammonium sulphate " -------------- 3 00 230 . Crude benzo _________ ~- 1 ----- 620 t 1'6 80 ___ _ Pitch Creosote ______________ ; 900 1,100 tf ?t- - 3 _-.__...-.-..,...._..__~._........~..... Crude na hthalene ------------ P 20 ! u I 2 - 5 I, rm~do ~n+hrono~~o It r7ca __ Pig iron Steel Pig iron Open-hearth steel n ______________ 17 -_.u~rrrrr $ / 530 91,200 j ~ (In springy 1953 Rolling Casting Electric furnace steel Medium bar mill Small bar mill Sheet mill 11 ------- 2,530 ~ 2,990 ~ 194,280 ~ 290 000 44, zul over 130,000 151,250 , 0 % f this ount ~ ~ Of which about 30% were i for consisted of ~ P~. , . g I , CdStltl for casting 36;000 130,000 i statistic revised to 114, 2~0 Some ' Structural steel , X100 s about 30,000 ~ Unlmown ~ Steel stock 6,000 1944 about 5,000 ! Billet 100,000 Sheet bar 19,000 Unknown ~ Steel stock 54,000 - I Silicon steel plate 3,500 Ordinary steel plate 11,000 Chilled 610 Chilled 1,000 ~ (?) (TN Sic.) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 0 2 0 0 N to cn m m r- rn a C) z Table No 10-3 Department Item Coke and j Lump coke Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Itemized Output of Products Output during the peak year j Output for 1952 jOutput for 1953 (Planned) before unitthe,nd of war (alt: ton) (unit: ton) (: ton 1942 , by-products n ar -- --- 00 -- 7 4 3 00 U nknown _ i . Ammonium sulphate " -------------- 3 00 230 . Crude benzo _________ ~- 1 ----- 620 t 1'6 80 ___ _ Pitch Creosote ______________ ; 900 1,100 tf ?t- - 3 _-.__...-.-..,...._..__~._........~..... Crude na hthalene ------------ P 20 ! u I 2 - 5 I, rm~do ~n+hrono~~o It r7ca __ Pig iron Steel Pig iron Open-hearth steel n ______________ 17 -_.u~rrrrr $ / 530 91,200 j ~ (In springy 1953 Rolling Casting Electric furnace steel Medium bar mill Small bar mill Sheet mill 11 ------- 2,530 ~ 2,990 ~ 194,280 ~ 290 000 44, zul over 130,000 151,250 , 0 % f this ount ~ ~ Of which about 30% were i for consisted of ~ P~. , . g I , CdStltl for casting 36;000 130,000 i statistic revised to 114, 2~0 Some ' Structural steel , X100 s about 30,000 ~ Unlmown ~ Steel stock 6,000 1944 about 5,000 ! Billet 100,000 Sheet bar 19,000 Unknown ~ Steel stock 54,000 - I Silicon steel plate 3,500 Ordinary steel plate 11,000 Chilled 610 Chilled 1,000 ~ (?) (TN Sic.) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 0 2 0 0 N to cn m m r- rn a C) z Table No 10-3 Department Item Coke and j Lump coke Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Itemized Output of Products Output during the peak year j Output for 1952 jOutput for 1953 (Planned) before unitthe,nd of war (alt: ton) (unit: ton) (: ton 1942 , by-products n ar -- --- 00 -- 7 4 3 00 U nknown _ i . Ammonium sulphate " -------------- 3 00 230 . Crude benzo _________ ~- 1 ----- 620 t 1'6 80 ___ _ Pitch Creosote ______________ ; 900 1,100 tf ?t- - 3 _-.__...-.-..,...._..__~._........~..... Crude na hthalene ------------ P 20 ! u I 2 - 5 I, rm~do ~n+hrono~~o It r7ca __ Pig iron Steel Pig iron Open-hearth steel n ______________ 17 -_.u~rrrrr $ / 530 91,200 j ~ (In springy 1953 Rolling Casting Electric furnace steel Medium bar mill Small bar mill Sheet mill 11 ------- 2,530 ~ 2,990 ~ 194,280 ~ 290 000 44, zul over 130,000 151,250 , 0 % f this ount ~ ~ Of which about 30% were i for consisted of ~ P~. , . g I , CdStltl for casting 36;000 130,000 i statistic revised to 114, 2~0 Some ' Structural steel , X100 s about 30,000 ~ Unlmown ~ Steel stock 6,000 1944 about 5,000 ! Billet 100,000 Sheet bar 19,000 Unknown ~ Steel stock 54,000 - I Silicon steel plate 3,500 Ordinary steel plate 11,000 Chilled 610 Chilled 1,000 ~ (?) (TN Sic.) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 0 2 0 0 N to cn m m r- rn a C) z Table No 10-3 Department Item Coke and j Lump coke Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Itemized Output of Products Output during the peak year j Output for 1952 jOutput for 1953 (Planned) before unitthe,nd of war (alt: ton) (unit: ton) (: ton 1942 , by-products n ar -- --- 00 -- 7 4 3 00 U nknown _ i . Ammonium sulphate " -------------- 3 00 230 . Crude benzo _________ ~- 1 ----- 620 t 1'6 80 ___ _ Pitch Creosote ______________ ; 900 1,100 tf ?t- - 3 _-.__...-.-..,...._..__~._........~..... Crude na hthalene ------------ P 20 ! u I 2 - 5 I, rm~do ~n+hrono~~o It r7ca __ Pig iron Steel Pig iron Open-hearth steel n ______________ 17 -_.u~rrrrr $ / 530 91,200 j ~ (In springy 1953 Rolling Casting Electric furnace steel Medium bar mill Small bar mill Sheet mill 11 ------- 2,530 ~ 2,990 ~ 194,280 ~ 290 000 44, zul over 130,000 151,250 , 0 % f this ount ~ ~ Of which about 30% were i for consisted of ~ P~. , . g I , CdStltl for casting 36;000 130,000 i statistic revised to 114, 2~0 Some ' Structural steel , X100 s about 30,000 ~ Unlmown ~ Steel stock 6,000 1944 about 5,000 ! Billet 100,000 Sheet bar 19,000 Unknown ~ Steel stock 54,000 - I Silicon steel plate 3,500 Ordinary steel plate 11,000 Chilled 610 Chilled 1,000 ~ (?) (TN Sic.) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 0 2 0 0 N to cn m m ^ ^ 0, 0 0 c~ z Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-11 Composition and Physical Strength of Coke Produced at the T'ai-Yuan Iron and Steel Works Part 1. Composition of Coke Period Moist ~ Ash Volatile matter ~ Fixed carbon Total I Porosity Remarks y 191+0 - 1949 8 - 13 15 - 22 2 72 - 80 100 40 - 50 I When unwashed coal was used the ash content once reached as high as 27 per cent. 1949 - 1953 5 - 6 10 - 16 2 80 - 90 100 40 - 50 After 1953, the ash content is kept ~ less than 13 percent. ~ Part 2. Sieve Tests of Coke Chinese Coimiunist Era Testing method . More than 50 mm - ._Physical strength 38-50mm i 25..3m 13-25 mm Less than 13 :a~a ~ Shutter test About 51 j About 15% About 20,$ About 9% About 6% (Drop test) Integration 5% Integration 65% Integration $5% Integration 94% Integration 100 (Drum test About I~O,$ About 2% About U' About A About I_(Rotating test) Integration 40 Integration 6 Integration $ Integration 9 Integration 10O` ~ Note; 1. In the shutter test, 25 kilogra,.is of test coke is placed in a steel testing box9 which is 710 ;rl long, ' mmwide and $0 in deep, and dropped fro1t the two ;peters high. Test coke ' ~.s sieved with s ~5. ~ position, PecL. 4 feed sieves, weighed according to sizes, and shown in percentages. In general,it is shown in integrating figures. 2. In the drun test, about 10 kilograms of test coke are placed in a drui and rotated for two minutes at the speed of 15 rpm. Test coke is sieved, weighed according to sizes, and shown in percentage. The drum is made of steel and measures 1,500 mm in inside diameter, 1,500 mm in length and 6 mm in thickness. It is rotated horizontally. In the drum six blades 250 mm in width and over six mm in thickness are installed vertically at equal intervals, Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 0 U, r{~ m ^ ^ 0, 0 0 c~ z Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-11 Composition and Physical Strength of Coke Produced at the T'ai-Yuan Iron and Steel Works Part 1. Composition of Coke Period Moist ~ Ash Volatile matter ~ Fixed carbon Total I Porosity Remarks y 191+0 - 1949 8 - 13 15 - 22 2 72 - 80 100 40 - 50 I When unwashed coal was used the ash content once reached as high as 27 per cent. 1949 - 1953 5 - 6 10 - 16 2 80 - 90 100 40 - 50 After 1953, the ash content is kept ~ less than 13 percent. ~ Part 2. Sieve Tests of Coke Chinese Coimiunist Era Testing method . More than 50 mm - ._Physical strength 38-50mm i 25..3m 13-25 mm Less than 13 :a~a ~ Shutter test About 51 j About 15% About 20,$ About 9% About 6% (Drop test) Integration 5% Integration 65% Integration $5% Integration 94% Integration 100 (Drum test About I~O,$ About 2% About U' About A About I_(Rotating test) Integration 40 Integration 6 Integration $ Integration 9 Integration 10O` ~ Note; 1. In the shutter test, 25 kilogra,.is of test coke is placed in a steel testing box9 which is 710 ;rl long, ' mmwide and $0 in deep, and dropped fro1t the two ;peters high. Test coke ' ~.s sieved with s ~5. ~ position, PecL. 4 feed sieves, weighed according to sizes, and shown in percentages. In general,it is shown in integrating figures. 2. In the drun test, about 10 kilograms of test coke are placed in a drui and rotated for two minutes at the speed of 15 rpm. Test coke is sieved, weighed according to sizes, and shown in percentage. The drum is made of steel and measures 1,500 mm in inside diameter, 1,500 mm in length and 6 mm in thickness. It is rotated horizontally. In the drum six blades 250 mm in width and over six mm in thickness are installed vertically at equal intervals, Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 d 0 0 U, r{~ m Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Carbon dioxide purifi- cation apparatus 'Carbon dioxide ;compressor Doc No 90225 (10) (PB) Table No 10.13 Facilities at the Armnonium Sulphate Plant of the Coking Department (End of the first quarter of 1953) 7Op erational met hod --------------------- --_- Gyp Sur method `\ Commencement of operation ----- --- --- ....__- August 1940 ). '\ Crystal ammonium sulphate output capacity --- TUro tons a day- Nomenclature I ime kiln lower FE:?. e.r axks i Amnwriia still Au iJiary tank Liquid ammonia tank ;lil:::uViJ_ w:l 5 LLL licit mother liquid tank ILiae slurry agitator Gsum pulverizer [Vacuum still l - ----- . _-_-__-_- _ _-- IAmmonia sulphat e (salt) collector Centrifugal separator J_evated tank Condenser 1 set 1 Recirculation cooler ;2 sets !Reactor Vacuum filter 1Preheater 1 1 1 set I 1 SPECIAL i!ANDLING BEOII?F:D 1 set i - --- Ivacuum pump 2 1 i Output capacity I Data and structure 5 tons/day ; Bottle-shape equipped with material elevators; i 2 ~ 10 1-n3/hour i Feldman still ti) c; u o tiiul:LViiJ_(:, t;L'1JJ eiiL, five per cent a:-- 2 tons/hour ___ The liquid ammonia tale is the same as the one listed under the suction plant. 340 - -----h------ -_-_ 1 15 hp 2 hp 3O hp NOT FELEASABLE TO 'S - 't 1 1 3O hp Equipped i?rith agitators Diameter: 2,000 mm i Length : 8,000 mm. -- _ Diameter: 2,000 riu Length : 6,000 ran Renoved and not in use after the Chinese Conriuidst control FOREIGN NATIONALS _- -----.---__.- -1- ..- --1- --- - -. -------- .i Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 .c,) rn C) rf~ for Release 201 0/08/1 8 : CIA-RDP81 -01 043R00060001 0004-6 Facilities at the Tar Plant of the Coking Department End of the first quarter of 1953 Commencement of operation --- August 1940 1 1 Processing capacity --------- 30 tons /day) _ I _ _._ - .___.._._... ~- f .____ Data and auxiliary Data and auxiliary Nomenclature Number Outpit capacity , facilities Nomenclature Number Output opacity oapa ' ' facilities Intermittent-t YPe 2 Distillation Volume 2 0 tons CrYstallizat'rn ~. $ Volume, 3 tons still 30 tons /day Total 40 tons tank I Heat exchanger 2 Hose-type Centrifugal 1 I separator Cooler 2 Hose-type Filter press i 1 200 kg/hr I , Light oil 1 Diameter; 1 , 200 :mm Rotary pump 2 T 5 tons hr separator Length: 5,000 ~rm ____ , J i 4 i Oil receiver Diameter: 1,200 mm ____________ Washington pump 1 _____________ 2 tons hr _________________ i ' I Height: 1,500 mm i i Pitch cooler 2 Diameter: 2,500 mm 2 , Diameter 2,000 mm Height: 4,000 mm 4> $ O mm Height: ? >O 0 i Pitch as cooler 1 Diameter: 1,000 mm Tank ! 1 Diameter: 1,500 mm ! Height: 2,500 mm Height: ,000 mm Pitch ba Y _ i?_ . i i - - Vo1ume 2 tons 5 3 4,000 Diameter: 00 mm set i 1 ~ Height; 5,000 mm i ~ . ---- -- - __________ -- Sanitized Copy Approved Sanitized Copy Approved for Release 201 0/08/1 8 : CIA-RDP81 -01 043R00060001 0004-6 f1, rn -4 San itized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-15 Facilities at the Benzol Plant of the Coking Department (End of the first quarter of 1953) (Output capacity --.-------- 2.5 tons/day . \Commencement of operation ---- September 1940; Nomenclature Number Data and Nomenclature Number Data and Light oil still Purification still (Column still) 1 (Column still) 1 C/) 0 ?m I- CI) facjliti.es set acid.-alkali tank. :1, 1 -. . Diameter: 2,000 mini Heat exchanger 2 5 ,000 m Oil cooler 4 1 ___--- --____ -- Filled th I Tank Diameter: 1,000 mm still ? Dia:neter: 2,000 mm Cooler 1 Oil-supply pump Centrifugal-type 4 - - _____ -- L: Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 _ --~- - .~ C, 7 1944 3,500 ' 200 430 3,000 700 1,950 1so ~ bo o! 194, I 2,400 ~ 150 260 1,900 1 x.30 1,230 110 36 rn 1946 2,800 ! 200 400 2,500 1 590 1,620 150 50 rfi+ C2 r ~ w.4 C~ ' ~` 1947 3,000 ! 200 ~ F 43~3_ 2,700 620 1,760 _ 160 ~ 54 W .> 1948 2,g00 200 ?1 ~ 400 2,500 590 1,620 150 50 r~ tT, 19k9 $00 150 260 1,600 ~ 384 _ 1,040 y 100 _ 33 0 195 3,600 350 ~ 650 ! 3,300 1 760 2,140 190 66 7 0 _ 1951 4,600_ ~'i 400 j ?900 3,500 ~ 850 2,300 ' 220 73 1952 6,700 230 I Crude 1,300 ~ 5,700 1, 100 Soft 790 Crude 196 100 C ~ Motor 380 Hard 2,200 ~ Industrial 60 i Output of BY-products i Tax Ammonium C~?ude benzol T Tar I Ammoniwn sulphate Crude benzol i Tar distilled amount ar I tons tons (tons) (tons) (tons) ___ r 1940 12,100 ~ 150 i 220 ~ 1,900 1+30 ~ 1,230 110 i 36 Remarks 1. All figures, with the exception of those for 1952, are estimated approximate values. 2. The 1952 column indicates actual figures. In addition, 16 tons of carbolic acid, 52 tons of solvent oil, 0 100 tons of anhydrous coal tar, and 2,$00 tons of quicklime were produced in 1952. The manufacturing of carbolic acid beg gan sometime in 1952? t~ C ----._ -- _ Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Year ( - `-~ Creosote (tons) ~ Pitch ' (tons) C de napthalene (tons) Cnzde anthYa,cene ~ (tons) 1941 3, $ 240 ~ ~ ------- 450 ~ ----. 3,400 790 2,210 200 68 _ _.- ' --- ~ i 1942 4,300 30L_ 620 : ; 3,900 ~ 900 2,530 230 78 1943 3,7~ 250 580 T 3,300 770 . 2,71+ 200 --- 66 Fable No 10-16 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 _ --~- - .~ C, 7 1944 3,500 ' 200 430 3,000 700 1,950 1so ~ bo o! 194, I 2,400 ~ 150 260 1,900 1 x.30 1,230 110 36 rn 1946 2,800 ! 200 400 2,500 1 590 1,620 150 50 rfi+ C2 r ~ w.4 C~ ' ~` 1947 3,000 ! 200 ~ F 43~3_ 2,700 620 1,760 _ 160 ~ 54 W .> 1948 2,g00 200 ?1 ~ 400 2,500 590 1,620 150 50 r~ tT, 19k9 $00 150 260 1,600 ~ 384 _ 1,040 y 100 _ 33 0 195 3,600 350 ~ 650 ! 3,300 1 760 2,140 190 66 7 0 _ 1951 4,600_ ~'i 400 j ?900 3,500 ~ 850 2,300 ' 220 73 1952 6,700 230 I Crude 1,300 ~ 5,700 1, 100 Soft 790 Crude 196 100 C ~ Motor 380 Hard 2,200 ~ Industrial 60 i Output of BY-products i Tax Ammonium C~?ude benzol T Tar I Ammoniwn sulphate Crude benzol i Tar distilled amount ar I tons tons (tons) (tons) (tons) ___ r 1940 12,100 ~ 150 i 220 ~ 1,900 1+30 ~ 1,230 110 i 36 Remarks 1. All figures, with the exception of those for 1952, are estimated approximate values. 2. The 1952 column indicates actual figures. In addition, 16 tons of carbolic acid, 52 tons of solvent oil, 0 100 tons of anhydrous coal tar, and 2,$00 tons of quicklime were produced in 1952. The manufacturing of carbolic acid beg gan sometime in 1952? t~ C ----._ -- _ Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Year ( - `-~ Creosote (tons) ~ Pitch ' (tons) C de napthalene (tons) Cnzde anthYa,cene ~ (tons) 1941 3, $ 240 ~ ~ ------- 450 ~ ----. 3,400 790 2,210 200 68 _ _.- ' --- ~ i 1942 4,300 30L_ 620 : ; 3,900 ~ 900 2,530 230 78 1943 3,7~ 250 580 T 3,300 770 . 2,71+ 200 --- 66 Fable No 10-16 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 r~ C) r. rn, ef) Mry ri .. ?, r Table Nn 10-1$ Hoisting Apparatus For Blast Furnace (End o the first quart r of of e 193) 5 ast furnace No 1 Blast furnace No 2 Classification B1 Type Bucket Ski A i___"___ __I horsepowers 60 horse~veers Capacity 60 , C ternatin current Alternating current Al 3 00 volts 3,300 volts 3 Hoisting speed Ab gut $0 meters per minute .-..__..__..,._.._.._ _.-... _ ...__." 0 6-inch ropes RoAe diameter I Tw Control apparatus n Blast Furnace J No and No Remarks - Double -drum t Ype Details on Electric apparatus About $0 meters per minute One 12-inch rope ~neti brake I gnetic brake i Magnetic brake Magnetic brake 0 C) 0 w 0 H 0 .r H C) G ru C) Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-19 Hit-blast Stoves (End of the first quarter of 1953) Classification For blast furnace No ;1 For blast furnace N 2 For blast furnaces N d N 3 Remarks o o an o 4 . Number of stoves Three Four Three each hree ch Normally, three to each r I blast furnace f i Type , Cowper Cowper Cowper Cowper Two- ss type I~ Diameter and height I Diameter 5,030 mm 5> Diameter 6>000 mm Out of four hot blast i r Height 25,000 mm Height 27,500 mm I furnaces attached to blast furnace No 2 one ! of them had a diameter of 5,000 mm and stood 25,000 mm high. ------- ---- L. _ . -_- Combustion method i Blast system Blast system I Heating area ~ Detail unknown About 5,000 square Detail unknown ---- meters Regenerating area Detail unknown --- 7,000 square meters I Grate ole laYer h S'nle ~ Si ngle Size of rate hole ~ 100 x 100 mm 120 ;rum x 120 rum I Grate brick 1s 60 mm I in thickness. f Amountof as used g About20 per cent of blast-furnace as p gas j Construction period p During Japanese nese control g pa Date unknown October 1943 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 rJ Table No 10-20 rw h l . 0 r~ c~ E~ w ~- ~r r~ ~ P~ cn r~ rn 0 L Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Blowers for Blast Furnace (End of the first quarter of 19 ? Classlficatlon Blower No 1 Bower No 2 I 1 Blower No i Blower No 4 Type Electric turbob1ower Electric turboblower Electric turboblower Steam turbine Horsepower 500 boo 800 1,500 A Air volume 00 500 600 Detail unknown cubic meters per minute , s Air P re sure I ands per square inch) Po e __ - --- _ 6 7 ------- . $_.___.._ _. __.. ._-__-__ _15 , Number of revolutions rpm ~O bJ 3bo0 3 ,600 2$00 ~ -__ _.._ _ _.. _..._ ...._ _...._..._ .1 ^ .... ... _ _ .~_ __ __. I I period Construction P 1 November 939 1 N nvem~er 939 November 1940 Just before the . ' end of the war, this second-hand equipment was 1 ~ . installed W ~a as in reserve at At the end of the f At the end of the , the end of the war war, it was attached i war, it was attached to No 1 blast fur- to No 2 blast fur- Usage _ - nace ..._ ...._..__....r_ nace -.- ____ -- Currently, 'n in Currently in After the second half After the seeond reserve reserve of 1951, it was at- half of 1951, it Cached to blast fur- was attached to ace No 1. blast furnace No 2. Note: from AN-SHAN but it was not in full operation. The condition of the bl-nw.er .which was.-used in the, small..biast-furl ace in .1944 is..unknown. Blower No 4 ' s an old second--hand e ulpment which was in use J'ust before the end of the war. It was brought in ~ g Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 w Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-21. w a i P . roducing area The T'ai- Yuan Iron and steel Works ' Pure has ing Plan of Iron Ore from OtherPro vnces for 1953 Irpe of ore ; LUNG-YEN Hematite _. _ i 1a gnatite I I I LT-KUO Magnatite Total Note: Qualit ! t ~ .w... y ;Ore ratio Tonra e ~ Mea7s a , f T i rans ort r cent p ~ i . tons tr ans f . portation dl t 55 5$ 59 1.76 s ante L__ ! I (kilometers) Remarks 1 7000 ~ 1 Railroad ~ About 0 ; 79 V~. I a the North ~ t T' una~Fu Line I -.._..~_.~ 74,000 Railroad ~ About 440 ! 43,000 ~ ~ ~ _... Railroad i ~ About $1 Via the S1lihte _.~_ Line ib 2 000 4 I ----?---.L. ._ -_,... _ _.. _----i- Z i addition, instruction was received from the Central Gove a ve ~ rn~nt to use ry small amount of ore mined in the province, a d 0 C) 0 0 N N ~n H 0 pc) w Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 2 I c Table No 10-22 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Amount of Raw Materials Charged into the Blast Furnaces (End of the Classification Blast furnace No 1 1 ton 11. to ~. 1.5 tons Coke ratio, 0, 140 I per cent !r- i n i , iCoke ratio I , per cent { i I i first quarter of 1952) Amount charged t o one tine Number of charges I Limestone .fan ane se Total -.- 0.45 ~.tr 45 r 0 to 0 k 4 110_ z. . 9 to .0 ~., . ~.. en to eight ~ to 1 0 ; Ore ratio 5 rams ~ , g tons I time s ~ an hour. about 0 The 3 amount dlff ' About 1~0 t vne s per cent r each day . , i a day. 0.6 ton i $0 kilograms 5.4 to .6 5 Seven to I ei ht g 110 to 1 I Ore ratio, , The amount d i + I ~.ff~Y tons times an hour. ;about 30 each day About 1~0 times I er nanf p a >u z Note: 1. The amount of pig-iron output at that t Lme was as follows. a. Blast furnace No 1 -- 160 tons a day average b. Blast f urriace No 2 -- 270 tons a day average Fluorite was not used. Hematite from P . ' ANG-ChIA_P U I LU11G-YFiu was mainly used as iron ore. u. hay Sanzed Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Coke iron ore r~ 0 n z 0 '0 ww0 {v ^ a 0 C) w Ut 0 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-23 Variations in the Daily Output of Pig Iron Unit: ton Period ~ Auttuim 1949 to ! Late 1950 ! Late 1951 ~ Late 1952 I Spring 1953 I Remarks ~ Blast furnace I Spring 195 ~Blas`c furnace No 1 I 40 ~ 120 110 ~ 170 ~ 175 ~ Rated capacity 40 tons -'- ~ "- Blast furnace No 2 120 j Total 160 j 320 380 '; 450 ~ 165 Remarks The daily output on this table indicts the average output of i iron (including ~ pig ! rejected big iron). . Note: Refer to paragraphs under im roverrent of facilities for the sharp crease in daily output. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 0 ~o 0 N N Ui w 0 Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 (fl rn C) .i+ .ns w H Variations in the Annual Output of Pig Iron (Unit: ton) Blast furnace No 1 Blast furnace No 2 f I i 1940 --- ---1941 i--- -- 1942 1943 Remarks -------_.__._-----. _ _--? - ' -------------- ___.._...._._ _,._.~ 10,907 1945 1950 1 1951 3,322 17,022 35,582 1~1~, 201 29,940 1952 1953 (Planned) Remarks 1. The output prior tot he year 1 is based on t 945 i he Japanese fiscal year. Thereafter calendar, year. 2. The amount indicates accepted pig iron. Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 62,$00 950 70,000 - 75,000 About 100,000 More than 130,000 88,450 2,79 I 32,73 I Initial firing of blast fur- i151 250 I Major repairs ~ on blast fur- I I nace No 2 after being blown out d Blast furnaces , Total No3andNo4 j . ; paces No an No -- I I Se tember 1 p 943 2,373 35,582 ~ 17,022 ~ Initial firing of blast fur- nace No 2 -- 1Qavember 194 3,322 Initial firing la of b s - t fur i -- ~ nace No 1 Novembe rl 13,280 Blast furnaces No 3 and No 4 were abandoned after being ~ bombed in late 19l~.1a. 950 70,000 - 75,000 'About 1100,000 Results of April to August 1945 More than 130,000 d 0 0 z 0 ~o O N ~n H O ro m N C' m Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No iaz5 II U, m c} rn W N Floor Space of the Buildings of the Steel Manufacturing Department Floor s ace of buildin s Before Chinese Communist i After Chinese Communist ;End of first took control took control i P of I quarter o~ 1953 ; One building I Building enlarged by One building I I 4,212 square meters 12 $0$ square meters 7,020 ~ square meters ; width - 6 meters width - 3 36 meters) I I length - 117 metrs ! (length - meters) I ! i 1. 2. One building ' One building added Two buildings The 1 6 square meters ! 39 1~0 square meters 396 square meters in g g width B meters width - 10 meters) 1~0 square meters , Ileng~n - ~yT met?rs) (ieng h -- l meters) One building 150 square meters width - 10 meters length - 1 meters One building 60squre meters a width - 6 meters length - 10 meters 1 ~ Sane as left same as left i V Same as left t S r f a a as le t ; ^ z 0 Installation s i Open-hearth furnace plant Gas producer plant ( r' Dolomite I plant i Remarks Under construction in I Spring 1953. ~ There were plans for con- structing a mixer plant i 36 by a ~ 3, meters). i newly constructed build- , was a two-story building. g z 0 0 N N Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 IM Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-2$ (Cont'd) Installation Floor space of builds _ Remarks Before Chinese Communist Afte Chi r ne se Communist I End of first took control took control quarter of 1953 Mister- One building laneous 90 square meters warehouse (width dth - $ meters TN Sic length- 15 meters Dressing room One building SO square meters width - $ meters length 10 meters Steel One buildin g manufac- 90 square meters turin width - office r ~ peters TN Sic.) length 15 meters Assay room One building 60 square meters width - b meters (length - 10 meters Same as left Same as left Same as left Same as left Same as left Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Same as left Same as left In Spring 1953, a new office building was being constructed ~ on the north side of the open-hearth furnace plant to make room for the projected mixer plant. Same as left For the same reason as above a new assay office was under ~ construction an Spring 19 53 a J b 0 C) 2 0 ~o 0 N N 0 v U, rn IM Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-2$ (Cont'd) Installation Floor space of builds _ Remarks Before Chinese Communist Afte Chi r ne se Communist I End of first took control took control quarter of 1953 Mister- One building laneous 90 square meters warehouse (width dth - $ meters TN Sic length- 15 meters Dressing room One building SO square meters width - $ meters length 10 meters Steel One buildin g manufac- 90 square meters turin width - office r ~ peters TN Sic.) length 15 meters Assay room One building 60 square meters width - b meters (length - 10 meters Same as left Same as left Same as left Same as left Same as left Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Same as left Same as left In Spring 1953, a new office building was being constructed ~ on the north side of the open-hearth furnace plant to make room for the projected mixer plant. Same as left For the same reason as above a new assay office was under ~ construction an Spring 19 53 a J b 0 C) 2 0 ~o 0 N N 0 v U, rn Table No 10-27 Refractory ' ~ U Materla.~s for ~ th ~ Open-hearth Furnaces End of the first carter of 1953) q Place used , I Refractory material used bottom of furnace Chamotte brick bottom layer, one I I ~ la ~ r onl r ~ ~ , Insulation bricks are not used . = brr 1%-I ,1,- Ch r Hearth Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 i Magnesium stamped dolomite P ~ clinkers Front and back w is al Bottom port I. Roof clinkers i.Ieta1 case lnside f 11~.e d Unknowyi S11ica brick i with magnesium --_ __ ._.--,._----_.--;----. - -Regenerator l chA?c_terwork ; Chamotte ' brick bottom layers of brick 3 or layers) Silica brick Size 120 x 120 x 00 to 00 cubic mllll.n~eters Remarks Size of the ch brick ecker~~rork $O x 150 x 300 cubic mil hinters r .s/ ~e o.. layers Outer side red brick Sanitized Copy Approved for Release 20 z 0 ern r Ii H J W Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Table No 10-28 Gas Producers for the U en~ a p he rth Furnaces End of the first uarter q of 19 3 5 ! F' ive lve Five ; ~lx Eight) Notes; 1. Old and new buildin s and the a' g min pipes are inde endent of each other, P 2. A detained Ja ane se t.echni cia rew p n d u the lans. O w P p f r tht t o ne~a Wood-t e as roducers.wh~ch w ere installed YP g P after the Chinese Communists too k c.ntrnl, S~nc~ he did not have time to la t ' Ps p n hin out he co led die Dlue ~ P rints left behind wh P en the war ended of the s roducers located at SH - -a ga p IH CHING H~u'~ . 3. In the Mox an-t e as - roducers n ' gyp g, p the c. al fe~,dxn ash removal and k~,r are all m?chan~.call O crate b, , po p d, Y Sanitized Copy Approved for Release 2010/08/18 : CIA-RDP81-01043R000600010004-6 Number of furnaces ..... _. _ .. .... - _. ... __...___..__.._.. _.__ Data - - ----- i B low --_----.._ ers ._.... ~nuntr Time ! Y nd Chinese the Nationalist TO a d Y I T e ~'~ Inner De th P RevOlu. . a ~ Co 1 where ~ o f - ~ 1 burn~n mana- ~ g manu I Number 1 i4otor ~ ' r control I ~a,, dl meter I I Lions ~ , as I pacit fc ctur~d .facture Y F~,ve Five Mora I n g I 2 SOu min. ~ A bout 60 r m p i 1 1.9 9, ; JAPxN I Jul Y Used for I I 4 000 mm ~ , 6 to 8 ~l 9 i open- I I ! tons I hearth i I ~ 1 a da ~ I ; ~ furnaces I I I 195 2. i No 1 and I _ 1 1 tons 3 I a da I Y I One No 2 ~ ~ 0 ne 0~ 5 - ne ; One Mor an ! g I ` 2 00 mm 5 , i Abo ut 60 r m p 1919. _ Nation , I 1 a7 4 , h o P 000 mgt 4 6 to $ a s h t motor . i I i tons CHINA i ! 1 I I a da y I ' I I 1952. ` I t s 13 on a da Y TWO' T I rood 3 000 mm About 6 0 r 0 m A I 30 tons I Commu- I Se t p One One Use d for new i ( I b oo0 , ~ a da ni st Y 1 2 9 5 - 0 3 o en- P I CH INS hp hearth motor furnace No , 0 0 0 N N H 0 ~ti wa