DEVELOPMENT OF THE ALUMINUM INDUSTRY OF THE USSR

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP81-01043R004000180001-3
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 127
• Document Creation Date: January 4, 2017
• Document Release Date: March 21, 2014
• Sequence Number: 1
• Publication Date: November 25, 1959
• Content Type: REPORT

Declassified in Part - Sanitized Copy Approved for Release . 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
.?1+,
..
Declassified in Part - Sanitized Copy Approved for Release . 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
v
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
AINIXILIMAAMOUftnaLZMUSWODDIELLM
AMvelopment of the Aluminum Industry of the USA.47
Meow, 1959,
Peps 45-160 I.M. Gratsershtsyn
Russian, per
ghauter II
Principal Stages in the Development of the Soviet Aluminum Industry
ZI&AbildnalablitaJladar--thILSMUltriall"Ilf
As &result of the treacherous attack of Twist Germany on the
Soviet Union, the aluminum industry suffered severe loose at the
beginning of the mere
In the autumn of 1941 the Volkhov and Dneyrovsk Alainum Plants,
the Tikhvin Alumina Oxide Plant and the Tikhvin Dwaxita =nes were
put out of operation; In this eanneetion the aluminum industry lost
a large part of Its productive capacity, including: bauxite 35%,
alumina 60%, slants= 55% and silumin 100%.
The Party and the Soviet govermment faced the serious task of
reocvering the lost potential in the shortest possible time and of
constantly meeting the meads of the front for aluminum and absinua
alleys.
During the eecond half of 1941 a start was made on moving estab-
lishments of the aluminum industry toward the east, *hitherto umheard
of feat in the history of world industry.
The equipment of the Dneprevsk, Volkhov 1n2 Tlichviri plants and
of the Tikhvin bauxite mines was dismounted and shipped off. On the
basis of this equipment the aluminum industry installations under
construction in the eastern stress were put into production at an
aooelerated rate.
It vas neeessai7 to erect new shops, install and put into pro-
duetion, the equipment at the aluminum and alumina plants under to*.
trimly difficult conditions and with a great shortage of material
and labor.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
?
The operation of the aluminum establishments during the ear
period mes complicated not only by a shortage of laborers but of
engineering and technical personnel.
The demand for labor, complicated by drafting of a porion
of the qualified workers into the Soviet Army, was net by young people
from the faetory vocational and trade schools and through mobilisation
of the public. During the three years 19434945 establishments of
the alumimme industry trained 33,000 workers, including 13,000 given
new training and 20,000 giving further training.
As a result of the Party and government's constant interest in
the development of the aluminum industry and thanks to the self-
sacrificing labor of workers and engineering and technical personnel
the production **penny of the aluminum industry increased from year
to year, despite the temporary oscupation of important epoonomio
regions of the USSR by the Fascist invaders.
During the war there mere major changes in th. supply of ore
to the aluminum industry (1160.).
Despite the termination of bauxite graduation at the Tikhvin mines
during the last half of 1941 the overall capacity ems rapidly regained
by expanding production from the Northern Ural and Eamenek mines.
Exploitation of the Ntethern Ural mines started in 1934.
During the Greet Patriotic War the Northern Ural Bauxite Nines
folioed the responsible task of providing bauxites for the expanding
capacity of the alumina plants and of meeting the requirements of
the iron and steel industry, and the abrasive, gement and other Indus*
tries.
In eueneetion with the *remotion of the equipment of the Tikhrin
bauxite sine* and the relocation of aluminum plants in the Urals and
in Siberia, the Northern Ural Bauxite Nines booms the liaiII source of
rem materials for the aluminum industry. The increase in bauxite pro*
4netion vas accompanied by a reduction in open*plt and an increase in
underground mining (Table 4).
*2
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
TABLE 4
RATIOTs zie.'rwrart oaat-pri ALILI atillaklitOtitID riktint% ragza AT
NCIRINERN URAL BAUXITE MINES DURIM0 THE WAR MRS
Year Production %
openvit
undergratod_
1940
76.5
23.5
1941
75?6
244
1942
7363
26?7
1943
71?5
26.5
1944
56?9
43?1
1945
50.8
49.2
At present reserves suitable for open...pit working have been
almost used up and undergrouni mining is the prinoipal practice at
113.31?11.
The Kamm& Bow:cite Mines were pat into produotion in 1939.
Administratively they became a part of the Ural Aluminum Plant with
the status of an indepeolent mining unit consisting of three bauxite
nines (Sokolovskoye, Bagryak and Pirogovskore) anti the Bagryak
Tony,
The principa1 operating mine since the start of the exploitation
of the Xemenek Bauxite Mines hes been the Sokolovskay* mine.
The Tikhvin bauxite nines owes into operation in 1929: Until
the war they were the principal supplier of bauxite to the aluminum
industry.
Besides the *lads= induetry enterprises in the abrasives, iron
and other industries used bauxites frost these vanes.
The maximum produetion of bauxite at the Tikhvin nines waa reached
in 1940 when it was 50 of the total production ani was twice that
of produetion at the Northern Ural mines.
The fourth five?year plea for the maceration ani expansion of
the =Mona *away. 1946-1950, aimed at restoring the Tikkivin
bauxite nines to a oapaeity suitable far fully supplying the opera-
tion of the Tikhvia Alumina Plant ant meeting the bauxite recdre-
nests of the *broth** industry of the scothwestern provinces?
db. 3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
-
Bauxite prolmotionst the So04horn Ural Bauxite nines started
in 1936.
Bauxites from the Southern Ural libaSS were Whipped to the Dmeprovsk
AlusimmtPlant, units of the abrasives industry, and other ouetemers.
The great expansion of the Ural Alminum Plant mode it the Trine?
pal produeer of alumina end aluminum during the Greet Patriotic War.
The output of aluminum at the Ural Alvainum Plant 14oreased rapidly
during the ler and after: The output of alumina inireased still
IWO rapidly: $y the beginning of 2942 it had emseeded the prewar
is by 501 end by 1946 b7 200.
During the wer there *ere considerable difficulties at the Ural
Aluminum Plant due to the irregular and limited supply of electric
power, to tiro shortage in qualified labor, material for repairs
(cathode rods, hearthblocks, cast iron, etc.).
bathe attempt to achieve new production levels all this lad
to a deterioration in *one technical asd ammonia aspeots eta*
operation of the plant (reduction in the production of first grades,
increase in the oonsumption of notarial end electric power par unit)*
The successful operation of electrolytio shops depends on a, number
of factors of which the principal aro the eleetric pm's, supply for
the cells, the number of oells in operation and their condition, the
composition, of the electrolyte, and the type of mainteaance given
the cells.
The power supply during the war years vas narked by great fluctuap.
tions both from the daily and from the annual point of view. Fluotner.
tions in amperage during a 24,..hour period hampered the smooth operation
of the cells and reduced the grows production and quality oft)* metal.
Great limitations made it necessary to shut out some of the operating
cells whioh reduoed the output of metal and led to losses in electric
power.
The higher load of the summer months brought on a disturbance in
the morsel worse of the electrolytic process. Fluctuation, intim'
electric power supply during the 24.1.bour period caused marked year
in the sells and redwood considerably their normal operating life.
Great difficultism in the operation of the alumina shops of
the Ur:lamb= Plant were occasioned by the processing of the
Northern Ural bauxites *doh have &higher calcite content.
4
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Thanks to the unselfish work of factory personnel the diffi-
culties of the war period were overawe and &high output of
yes assured to meet the needs of the front. In 1944 the Ural Alum&
num Plant was awarded the Order of Lenin.
In 1943 the alumina division or the Begoslovskoya Aluminqa Plant
in the Northern Urals was put into production. The plant was located
near resources of raw materials and power.
The electrolytic division of the Dogoslovskoye plant vent into
operation the day of our victory over Germany, N479, 1945.
In 2943 the Stalin Aluminum Plant started operation. It pro*
duces metallic aluminum from alumina brought from elseehere. The
looatifin of the plank in Western Siberia was determined by nearness
to the power resources of Xemorovo coal.
Western, Siberia is ono of the riehest fuel sources of the area.
Here is located the Kusnetsk Goal Basin, the richest in the world.
The sise of the- power resouroes of Western Siberia and the low
cost of coal production (treated favorable eonditions for the develop.
mint intim &Lanett* Basin area of an aluninua industry utilising
considerable power.
The constructies of the Stalin Aluminum Plant was stitrted befope
the ear.
The difficulties of the ear years and the necessity far rapidly
extending the capacity of the slImAralm industry were reflected in
the condition of the equipment of the electrolytic division of this
plant. The cells install,' have a simplified design (oval shells
without gas exhaust). There were no transportation facilities for
all movement within the shop.
=these circumstances complicated the work of the plant to
a considerable degree.
The average current was below that foreseen by the plan and
this reduced the productivity of the cells.
Output based on current and energy was small. The principal
**uses of low oupput mere the irregularity of the power supply and
the failure to supply sufficient electricity, defeats in cell design
and installation, and shortage of qualified personnel for the electro-
lytic processes.
5
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3 ?
1,a
Declassified in Part- Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
Tho shortcomings in tho dosign anti Installation of the collo was
revealed as early as 1943. The shells of the twine were not mufti.
ciontly strong. During operation crooks appearod along the seams of
the shells and they had to be strengthened.
As the result et failure to *mbar the *ells strongly enough to
the foundations tho cons underwent widespread tilting which made
their operation difficult-and re.-duced their effective
The oval shell* wda f.row 6 -Thas iro?dw.--1.1 intended for 1.5 - 2
years of 11101"6211. In fact they wore in operatics without roplmoemost
for 3 you's humans* of the look of /bolls to replace thous Which were
worn out.
The consumption of raw material and electric power was relatively
high.
Despite difficulties in mastering production during the war years
the Stalin Aluminum Plant 111116'11 supplementary 'aurae of alumina for
meeting the needs of the front line.
now with an ineroaas in quantity the elvainum industry of the
ITSM also achieved marked *unease during the Great Patriotic War
in improving equipment, in rondaring production processes sore stti.
cient and in improving general operating factors at aluminum plants.
During the war years them mere great *bongos related to the intro-
auction of the Bayer method* the most modern method for pro:lulling
&Lyda*. While the Boyar method accounted for only 42% of the total
alumina production in 1944 up to 9451 of the total alumina was pro-
duced by this method in 1945 (Table 5).
Lumaximmarnoll
itopthod
TABLE 5
2941
Plant
: ODS DURING MR WAR
1945
Mat
Dry sintering
Volkhov Alum. 14
Wet
Tikhvin Alum. 3.1.
Bogoalovakoye
6
Aluminum
Eleatrothermal
Dneprovsk, A1um.33
Bayer
eral Aluminum 42
Ural Aluminum
94
Total
100
100
6
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
I
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
111
At the Begoslowskoye Plant the sisterirg fur:moos were operated
OA powdered *eel imetead ef fMel oil for the first time in the vorld?
At the Ural Plant the Doer method was adapted to promessisig
bauxites with a high ealeite content. For this purpose the plant
built a *pedal eaustisising installation *Isiah eomvarted into mastic
sods this essees soda famed from the calcites which are brought in
with the Northern Ural bauxites?
Tesissicel changes in this production of alumina are obareaterised
hi the develops's* and introduction of improved largesespasity eliettre?
litho *ells with oontinous anodes designed * Soviet seientists?
Wore the ler amall tolls with baked anodes were used in the
elootrokvtio sections of the Wisher and Dnepr Aluminum Plants.
The presence of a large wailer of ^stades in the bath complicated
regulation". did not guarantee equal diatoms between poles throughout
the entire cell ami **used local overheating* he use of baked anodes
in the *ells necessitated the coastrustion of electrode plants and
the installation of largo anode presses with pumping apparatus and
the oonstruotion of expensive turn*** with sae generator statitmis.
For cells with periodic baked anodes it vas impossible to design
etsaust apparatus and to mechanise the hardest processes.
For this reason the introduction of a large meobanioally operated
cell with a continuous self.baking AWC43 marked a raise in the teohno.
logical level of the &Insist= industry of the UM.
In Table 6 we have data *doh describe technical changes in the
production of aluminum*
TABLE 6
ma OP EIZOTROIZTIO CELLS Di MOMAGS OF TOM
?SP*
1941
1945
Small 'with prebakod anodes
54
Large with continuous anode
46
100
Total
100
100
^
-
??
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
1U =mai= from cells%wrath viebaimi anodes to ?ells with
self..beking eaegies underwent an intereidiate stages the une of cs11:.6
with three self..beking anode* in the Mat aeries at the Urel Aluminum
Plant ebb* went into operation before the ear. These threemeutods
cells gave lower production:IL and used more sleetrioity than
anode *ells* were hard to maintain ani did not provide for the nod:aunt
of fluorixa wits each made for bad working conditions. These
cells opt/anted in the first series during the entire ear period.
During the Groat Patriotic Tar the production of ;silicon sad
'Main was organised and put into operation. In 1944 the production
of silents of grades 0 and 1 resahed 917A. The dementia of the aviation
and tank industries for silumin were oomixlintely satisfied by Russian
production,
The production of pyrotechnic mixtures ens also organised end
put into operation.
Technical progress in the produetion of flumbine salts is shown
by the adoption of a continuous method for the produetion of stimolite
at the Polevekoy Cryolite Plant which doubled the modest/can capacity
of the apparatus old improved working oonditioost by laproving the
fluorspar flotation system* and kr developing a promos for the Mow
duetion of hydrofluoric acid in furoress with internal heating.
As a result of the heroic efforts of the Soviet Union the eartime
objectives in the development of the alutd.zest industry were sucoese-
fully met.
On the basis of the modern aluminue industry developed during
the fiveirwar planet the erection of plants in the eastern areas of
the Gauntry (thin* had started before the war)* the rapid restoration
of the evacuated plants and the oonstreation of new owe* the aluminum
industry during the Gr7..t Patriotic War inereased its prOdUlltiOR
capacity* expanded its inure* of raw material* reined the teebnical
level of aluminum anni alumina production and supplied the ear Indus-
tries with alanninum,
The Soviet state during the war summoned up sufficient strength
and material not only to reestablish the evacuated plants but to
accelerate the construetion of new eetablishments in the aluminum.
industry.
4. The Aluminum Industry During the Postwar Period
The fourth five.guar pima fcr the reconstruction and expansion
fifths Soviet national inoonoey for the period 19464930 aimed at the
? 8
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
4a'vlorr-Art of -41 t-s=7Ch6s- a the newomm.eue metal Lefts*
try. The plan proposed rapid rates of growth bathe produstion of
nonfarm= and rare metals in order to satisfy the growing demands
of he national seaway.
The grandiose objectives of the fourth fivewyear plan required
still further and more accelerated teohnical progress in production,
the over-all introduction of the latest equipment and the nechanisa
tion of operations requiring considerable labor, 4 high level of pro-
duction, laucimum eoonomy and efficient organisation.
The fourth five-year plan, OA the basis of improving the operam
tion of existing enterprise;, the construction of new plants and
the reconstruCtion of plants in areaa lei& had been under occupation,
planned to turn out Woe as mudh aluminum as in 1945.
In order to meet this ninths law governing the five-year plan
provided forth* restoration of the Tikhvin bauxite mines, the Dneprovsk
and Volkhov Aluminum, Plants and the Tikhvin Alumina Plant, for increas-
ing the amenity of the Northern Ural Bauxite Mines, the Bogoslavskoye
and Stalin Aluminum Plants and the oonstruetiom of a number of new
enterprises. Actually aluminum production in 1950 was 1.8 times that
of 2945. There was a naked increase in aluminum production at the
Ural, Stalin, Bogoslavikoye and Volkhov Aluminum Plants.
During tho fourth five-year plan the Volkhov and Dneprovsk
Aluminum Plants were reoonstructed. Aluminum production started at
the Velkhov plant in 1946. The Electrolytic section of this plant
had suffered comparatively little and for this reason it was restored
to the prewar system of coils with baked anodes and the prewar level
of aluminua production was surpassed as early as 1948. As a result
of improving the technological system and the general development of
modern working methods the production capacity of the electrolytic
section continued to increase in 1950 and emnseded 'hat bed been
planned. The Volkhov plant reached the highest output per current
consumption in 1950 in the aluminum industry. The alumina section
of the Volkhov plant was restored in 1949. During the period 19496
1950 the alumina seetion of the Velkhov plant adopted anew system
for processing nephelinesleith the simultaneous production of cement,
potash and soda. The output of alumina did not satisfy the domande
of the electrolytic section which imported some *lamina from the Ural
plants.
The Dneprovak fluid** Plant went bask into production in 1949
with its aleotrolytio section. The restoration of the alumina section
to its prewar state was admitted to be impractical in view of the high-
- 9
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
produation ?eat or..1u-r.ina obtained by the Xnr-mitsc7C-mIzovezir
method and the absesee of known indestrial aouroca of local almAta
raw material. 7ot this reason it las planned to reestablish the
plant on the basis or processing iaported biancites with the possible
subsequent conversion of the plant to Russian raw material.
The electrolytic section of the DneprovskAltsminimt Plant ems
rebuilt according to a new production system (electrolytic calls with
one self-baking anode).
The starting period dragged out became of poor cell installation
and the instability of the lining blocks as well as the irregularity
ail* power supp2/4 the leek of a well..developed optimal ',stem for
type of cell decided on and the lack of reserve capacity at the mercury
conversion substation.
The restoration of the electrolytic section of this plant was
not completed until 1951.
During the postwar five...year period the capacity of the Stalin
sad Begoelovskoye Aluminum Plants was expanded and the Ianaker
14111 Plant was put into operation in 1950. The Itandalaksha Aluminum
Plant was suds ready for operation and the Sumgait Aluminusa Plant
was built.
During the period 19464950 cells with rectangular shells at
the Ural and Stalin Aluminum Plants were replaced by the lighters.
type cells with oval shells as planned. In addition, the three-
anode moils at the Ural. plant Which had provided a low production
level and hod undergone considerable wear were repleoed by singlei.
anode cells. At all the plants the equipognt was improved, the venti-
lation Weems INM4P- repaired and better imictog conditions were pro-
vided. Work was done on making production processes automatic in
the alumina sections and on providing them with control and measuzing
apparatus.
At the Bogoolovskoye plant an alumina section was built to operate
on the Beyer water with simultaneous reconstruction of the section
operating oath* sintering systole in order to convert the entire
produetion of 'lumina lathe plant to a combined Beyer...sintering system.
lathe electrolytic sections of iluminun plants there was increased
use of pneumatic hammers for breaking the electrolyte crust in the
oells and of devices for pulling the pins. The eleotrolysers were
furnished with louvered covers and pipes for the removal of harmful
exhaust wee into the upper layers of the atmosphere; the metal was
a. 10
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
I
tapped from the baths by means of a siphon and votuum ladle; the
level of metal following tapping vas raised; the casting of ingots
in molds /as replaced br semicontinuous casting; a ehole aet of
operation* was carried out to reduce voltage losses at anode and
cathode contacts; calcium fluoride was added to the electrolyte;
all this led to an improvemeat in technieal and economic factors
relating to the operation of the electrolytic sections'
At the Ural plant work was done on making industrial use of
processes for the continuous leaching of bauxite' in a series of
autoclaves =Vilest* mere rum on new designs of electrolvtie ?ells
with top current lead and inereseed capacity.
A major achievement of the aluminum industry during the, period
1949-1950 was the production of highoTurity aluminum on an industrial
scale.
The raw material supply of the aluminum industry, was oonsider-
ably expand.d, There was an interims* in the kaown reserves of raw
material for the aluminum industry. The production of bauxites at
the Northern Ural Bauxite Mine in 2.950 was 1.34 times that of 1945.
A, number of major shafts were started at the Northern Ural Bauxite
Mine in order to expand underground extraction of bauxite*.
Most of the operations in extraction mere medhanised. The Tikhvin
mimes were rastored and work:vas started at the Southern Ural Bauxite
Mimes. Commercial use was made of nephelive concentrates at the
Kirov? Comcemtration Plants The great expansion in, the supply ()free
materials in the USSR was due to the use not only of bauxites but
nephelises which made possible the orermall utilisation of raw material
with the production of &nigher of nationally important products and
the creation of an aluminna industry in s. number of new areas in the
country. Alwainum production was to increase 2,6 times during the
fifth fiveeyear plan but did in fact increase 2.77 times.
Along with the expansion of production at axisting plants, the
now Mandelakshat Madvoytey and Sumgait Aluminum Plants vere built
and put into operations Considerable work: was dot* on intensifying
the eleetrolytic protons at existing plants by increasing current in
the electrolytic **Hee and by adopting modern techniques with the
use of acid electrolytes and increasing current density with current
stabilisation in the series.
\
Increasing current density became the basis for development and
improvement in the technology of electrolysis. During the period in
e
U-
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 ? CIA-RDP81-01043R0040001Annn1zl
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
question current density in the eleetrolysers of all the aluminum
plants inoraasad conatantly. For instance *node current density
itoroszed 16% at the Ural nnd Kanaker Aluminum Plants: 20; at tba
Dneprovek Plant, and at the Volkhov plant anode density in 1936 was
27% bigher than in 1947.
An electrolyte formula enriohed with aluminum fluoride ems
developed and adopted. Ay t:14, end of 1955 the eryolite proportion
of the electrolytes in the aluminum plaits dropped to 2.2 2.5 as
compared with 2.8 3.0 in 1951.
There was also a considerable reduction Lithe number of anode
effects.
The Volkhov Aluminum Plant was able to reach and maintain at
length a small nunber of anode effects of the order of 0.2 0.3
per 24 hours in eultianode eleotrolysers. The frequency of anode
effects at the Kanaker plant in 1956 was approximately 0.2 per 24
hours.
Ar intensifying production the capacity of the aluminum plants
was 20% greater at the end of the fourth five-year plan than at
the beginning.
Bleatrolyser capacity continued to grow. In the new series
the capacity of the electrolysers increased to 80,000 amperes.
Work was done on modernising equipment. In particular, the
Stalin Alumina' Plant reconstruoted the different electrolysis
buildings with the installation of more powerful electrolytic cells
whioh assured an increase in the weeny of the electrolytic sections
and a great improvement in working conditions.
Along with this reconstruction in 1949 new series of alectro-
lytic baths were completed in 19514953.
The principal trolls in the improvement of the electrolytic
process during the fifth five-year plan at the Stalin Alumixam Plant,
in addition to increasing current bathe electrolysers, were raising
the metal level, reducing the eryolite fraction oft)* electrolyte,
reducing fluctuations in current, reducing the frequency of explosions
and strains in all ourrent-oonducting parts of the electrolysers.
At the Tolkhov Al{ Plant the production of high-parity
aluminm was put into effect one oommercial smile, a powerful
electrolyser for refining aluminum was developed and built in 1955-
1956. A. number of difficult and labor.00nsuming operations were
- 12 -
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
also meehanised at the aluminum plants (drawing and driving pine in
tho anodes of elettraytio bathe: breaking through tilts-top crunt_and__
cleaning off ihe side erual oath* walls, switehing ocataetfifin the
pin.ber area, cleaning the 410044 surfs.s of the copPer'Vlps of
the anode lifts, rubbing the surfs?s of the mid* carbon block,
pneumatic raising of theclouvered covers) and work was being done
on automatic control of the aluminum slectrolytie proms.
In the fifth five...year plan much moan* was also done on
testing and developing new types of aluminum electrolysers, finding
ways for further intensifying existing Aeries and increasing the
wile, life of the electrelymer bottoms, and studying promises
which take plaoe at the anode and cathode in aluain= cells. .
In conneotion with the introduction of a number of technical
measures during the fifth fivewyear plan there was an 182% increase
in the production of alumina with marked improvement in all technical
and economical factors. The extraction of alumina from bauxites
increased 7% at the Ural plant and 13% at the Bogoslovekoye, for
example.
At the Bogoslovikaye Alumina Plant a new erste* for producing
alumina by the Bayer..sintoring method with the most modern equip*
vent was introdueed (nonologging crushers, apparatus for continuous
leeching, multistage thickeners, etc.).
After the reconstruction of the Tikhvin Alumina Plant in 1952
a system for proCessing low..grado bauxites for alumina was introduced
which was superior to that used before the var.
tit* Volkhov Aluminum Plant a method was adopted for the
over..all processing of nepheline raw material for almina, soda pro-
ducts and cement which is very important for the further development
of the over-all processing of nephelinse in the different areas of
our nation. For this work a group of factory 'odors, scientists
and researchers was awarded the Lenin Prise in 1957.
In 1955, following reoonstrustion, the elmiina deeion of the
DriopeovekAludnun Plant started operation under an improved system.
At the Ural Aluminum Plant a method was introduced for the
continuous leaching of bauxite* in autoclaves at high pressure which
made it possible to increase this production of the autoclaves 2.5
times, reduce the eonsomFtion of fresh steam by 30% and greatly
increase the extraction of alumina from bauxites.
13
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The aiugli-4-`--..agr. Dom apparatus for thicti =shim r'M
slurry as motiernised isith taw installation of an additional stage
in each apparatus* This ado it possible to inerease the preda-
tion capacity of slurry thickeners 1.7 times and the (*peaty of
washers 1(.5 times with the sane spice and personnel involved. Con-
trol filtration of the laminate solution vas dons in one of the
aiming sections an Telly if filters using a paper mass fu' the
filterIng material instead of the previously employed Abrahes filter
presses (with cotton *loth).
Many other improvements were also made in amine produstion.
For instate*, in the evaporation of mother liquors a two-stage
method was introdused for separating sada from the working solutions,
and a system for separating Weal o-rgenie admixtures fret the
solution* as adopted* in oalcination the lining of the rotary
furnaoss was *hanged Awe smooth to honeyemb?ribbed; the heat of
the *lamina eating from the fumes was utilised for additional
heating of the steak entering the injector for atomising the Awl
oil; the gas cleaning syetem was altered.
All theee meetoures introlueed in the ealcination of alumina
made it possible to berme foresee production by 40A and reduce
the unit exemption of fuel oil try 20%.
A new system as developed (redustion malthol) for the over.all
promising of alminite for alumina, sulfuric said and fertiliser*.
Work was done on automatising the separate phases in alumina produc..
time (bauxite grinding, eatinuons leaching, oalaination turneceo, eta.).
, The Party and the goverment have paid particular attention to
the development of a source of raw material for the gamin** induoi--
try, Hamite produotion increased 2?33 times during the .fifth tim
yew plan.
At the Northern Ural Bauxite Wass major new shafts ware put
into operation for the underground extraction of bauxites, not only
basic but auxiliary operations were moobanised, work we begun on
automatic control for ohaft, pumping 112111 Ventilation motallations,
and voarroimaiLdone on improving the processing system, etc.
Ot considerable importance in inereasimg bauxite production
at the Northern Ural Dealt Minas was the introduction of hies,.
speed drifting 'blob greatly increased the average speed of mining
working operstiones.
14
.?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
In 1947 upon, the initutiva of ir-at=tor driftere et the
Northern Ural Bauxite Mines au A11,--Union ScalaIiat Competitition
for Tunneling Brigades in high-speed mining operations.
Fran year to year the %Ahern Ural nera have stepped up the
tempo in opening drifts, the total number of *Loh emoieded 700.
Ihile in 1948 and 1949 there 'ere 11 high-speed drift openings per
month, in .1950 there were 27, in 1951 43 in 1952 72, in 2953 89,
in 1954 119 and in 1956 225. The rieet rate of opening horisontal
vorkings (drifts) reached 203.4 linear meters in 1948, 254 in 1949,
^LA 4 i" men 11.11mikaule....imaa. 4. Inick
00:70401) 41.41 64.7/1", ...lhamormac- IIIMI1011144111 411670....
There wee a narked inoreame in the monthly high-speed opening
of inclined workings: 73.5 linear meters in 1147, 205.3 in 1951,
1.34 in 19321 1.33.2 in 1953, and 225.8 linear miters in 1956.
During these years a. total of over 225 kilometers of underground
mine room wee opened, approximately one-half of them by high-speed
mottiods. Sudh speeds enabled the Northern Ural Bauxite Mines-to
obtain ores where necessary at great depths where it was impractical
to use ?pomp-pit methods, although open-pit methods were also used
at the mines.
The amount of ore extracted and the amount of rock waste removed
at the Northern Ural Bauxite Nines in 1955 was twice that of 1950.
The restoration of the Tikhvin Bauxite Mines was completed in
1948. In 19494954 new mechanised quarries were opened.
At present the 11`4!_thein beLitite mines ire a major mechanised
mining operation provided with modern equipment for open-pit mining.
The removal of overburden and the loading of the bauxites is
done by. excavators 'bile transportation is in 60-ton dump oars.
At the.. *Lae* AA OPierepit 'vat= has been adopted as developed by
the State Planning Institute far the Nickel Industry in which open-
ing is dens 'without transportation by powerful Eh-4/40 walking
excavators.
During the fifth five-year plan the removal of overburden to
obtain bauxites at the Tikhvin bauxite mines increased by more than
4.5 times and is illustrated by the data in, Table 7.
15
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
9 '
;:;--
TA.812
DirtIMA'-z"imr. OViLtlititDEff mniv
Fat 1951956 =01ISAIIDS Or CUBIC =TEz.S.
(sat'
1950
Total
311,1
Overburden
removal
By the Bentranaport system
apiair
1951
545.1
.
1952
672.6
Ina
1953
957.6
431/40
1954
1193?7
998.6
1955
1400.1
994.2
1956
11336.0
1212.6
11011111x~arlar,?????IIIIIM111114
.;(23i1TIR 11.1
LAKE PRODIXTIVITX DI T.,10 ALBUM DIM= OF THE DS5R
1. ZatigiStaark-ajtajalatta-All-TAIBM-DZIA' latititc
The inoreaee in labor productivity in the aluminum industry is
an important fastar in the LWOW, in the produetivity of amesuael
labor in ths Soviet Nies educe aluminum plays a. most important role
in the sion of the branches of irsUetry and in the
improvement of their equipments Purther teehaioal progress im a
umber of broashes of industry (transportation, maohinery namefasturep
elestrieal. soastrantion, etas) is ooneested with the extensive elle
of amain= and its allows*
An increase in labor produstivity in the alusibum industry leads
to a reduction in U. *moat of lawn labor expended per twit of
the metal produmed shish will result in a rethastion in the amount
of oommunal labor utilised in all brandses *lob employ alumina*
During the prewar period the level of labor productivity in the
alwainem industry vas rrIsAiveki lows Because of the leak of known
highngrade bauxite deposits the abode= industry was oblIgist to
utilise during its first years the Tildnfin boodtes with their high
silloon ?onto* and they bed to processed into *lumina to sinter-
ing and not by the improved Beyer method* Elaetrolytio production
16 -
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
utiliaad primarily? collo with babad 01410 ?etas rhl oh =a lc= moint-
time than oella with salt-baking anodes.
Not long before the war alumina plants were operating pertially
on. Northern Ural bauxitee.
During the Patriotic War the aluminum industry eomverted completely
to the processing of high-grade bauxites from the Northern Ural mines
and to the predominant use of the Bayer system in the prodisrtion of
alumina. At aluminum plants the principal type of elestrolyser became
the more productive sells with a single selfi,baking anode. By this
time the alumina industry aIreedar halet Its dlappaal ozp4rismazi
workers and engineering and techeieal personnel who were used to staff
the new aluminum plants in the Urals and Western Siberia.
In commotion with the difficulties of the war period there was
an interruption in the normal power supply to soterprises, in the
provision of basic and auxiliary materials and spars parts and there
was a lowering of the level of labor produstivity, particularly during
the first years of the war.
During the initial period of the 'mut the influx of a largo masa
of workers, including women and 'wog people not previously empaoyed
in industry, naturally caused a drop in labor produetivity at alumi-
nue plants. A oertain period of time was required in order for the
new pereomnel to luster production teohniqme and become qualified
vorkers. Thanks to patriotic labor efforts the markers acquired work-
jag habits and became skilled personnel very rapidly and by the end
of the ear labor productivity substantially emeeded the prewar level.
Tbe postwar period was a period of reconstruoting enterprises
destroyed by the ear and of further expending the alumimma industry;
it is characterised by a great increase in labor productivity. During
the fourth five...roar plan (1946-1950 labor productivity increased
46%, or by 48,6% as competed with 1940, Aa a result of the tempo of
growth, labor productivity in the aluminum industry exceeded the
average for industry as a whole by 37%.
Improvement in teohnotagical processes, the reconstruotion of
elsotroiytic planta at operating aluminum plants, the mechanisation
of the more difficult operations, the acquisition of greater skill
by the workers, the development of modern forms and methods of work,
and the ieproved material eelfare of the workers served as a basis
for a further increase in labor productivity.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
In eke fifth fivaaiquar plan (1951-1955) the toisPo of growth
of /mhor moductivity in the aluminum induetry waa still uore
marked.
In 1955 as pampered with 1950 the gross production per vorker
ihommod 641% with an average index of increase in industry as a
whole of 44%.
The protection of market abaltinlill par regular employee in 1955
vas 7400 greeter than that la 1950,
*boipeolvatiAty 2 196, the ffrot er of the '14v+-h el-Vad`
year plan, inereasad ever 3.955 by 11.8% at the Urfa. plant, by 10.2%
at the Stalin plant, by 914.1% at the Xandalakiha plant and by 13.6%
at the leneker plant.
The achievements made In the groeth of labor productivity did
not exhaust all possibilities in this area. The revelation of furip
that' potentials for the growth of labor productivity requires a
detailed study of isolated feetors, an analysis of vidoh requires
consideration of data oonmectad with the introduction of new equip-
ment, the use of meehinery and automatic eontrol in production pro-
cesses, the comditions surrounding the exuraction of raw material
and the organisation of labor and production.
2.
Where production methods are idestioal, greet importanoe will
be attaohed to the seleotioa of the largest highiprodustion apparel..
tun viatitidal provide the maximum &Ire* of mechanisation and the
possibility for automatic oomtrel, vileh is connected with the les-
ser number of operating personnel (formai**, the %gee of continuous
leashlog of bauxites, the replacement of single-stage thickeners by
multistage, tvapatage crushing of bauxites in different types of
or-agars replaced by eruAthinit in noverful 'rushers. suhatitution of
apparatus with simultaneous soda crystallisation for ordinary evaporm*
tors).
In planning new plants and reconstructing old coos it is necessary
to aim at more powerful units of improved design in the different areas
of alunima production instead of the installation of numerous apparatus
of low production eapaeity.
The influence of the design of apparatus on labor productivity
can be illustrated by the electrolysis of eryolits-alunina nelts.
- 3.8 -
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
CS,
Declassified in Part - Sanitized Copy Ap roved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The design of electrolytic cells is an inportamt faster in
lab' productivity in aluminum plant es determining essentially
the level of natal output per cell per 24-hours.
This factor under a normal power oyele is Movies determined
by the continuity of supply of raw material and excellent maintenance
of equipment.
In addition to technological advantages *lob assure a higher
output per cell per day, eingle-anode cells are zimpler to maintain
than multianode molls and require leis expenditure of labor.
Progress in the electrolytic promise leads to an increase in
the oapeeity of the calls. The design of cells for operation on
higher ourrent assures increased output per cell-day and greater
labor productivity,
In the history of the development of the Soviet aluminum Indus-.
try we observe a progressive temdency toward increasing the **piety
of the electrolysers by increasing the current with corresponding
changes in *ell design.
Workbag been don* in the USSR on finding the most produotive
disigas for electrolysers with current lead in to the anodes on
the top, a reduction in the amount of electric power consumed and
an increase in metal output per cell-day. Through more *ample**
mechanisation of promisees of charging the alumina, reerramgememt
of the pima ani the elimination of the operation of servicing the
contacts, the number cl'acrters engaged in maintaining cells with
a top currant lead-in is being markedly reduced&
At present the current in the different series of 1.1ectro2ysers
wit eoatinuous .el-baking anodes has reached 80,000 amperes while
of Ave am aluminum plants under construction the plan calla for
t 4 installation of powerful electrolymers operating on 130,000
ampowes and higher with top current land=in, and the meohanisation
end automatie control of the electrical portion of cell operation.
At aluninan plants considerable work is being done on intro.
ducing new equipment and modern techniques& For instance, at the
Stalin Aluminum Plant reoonstruction of electrolytic series 1 to 3
was finished with the installation of more powerful cells; the
cryolite portion of the eleetrolytes was reduced and automatic con-
trol of ourrint stabilisation in the series was set up; the frequency
of anode offsets was reduced; pneumatic machinery was installed for
cleaning contact surfeees; all cells have Neon converted to tapered
- 19 im
npriacsifipn in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
=
pia:whir contr....smt and aeries of organizational ad technical
measures have been oarried out aimed at inareasimg the teehnioal
level of protection.
In conjunction with the All-thdon Aluminum and Magnesium
Institute produotion tests are being wads of anerimestal eleetro-
lysers with top current lead?ins, and of an anode oospouad mode of
coke from petroleua with a high sulfur content; a method is being
adopted for determining output per current unit by using radioiso-
topes; a study is being made of the circulation of the metal and
electrolyte in the cells as effected bv- nagisetin field) a teat
is being made of longer pins for sells with lateral ourrent
and a number of other irojeats are umber may ehieh are ut great
isPortwanse for improving all alu .einkne production fasters.
A great role in the increase in labor productivity in alumina
production is being played by the further imprsvelent of apparetus
at taming plants with relation to Increasing the Tereduetivity cd
the basis units, to providing maximum neohanisatien ant automatic
control of prooescire and ()emersion to oentinuous promises.
partioular, there sksould be greater speed la introdusing
into -alumina production the NM types of high?prodnetion apparatus:
tubeball sills 3.2 meters in diameter and 13 meters long for net
grinding of the *barge; sintering Arouses 4-5.5 meters in diameter
and 100 meters long for the bauxite mixture; ealeinatice Ammo**
4.5 meters in diameter and 100 meters law a five?ehanber thickener
20 *eters in diameter; an 1000 mobil: meter decomposer with air stir-
ring; a tube leaeher for leaching almeinate oaks ohnnks.
Of great promise are also the use of bydrocyclones in claseilsp.
ing or settling apparatus in a amber of prams in alumina proluation,
turmoils with fluidised beds (oaloination of aluminum hjdrecide in
fluidised bed). it..
At the Ural Aluminum Plant tests have teen made of hqdravolones
in different areas of alumina production* bite grindinw. thicken-
ing the red ilueryt classification and thickening of hydrates pulp
and thickening of lilts slurry, obtained from oametioation of the
carbomate soda. In the bauxite grindieg units mime the hydrofoil:acmes
have bees put into produation there has been an ixesrovement in grind-
ing and a reduction in power oonsumptions Teats under production
conditions ham also been mode of a pilot refrigeration plant for
chilling the alumina in a *fluidised bed.* The full possibility of
shilling the alumina in a "fluidised bed" has been established.
26
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-'4141 -:j:177. ?
I I VIA
*fg,)
As a result of ititrodusing new aed inproted eqmtipmento. the
? pei-ttt.01 e.,--otleaita.
provement in productica and labor wpm:IA:ties, meltiple-unit
melmtemenee (beigades have bees unverted to maintain 10 ar mare
sells) the =lbw of workers bas been i%dueed t1. there has
beat an iserease in produlation. I artioulart. there was a 3.7%
robotic* in the xenaber of workers at. the Ural pleat fret 1955 to
1956* at the Stella: Plant a 14.3% radiations at Natmlalaiutia S.%
and at lanaker 10.940,
3.
??? Ill IL ? ?
The basis for the imams* in labor productivity at the Northern
Vrta. Bauxite Mines was the mecikantattium of prodeetiam pro:fosses.
the 11101411100 in implying labor with parer equipment, improvameat
in twaeling and minima operations eel in the organisation of laboz.
During the fifth awl/0,year plan the coefficient of power equipment
in use more then doubled.
Simultaneously with the improvement in the system of top
allele( salt was done on finding a mor* miffieleat operating system.
Siam 1954 operation hes been started on the gratis of open 'toping
with beads examition end tiering withpc...lvs# as propeeed
Enginete Ne A. AlekeloPevekly.
RooentIty the Northern Ural Demdto Mines hew seen the intros
duatiat of a room wietent in .attesting are with polo timbering
and subsequent working of the pillars between roue by a system or
top sliming. The use of this system bee given good results. The
SUP. brigade Indio ?amide Reehkow at miss 1e.2 of the seam(
Sather* Nine inareased extra:ties of are fran the bleak up to 240
tons tibidt eorresponda to the probation of ore at a mime with four
Meeks. The production per stopeleut per shift is 6.3 cubits meters
of oto whi:mh is doable that *lob bad been planned.
With this system the oast of exttractiat is iimAch lower than
with top elloing and- even with longio*U mining of the blocks using
pole timber-btu for ibei: t-M lower layers are worked it is not
neoessai to timber the room.
The pillars between the roams which are =Iced by top slicing
after the &ambers have been awed int fulfill the role of roof
support': reinforsed poles.
The nee gratin else has the **fruitage at exoluding irretrievable
law* of ore eltioh is inevitable in other extraation systems.
21
, Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
(
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Labor productivity or miners 1=nozcp-1 2,2 tirmo Iron 1949 to
1956.
The basset level of labor prcluctivity during the fourth five-
year plan was 1946 vibes the proportion of undergread work Imereased
aid there was marked deterioration in nining eemditions, eid improve..
meats In the working Kyoto* and the mechanisation of operations had
been itstroduoed to only a slieat dogma.
The proportion of opes-pit operations has declined tem year
to peer, causing a drop In the labor productivity index although
therm wail on increase in individual open...pit and underground ?pore-
time.
The proportions of ore obtained by open-pit methods was 1,5%
of the total ore in 1950 and 15414% in 1955 and. was the result of
bringing into exploitation portions of upper lams of the ore seam
earlier considered below standard and for this reason not worked.
The mount of ore in such sectors was very limited and the wain
atowlit of ore is extracted by underground methods from the lower
The biomes* in the proportion of undergrourd operations was
accompanitod by a shift to mare difficult oonditions of extraction
In the lover layers marked by a great excess of meter.
TOM II
Proportions of underground and essenr.pit mining %
1940
1941 1942 1943 1944 1945 1946 1947
1948
1949
Peroentogo of underground mining
22,3
24?4
26,7
26,3 43.1 49,3 544 MS
74,5
90,7
Peroentage of open...pit Alining
77.7
75.6
73?3
71.7 56.9 504 464.6 32?3
25,5
9.3
Proportions of
1951 1952 1953
99.65 92.2 91,9
0?35 7,6 8,1
undergrowd and open-pit mining %
1954 1955
Pereentage of underground mining
84.1 84?6
Percentage of open-pit Amine
15,9 15,4
1950
9B?5
1,5
With a decrease in the proportion of opeerpit operetta* there
was an Ingress* in the amount of labor used per ton of bauxites sbioh
also led to a reduction in labor productivity at the nines as a shale,
Since 1947, despite the (mutilating increase in the proportion
of undergrouni operations, there has been a oontinuous increase in
labor productivity at the nines as a whole shioh can be explained
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
by th tLo f produatiLa processes and the extenotim
expansion of modern work methods.
In Fig. 2 we see the dynamioe of labor productivity in milder.
ground operations during the period 1940-1915.
Underground operations started in 1938. Labor productivity,
as a rule, was at a, low level bsoause of the lack of meebamisation
and an efficient working eyetem.
In 1941 labor produativity increased 8-10% over 1940 as the
result of working more produetive sectors.
In 2942.1944 labor productivity dropped. During thee* years
horizons were opened whisk ley below the level of the umderground
waters and working in them was complicated by 41X040111103, mins 'water.
The work of the nines was also greatly hampered by wartime
difficulties eaused by the lack of natorialat mining equipment and
tools. The absence of a 'efficient number of qualified persomnel
and idle time of eqwdoent led to failure to fulfill laioduationk
norms and to a drop in labor productivity.
A positive faster in the work of the mines during the parted
1943.4044 was the start of neohanisatioa. Meahanisatica in stoping
operations laaraluied from 5.7% in 1942 V) 22.4% I* 1944.
Starting with 1942, clearing operations indrifting 'ere
meshamised. In 1943 21.3% and in 1944 28.8% of clearing operations
in &Mimic were neehanisee6
However, as the result of the negative influence of the above
enumerated factors labor productivity declined despite the increase
in arahantiatien.
Starting with 1945 labor productivity increased in underground
operations which was achieved thanks to &tangos in the mining system.
The shift to combined top slicing mado possible more complete
mechanisation of the production procesees (mechanised hauling increased
to 44.1%).
As the result of improving the nining system labor productivity
inoreteood per stops, underground, and per nine laborer).
In 1946 there was an extension of the combined mining system
accompanied 47 an increase in nronanisatian of production processes
23
ammo.,
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
oti
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
(bo)e. hauling of roOk; wanu41 hauling of timber to the it-opo
completely eliminated) and in labor produetiTity.
Labor produetivity intim* blocks greatly ameeeded the usual
ihich ems the result of the meehanisation of prolustiom preemies*
and correct labor managc=snt.
The inorease in labor preductivity was also accompanied by
the extensive introduction of highp.speed entry operetioms. It
should be mentioned that the level of lebor productivity would
have been higher if the ocebined gates of fel) slicing has been
used to the aseessary extent. In the meentilas large sectors which
could be worked by *toping with a broadimeking front and looser -
quently high labor productivity were worked in part by ordinary
pecceduress
Labor productivity in open-pit operations during the period
1940-1943 was at Approximately the acme levels with the oreeption
of 1944 ihen the produetion ;or mine worker we 72.1% of the 1940
level which sante .spialmed by theed.drop of wear of the exoavators
and the absence of drilling equipment,
In the period 1946..1949 labor productivity of workers in
open-pit operations rocs markedly. This was furthered by soolalist
competition among workers in exeavator teams. The principal faetors
*Johns& for higher labor productivity among workers on excavator
teems were:
mutter/ of their occupation by members of the excavator team;
consolidation of the workday (teems reduced the time for
loading ome train from 33-40 *imam, to 2045 Matto.);
seintenaase of oxeaveters in good condition., careful inspection
and prompt elimination *ruiner defect* during the shift, prompt
preeautionary repair as planned (teams greatly reduoed the idle
time, of soosavators for repairs *Joh lel to increased produetivity
of maohiner.y);
Th t hourly cxbaation of the excavator vas 37.9 cubic meters
in 1945, 4.0.6 OU.S6 in 2946, 41.4 mos. in 1547 and 41.9 ou.m. in
1948.
use of a bonus wage system;
strict coordination of the work of excavator teams with the
work of train crews.
During the fifth five.year plan there we a continued increase
in labor productivity, greatly surpassing the 1950 level (Table 9).
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
La 1955 twisz aa srs;aa iwcauaad as 1=2950. Of iLlo
total increase in ore extraction mere than, half vas eihieved
*brow& the increase in labor productivity. For Instance, in. 1955
the propmtion of inoreaee due to an inoreeee in the nulibm of
naardays worked was 40,9% and that due to increased labor prods**.
tivity vas 59.1%,
As we Imre in the data fron Table 9 labor productivity with
regard to the snood of rook renewed per atop' group was OA%
hiibm in 2955 then 1950, fer all uaderground warkere 54,1% and for
the workers in the meow division' 46.3%.
TABU (9)
DYNAMICS or LABOR FRODIETIVITT BY SIPARATE CROUPS OF WORMS
19514955
Indexes
1930
1931
1952
1953
1954
1955
Labor product.in aux, of rock
per stops worker in % of 3.950
100
105.9
112.9
113.8
139.7
148.4
Per underground worker in % of 1950
100
1224
123.6
229.5
144.8
154.1
Per worker in surface installation
in % of 1950
100
111.9
120.9
123.8
137.2
146.3
Per nine worker in general
100
115.0
121.5
132.2
139.3
133.6
Labor productivity per nine worker in 1933 was 53.0 over that in 1950.
Such a difference in the rite of increase in labor productivity
of the different groups was the result of changes in the structure
of the labor faro. in the nines during these years.
For instants, in 1952 the ratio between the number of workers
in the stops *rows, underground operations, surface installations
and total nine were 1: 1,9: 3s 5,4 an while in 1955 this ratio was
1* 2?1: 3.2s 6.1.
This change was accompanied by a lag in the rate of growth in
labor productivity in other groups as compared with that of workers
in the stops..
- 23
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
agivrtgttetion
There are emeedingly great possibilities forimoreasing labor
productivity in the aluminum industry by reducing the amount of
labor through mechanisation and automatic% *carol.
Problem in mechanisation have been the focus of attention of
the Party and government during the entire period of the develop.
nent of the national eeonomy.
The meohanisation-eprooesses utilising mob labor has an
effect on increasing the efficient use of marking time, easing
labor conditions, reducing the auxiliary labor force and the long*
of work prooessosp, increasing the ikill of laborers and, ocesequently,
on increasing labor productivity.
At plants in the aluminum industry eonsiderable work has been
done insolvent years on the neehanimation of heavy promises eith
the result that the basic premiums in electrolytic and limning
production have been almoet completely meehanimed and manual labor
is being used only in auxiliary and subsidiary sectors.
Intim mining industry problems in neebanisation are of'special
importance because of the diffioult nature of the production prooisees.
Tte use of nee equipment in the fifth five.year plan has mode
it possible to complete the mechanisation of anniber of basic
prooesses in extracting the rot ore (Table 10).
rzg-...e.? Et *ha
TABLE 10
oF THE LEVEL OF MECHANIZATION OF BASIC PROCESSES AT
MINING ENTERPRISEA OF TUE ALUMINUM INDUSTRI (IN % OF TOTAL
VOLUMZ OF ROCIE)2 NOM EX. EMMA "DMITIOPMENT OF TEE
MINE BASE OF THE ALUMINUM INDUSTRIE", BULLETIN OF THE Ts/IN?
NO. 6, 19572.
Process 1942 1943 1944 1945 1944 1949 1950 1955 1956
Clearing in drift-
ing _21,g 2,M, ?9,A 5g.$ 75.2 80.0 94.0 9445
Haulage in extra*.
ting 5.7 19.3 22.4 442 34.0 63.2 76.0 974 745
Underground haulm.
lug of rock 23.0 42.3 57.0 99.0 90.0
Extraction and load.
ing of rook in open-
pit operations No data 904 No date96.0 100.0 100.0
26
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 ? CIA-RDP81-01043Rounnn1Rnnn1
Declassified in Part - Sanitized Cop Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The data shoving the state or_.,14,-atitzt et the Norther-it
Ural BeAmite Minos ars cited in Tata* 11.
TABLE 21
ItECHAIIIZATICti OP BASIC PRCCESMS AT THE NORTHERN URAL IIDIRS 19404950
(in to tel volume)
Process 1940 1941 1942 1943 1944 1945 2946 1947 190 1950
XiUiDg 100 100 100 100 100 100 100 100 100 100
Transport in
st opines
soobanised 5?7 19.3 22.4 44.1 4414 44.8 55,2
gravity 17.4 10.8 16.2 1,6.6 24.7 15.2 770
senora 100 100 94.3 63.3 66.8 39.7 39.26 30.5 29.6 23.0
Underground haulage
of reeks
seebanised 2.96 17J 65.9
here...drawn 2.31 164 9.0 4.4
mama 103 100 100 100 100 100 97.69 80.94 73.5 29.7
Haulage on the
surf/root
arratminised
11101111112,
1?66 13.9 50.8
100 103 100 100 100 100 100 96.%86.1 49.2
Clearing in
drittings
sechaniesd 21.3 28.8 54.9 58.54 70.6 81.2
gravity 4.?7 5.2 7.1
usaaal 100 100 103 74 66 38
00.awitioromorampa
Removal of ore from the stop, and its further tratreportation
to the Maine drift are the scat laborious operation in the trictrao-.
tie* of bauxitsis.
In 194049,41 the transportation of ore was by hand dumping and
on eats. This required a great deal of labor ard labor prr4uctivity
vas very Us.
In 1943 the nines introduoed the removal of ma frmi the
stops by serepers and sanity reroval of ore fryer inclined galleries.
Sines 1945 belt conveyors have been oaring into use.
.?
27
di
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R00400018onn1_:1
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
In 1946.1947 sorapor removal ate emtended (bilateral =aping
and Doming at an angle).
In 15484950 great *lark:was done on meobanising transportation
in steeling operations (up to 77.0%).
The process of underground healing of rock was mechanised te
the lowest degree. In 1940-1943 all the hauling of the rock waste
was still done by hand.
In 1946 horse haulage was used for the first time but to a
very slight degree (2.31%). In 2947 home mere doing 26.1% of
all this mark.
In 194761948 electric l000motives came into use for hauling
in mine opening operations. The use of electric locomotives
required inereased speed in opening drifts.
In 1950 the proportion of manual labor was relmed to 29.7%.
Up to 1943 removal in drifting operations vas done &massively
by hand (shovelling, puking in hand carts or rail cars). Labor
productivity during this period was low. As s. rule, up till 1943
the rate of tunneling did not exmeed 25-30 linear meters per month.
In the period 1943-1945 removal by scraper VOA adopted at the Northern
Ural Bauxite Mines. In 1943 mechanised removal of rock in tunmeling
was 21.3%.
In 1943 gravity removal in sloping galleries wax used for 4he
first tine (steep inclines required). This type acootaitad for 4.7%.
In 1945 refooval by Wuxi soconged for 30.
The nee of scrapers in raisoving the rook during tunmelimg
operations resulted in an increase in vr-Aning drifts and a rias in
labor productivity.
The start of the mechanisation of rook clearing operations by
using scrapers operating on a cyclical basis goes book to March 1943
when Sabirev's Crew tunneled 73 linear meters as a single stop*.
In JUZT 1949 the ores under Stalin Prise Winner N. Minsaripov
penetrated 254 linear meters adrift in a single stope. In, 1950
a maximum tunneling rate of 2611.6 linear meters per month max reached.
During regent years mines have carried out more than 80 hi/1**speed
drifting operations.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
In Table 12 we have data on monthly tunneling rates by year.
TAME 22
DATA swam Roma rearm RATES m 1943.1950
IN LINEAR moms
Indict
1943
1944
1945
1946
1%47
1948
2.949
1950
Average speed
73
90
13.8.7
127.3
135.5
332
134
135
MaximUn
13
90
162.4
272
18164
203.4
254
26146
speed
Starting with Deeember 1945 RialliitA loaders were used in clawing
rook from drifting operations.
Rol* ritaaval from drifting operations at the northern Ural
Bauxite Mines was the most hilKi neehanised process. The remorS1
oft)* ?oakum** on the surfeee on the other hand was poorly meihe-
nised. In 1940.1946 the transportation of the rook on the surface
was done vholly by hand. In 1947-1948 some mines started to U.S
scraper winches to transport ore em the surilee. However the per
-
montage of usohanised transportation on the surfs.* sus still
satisfactory.
The peroentage of hand transportation yes 49.2% in 1950.
Daring operations, *Joh are one of the most important in the
production cycle, were *ally mechanised both in stoping and in
Mn. opening operations. The number of boring hammers on January 11
1956 as compared with January 1, 1951 had increased 84.4% vhile the
degree of their use had increased by 8.3%. /n 1950 mechanised and
gravity transportation of ore was 77% in stoping operations shill,
mechanised haulage ?sashed 98.2% In 2955.
The level of seahanisation in the removal of rook in sine.
openimg operations vas higher in 2950 than the transportation of
ore in stoping operations. In 1950 the remov41 of rook training*.
opening operations was 92.2% mechanised in 2955 and 91.9% in 1955
(Table 13).
29
Declassified in Part - Sanitized Copy Approved for Release a 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Wu= '13
DM= OF RECRENIZATION OF TRANSPORTATION at CU AND ROCK Th
STOPTh0 MD IIIKR-OPESING OPERAT/011,3
Index
Total volume of Irork
in rock haulage in
stePinlle %s
osohenised and gravity
by hand
Total volume of work
in rock removal, %$
mechanised
by band
1950
1951
1952
1953
1954
1955
77.0
81,0
92.0
96.5
97,7
98,2
230
190
8.0
3?5
2.3
loll
92.2
93.7
90.0
96.0
96.7
97.9
7.8
60
104
4.0
3.3
2.1
The inns**, in the number of scampor minehes and loading
michincs wee an important factor in increasing the growth in the
mechanisation of ore transportation IA *toping operations aid
rook haulage in ;reparatory operations. 7dir totem*. the ausiber
of sereper minable* in nines in 1955 vies ISOM than 3.7 time sore
than in 1950 while there were 215 times as many loading maebilleat
the coefficient of use of the scraper winehes at hand inereesed
during this period from 0.79 to 044 and of loading machines
frac 0.45 to 047.
Ons of the eonditions for the increase in labor proluctivitr
at the Mite* was the further sosobenieetion of underarm:id rock
haulage sad the trarspertation of rook on the mesas (Table IA).
TOM 34
DATA at RECRANIZAT/Cti OF LABOR AT BAUXITE LURES
Index
Underground heu1-4
mg* of rook* %I
mechanised
horsemdrewn
by haat
Transportation of
rook on the ourineet
msebanised 50?8 5743
by held 49.2 42.7
1950
1951
65.9
96.1
444
2.9
20.7
1.0
1952
1953
1954
1955
98.2
99.0
98.7
99444
1.8
1?0
1.3
0.6
684
76.4
93.0
94,0
31.6
23.6
7.0
6.0
30
44,
,????????fti??????????1....11
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part- Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
An important factor in assaying tho'incrftee in the wechaais&-
tion of underground hauling and transportation of reek on the maw.
face ems the constant growth in miens of transportation during this
period.
The number of electric locomotives at the beginning of 2956
was 4.5 times greater than at the beginning of 1951. The seiber
of cars increased more than 150% during this sans periods
As the result or work done on mechanising the betels promisees
(delivery, clearing, uederground haulage) the proportion of
workers to the total number of workers dropped gad stood at 1311711
in 1512 end 31% in 1955 While the ratio to the number of *las workers
in general *al the somber of workers in production promos', was
1.g.7 and 26.3% reepectively.
Thus labor productivity among eine workers at the Northern Ural
Bauxite Mines doubled from 2940 to 2955 as the result of improvement
in stoping methods, the meehanisition of basic produstion processing,
and the use of improvel week orpanisation lathe Asps.
lathe alumina and electrolyto aeotitIns the baste produstion
proossses were sore ocepIetelyneehenised and manual laer was
utilised in auxiliary and subsidiary sectors. The us e of aschanise..
tic* through local ingenuity and adaptations node it partible to
reduee eonsi4ereb4 the number of anxillary 'markers. War butanes,
at the Ural Aloeinan Plant U294902950 there was a growth in pro-
doation with a ooneositant rotation in tha labor forae through
mechanisation.
In the slectrolytio divisions, diffloult operations in trans-
porting the alumina, anode notarial, oryolite and alumina' fluoride
tiers dons *014 with electric trucks which made it possible to
reduce considerably the transportation labor force.
Heavy physical labor in, pulling out the pins has beer eedhanised.
Koryrev machines and Shishkin hydraulic jaeks have been woad. In
addition Snesbko pneumatic akachinar operating one percussion
principle have been used to pull the pins out of anodes of electrolytic
In iaproving the design of the pneumatic nachines the sane
designer node and introduced a sew improved pneumatic mecbAne *Leh
eliminated the necessity farimaneal labor in pulling cut the pins.
31
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 ? CIA-RDP81-01041Rnunnn1Annn'l
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
"
I s
At sows plants the Anikin machine has boon mood for driving
pins into the ak,444aes.3 of elot;traytic collo* The l000baninetion of
the presses at pin driving ban ar,:,cdal up t1Lis oparation mere,
times and lightened the labor of the anode operators.
The difficult prooeee of servicing the *ells (reeking through
the top trust of the elestralyt? and breaking up the crust cm the
sides of the aluminum eleetrolysers) was for & long time dew by
head with embers and with pneumatic drills. At present a nos
penitis neohazilot is used in brooking up the top and aids *rust
which has mode it possible to neohanise a difficult and loam**
consuming operation, inprove and speed up the proms' of servicing
the *ells and improving working conditions from a sanitation point
of view.
Wedgegetypa barpin oontacts have been adopted for eleetro.
Users and a pneumatic drill is used to drive in and pull out the
wedge. Thin mentors has made it possible to bliprOVIO working condi
time, incrinee labor produstivity sal *thieve great wow of
electric power sines the average drop IA voltage in the wedge
bar-pin contact is 4..6 millivolts instead of 15 millivolts.
Work is being done in electrolytic sections on installing
mechanisms with electric drive for raising anodes from the *ells,
for nechanis the raising of lowers on the cells, and tenting
new maohinery designed by Booherov, Gerasimov and others for
breaking through the electrolyte crust.
Cleaning the dust from anodes by hand before loading the
anode material has been replaeed by mistiming with on air spray
which improved the qxuslit,y of anode. cleaning and reduced the work
time involved in this operation. The loading of the anode material
in the form of largo briquets has made it possible to use gentry
cranes for this operation. The canting of wire bars ant silunin
has been mechanised.
In alumina shops at the Ural plant mechanisation is employed
in unloading, grinding, screening Awl feeding the charge into the
lime 'furnaces and transporting line into the flotation division.
Remote control from the upper level has been organised for
senplIng craws on the 'hit* side. Pulp ani solutions are being
reserived
by pump from the apparatus before cleaning and the appare*
tut is cleaned by water at high pressure. Parts are hoisted
vertically by winch** which has med. it possible to reduce the num-
ber of auxiliary workers carrying up. parts. Conveyors are used for
unloading soda.
44, 32.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
0
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
.....,z1=7 is we fw loading 'ths bolls into the beri
by overhead line and electric magnet in the first block of
alumina shop* etas
Considerable work on the mechanisation of major prooesses
in the alumina sections of other plants has also been done*
Instructions from the Party and the goverment relating to
the poor meohanisation of auxiliary prooemes at plants *ere
basic processes are highly mechanised also apply to the alumina:
industry*
In the auxiliary shops of aluminum plants there are a :umber
or sectors now being meehludsed*
In the repair shops of scan plants there are no machines for
hoisting parts and loads during repair operations; above some
apparatus undergoing periodical repairs there is no auxiliary equip-
ment mob as crams, overhead oonveyorsit etc* with the result that
the speed of repair Jobs is slowed down and the work of skilled
laborers is used ineffiniently* In railroad shops sluidnut ingots
are loaded anti Apse goods are unloaded by head.
Deapits the gnat =it. of 'sock on med:anising hammy mon...sees
done in recent years at aluminum plants it 0101110t be considered
satisfactory or equally well done at an establishments*
WO Maui& provide for further mechanisation of all heavy Jobe
in servicing cells in electro3.7tic sections and the various sectors
of other sections* total mechanisation of all transportation within
the sections by using the best types of corrming oluiPuleut (us*
of dump oars for aluitina section* with a great flow of material;
loading and unloading pulverised materials in special eelfaidumping
care); maxim: use of resumatie tube transportation; auttic
oomtrol of separate operations in alumina Amnions and oentral
control of production prooeseee by providing for a await* supply
of oontrolg nemoring and signalling apparatus* The meehoudsation
of loading err' unloading operations makes it poesible to get rid of
the greater part of burg unskilled labor used in a given branoh ard
to reducle the number of the auxiliary ani subsidiary labor form*
Considerable influence on reducing the number of workers
engaged in repair in the aluminum industry might be exerted by
oentralised production of spare parts for the aluminum industry
at specialised repair as-fd machine plants* The organisation of
centralized production for the principal spare parts at specialised
repair ant machine plants will contribute to an increase in labor
- '3..
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
_
productivity. Such speeialised repair and machine goats, replea?
in moducticn cm m limited er individual production basis at the
individual aluminum, ostalbiont4 be orgenined in the
various regions ami serve the group of establishments looated in
that regioe.
The effectiyenese of mechanisation is also determined by the
degree of use of the machinery. Maehinery idle time sometimes
reaches very greet pow:time. Per this reason it is important
to campaign for the total utilisatioa of meehinery now available
at plants (truek?mounted cranes, steme.orenes with tropics, various
comma).
5
?. 1 ' ;P???.. :1 , 1
kessaissitacaLligaie
With these systems of raw material extraction, alumina 'reduction
and its layout and existing designs of electrelytio cells I, considerable
influence on labor productivity is exerted at different enterprises
by the organisation of labor and the 'age systole., the provision of
advanoed training for workers, the degree of timo?use efficiency, the
adoption of urtordate methods, working a:witticism and other questions
oonneeted eith the functioning of the labor Throe.
The level of labor productivity &oasis to a great extent on the
level of Skill and the length of employment at eetablishmalts in the
aluminum industry.
The skill of the labor staff of the different enterprise* depends
Oath. Armature of the sections and on the qualitioatioms of workers
in the different shops.
-The relative reduetion in the number of poor skilled workers
and the oorreeponding increase in the number of workers of great
ami average skill at the Northern Ural Bauxite Mines is indicated
by the ineresee in the nunber of skilled workers (the proportion
of highly skilled uvekers roe, from 20% in 1952 to 24.5% in 1955).
The average wage category of workers in the industrial produo?
tion group of the Northern Ural Bauxite Mines mos 5.26 in 1955 as
against 4.8 in 1950 and 3.85 in 1946. The average wage category of
sine workers (5m45) is higher than workers in the auxiliary sections
(5.0).
This was achieved thanks to well organised work in training
personnel st the enterprises.
34
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
That =Graz) raze eategat7 of workarri- at tho tte
Plant during the period 1942-1950 is illustrated lir the data in
Table 17.
TABLE 3.5 ?
AVERACZ WAGE GREGOR/ OP WORMS AT THE 1MAL =MIMI
1942
PLANT
1943
19424950
1944 1945
1946
1947
1948
1949
1950
Entire plant 540
4.8
4.7
4.6
4.6
4.7
4465
4.7
5.0
Including the
basic sections 5.5
5.4
5.3
5.2
5.1
5.1
5.0
5.0
5.6
Auxzliary emotion* 4.5
4.4
4.5
4.3
4.7
446
444
4?6
466
The most qualified personnel aro implcored in the electrolytic,
electrothermal and power sections.
The average wage eatsgory In the electrolytic sections fluctuated
between 5.5 and 5.7, utille? among workars in basic production
in the almetrelytie section 5.2?5.5 and among markers in basic pro-
duction 546.4 ~peel:v*174k
In the elladne sections cni in the otleinstica sections the
average wage eatery:* fluctuated between 4.5 Mt 44 and along workers
in basic production from 5 to 5.4. Tb. Mount aVilealfe visie category
was reached in the electrolytic sections of the Begoelavskoys Abaft=
Plant (5.85).
The number of skilled waters coning to the aluminum plants from
factor7 schools and technical salmis eas 945% of the total amber
of
Up to 3.947 a very wean number of iforkers free those ibo had
finished the fluttery sebools remained in omploymect at the aluminum
plants. Xoung workers Who heti finished the factory schools and
teshaioal
schools were employed primarikv la the basic sections,
alumina and clectrolytie, and in the substations, repair Ng found.
ing shops.
The turnover of workers in the aluaimm industry efts high,
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
ii
The in moons for the turnover were the difficult working
conditions in the electrolytic electrode and calcination shope
(poor vonbilation, high gas arel Itest content ethei air), unsatis-
factory-veep of a large nunbnr o manations in the Northern Ural
Bauxite Mines by comparison with workers in other enterprises in
the ease district, 'hose pay wam based on higher magi mottles, and
poor housing conditions.
The lack of housing oaused an increase in worker turnover at
all aluminum enterprisee.
In order to keep workers in the aluminum industry a decree of
the government in 1948 on:tended the regulations on wages for workers
in the Ter north to workers in the Northern Ural Bauxite Mines.
) By a decree of the Council of Ministers of the USSR ?On inoreas-
ing ears and constructing housing for workers and engineering and
technical personnel at plants and construction sites in the Urals,
Siberia and the ler Best* there was a 20% increase inwages for
workers and engineering and technical personnel in the leading
brandhes of industry in theme regions as of September 1, 1946,
After 1948 there ems oonsiderable housing construction by
the Northern Ural Bauxite Mines and other enterprises of the alumif
nom industry as well as construction of individual homes on favor-
able terms by workers and employees.
A decree of the government regarding worker:4 managerial,* and
engineering and technical personnel at enterprises in the nonferrous
metals industry established advantages and concessions for temporary
disability and pension insuranoet the award of orders and medals,
and yearly oompensation for years of service.
Those dowses and a nueber of other governmental measures
aimed at improving the "ages and living conditions of workers in
the aluminum industry as well as the work done on meohanising the
promising requiring the most labor and on inproving working oondif
tions played a decisive role in redwing the labor fore. turnover
in the industry as a whole and at individual enterprises.
During the fifth fivoller plan labor turnover was reduced
considerably at the majority of aluminum plants . Y instance,
at the Ural, Aluminum Plant the turnover vas 15.1% in 1955 as oat-
pared with 20.7% in 1950.
36
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
( et
-
Further expansion abet:wing construotion, improvement in the
living conditiotB or maeros set an improved vege itryetet4 to give
the workers greater partioipstion in tbe results of their labor
have been the basis for keeping workers at their Ogees of employ.
sent,
6.
I. ?
? I ?
Of great ipportarce lathe increase in labor produstivity
is well arranged work in establishing production standards.
Production standards must be the basis forth* correct organisa-
tion of labor and production. In order to establish standards with
a technological basis an analytical method must be adopted.
In this system technologioally based standards are oomputed
on the basis of a detailed analysis of the technical prowess and
the astern, the organisation of labor and the working site, a
detailed verification of all production ;visibilities and en ail.
Around consideration oft** advanced work practises of innovators.
Standards based on practice and statistics do not take into
consideration the sehiovements of the moat progressive workers,
conceal ahorteomings tit* organisation of labor and production,
do not mobilise workers and engineering and teehnical personnel
towards evereasing theme shortcomings and for the eampalo to fol..
fill the *tate plan and leed instead to an unfounded ovardisburao.
mint of wage funds.
Unfortunately standards based on ;viatica and itatistics are
still in effect at establishments in the aluminum industry (Table 16).
TAMS 16
Ammus OF =RENT PRODUCTION STANDARDS IN EFFECT IN
TEE ALUMS INDUSTRI? IN %
Name of Plant Method for establish. 1940 1941 1946 2950
ing current standards
2955
1956
Ural Alusdnum
Technologically based
I=
10.5
39.7
67
56.5
65.6
Mat
Practicalfstatistioal
98.8
89.5
60.3
33
0,5
3444
Stalin Alumi-
Technologically based
39
55.3
58.5
Plant
Practioal*statistioal
61
44.7
41.5
na*
37
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The data citad indicato that the paroontage of standards
establish,/ on the basis of a tochnical analysis end by photo-
chronometric *thou has boon increasing at aluminum plants.
However the percentage of practicali.statiatioal standards is still
Ugh.
Practical statistical standards are used primargY?inrepair
operations lathe basic and auxiliary divisions. They do great
harm to production, loading to overdisbureement of the wags fund
and do not stimulate labor productivit7 as they should. The dyne,
mice of the meeting of standards during the period 19504956 shoes
that the greatest overfulfillment of standards ses to be found
among auxiliary workers working wider practicalpistatistical standards.
This is evident from the following detas the overfUlfillment of
production standards in all aluminum plants vas 135% in 1950 with
workors in the produotion divisions having 125.4% and workers in
tha auxiliary divisions 150.9%.
The *Imago &grim to ehich standards 'era net at the Northern
Ural Bauxite Mims is indicated in the following fashion,%1
1949 2950
Throughout the nines; 137 130.6
in production divisions 128.5 220
in auxiliary divisions 146 143
At the Ural Aluminum Plant the average satisfaction of standards
in the main divisions (in %) was 106.4 in 1956 ehila it was 1646
in the auxiliary divisional at the Tolkhovskoye Aluminum Plant it
was 234.7 in 2955 and 129.6 in 1956 for workers in the basic divisions
while in the auxiliary divisions it was 154.5 and 1641 respectively;
at the Dneprarlk Aluminum Plant in 1956 it was 123.1 for workers in
the basic divisions and 161.6 for workers in auxiliary divisions.
Repair operations are characterised by a great divlSruity and
plurality of standards. Practice employed in establishing standards
for repair operations in the alumina and olactrolytio motions has
a great number of defects. In the alumina sections that% are col.
lections of standards Ar separate repair operation.. These standards
were drawn up many years ago and have not been verified by photochro-
nometric obeervationee Time standards amompass a great number of
operations in repairing different parts of the apparatus without
indications for the exact volume of work involved (then, is no
schedule of all operations involved in repairing a given pert).
The shame* of ?pond/anal standards for repair work has lad to an
imarreet detersimetim of the necessary expenditures of tine and
as a consequema there has been a high peroomtess of ewerfulfillment
of produstioa standards.
a
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
1
The eatabliaseWt of standards for repair operations in both
the '14 A37 aMtziix7 dio foneeti the setiefeation of
standards in aci.owdzialz with cztualrivr,44:01-tm,e3 of t41,..4_0 which ma
not stimulated an increase in labor productivity*
Despite an almost yearly revision of standards, the degree to
which they have been met in the auxiliary division has oontinued
rather highs on the ceder of 130.160%.
All thee* data indicate the laxity of standards now in *that*
The rate of Uwe's* in labor productivity hes to a great
extent been weakened by too low produstion standards for operations
it the auxiliary occupations. For this reason, the =maw of auxillaty
waiters has been too high and this has led to a reduction in labor
produetivity th. ctt the raant as a whole.
A really efficient use of work time serves as a vest potential
for inereasing labor productivity. The degree of efficient utiliser
Jim of wick time is one of the basis indications of the degree of
officiously of ourremt production arganisatiiss -;shieh has. direst
*Meet on the level of labor produstivity. n practice* hammer,
problems in the efficient utilisation of work time and in setting
mare out of the work der have frequently not been given sufficient
attention.
An analysis nide of the nee of nark tine during a portion of
the year and the work day at different plants in the aluminum Indus..
try revealed the aeourrenes of great loses* in writ time.
As shown by data for a number of yearep approximately 71.77%
of the total number of working how* in the calendar year ware
utilised at plants in the alasainun industry. During the war there
was a grottier use of the tottp,1 amount of calendar work tine through
reductions in leave tine and throw* operating with no free days a
seek. During the postwar period the amount of calendar work time
utilised was reduced* During all the war years MOM of the
postwar years there was a groat percentage of the work tine not
used through illitat WW1 gado up 440% of the total amount of
work tins available.
As a result of strengthening labor discipline end improving
the organisation of labor* absences from work have decreased in
number frog year to year. For instant*, at tt-1 Stalin plant ab..
seams made up NO of the tete &meant of oaleniar work tine IA
1946 but only MO in the period 194949500 At the Ural plant
it was 0?06X,
39
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
During tho blab. nlevevr gen the ammgo nu-Abor of deora
worked per year per worker inereesed oonsiderably. In 1955 at the
Northern Ural Bauxite Nines eadh worker evereged 74% of the total
'MN, at the "folkhovskorp Aluaimos Plaat 754E4 at tho Da;ipr Al=mum
Plant 74% and at the Tikhvin Abaniza Plant 76%. The Immo* in the
number of days welted 'es influenood by the reduotton in less of
work time through inmost and voluntary abserces4
Possibilities for increasing labor produotivity through the
more thorough utilisation of work time during the year inslude a
reduetion in illness among workers by improving working conditions,
by reduoing approved absences ani by complete elimination of unauthor-
ised *booms.
As a result of elislauting these losses the utilisation of
the working time during the year eau be increased.
labor productivity during earl work shift depends not only es
the use of time in carrying out individual operations as determined
by the technology of modesties and the skill of the worker but es
the use of the shift's work ttse as a ehole, i.e. length of idle
time within the shift. Depending on this a greater or lesser *Saber
of operations can be carried out during a shift.
The analysis made of the use of work time over a period of years
at the Ural Aleminum Plant shooed that looses of time within each
work shift WAS 13.7.25.9% of the time worked.
In the auxiliary divisions the degree of work time utilisation
was loser than in. the bad* divisions.
The failure to utilise the work day fully in the basic divisions
is largely due to idle time depending on the workers and on idle time
of an organisation nature caused by interruptions in the delivery
of bauxite obi caustic (1942, 1945 in the &taint sectione), coal tar
pitch and coke (1944, 1.946 in the electrode section), charcoal (1944.
1945 in the eleetrothermal sections), interruptions in the power
supply (electricity supply in the electrolytic oortions and steam
supply in the alumina sections)*
Idie time of a technical nature are in the majority of oases
connected with breakdowns or accidents with equipment.
Observations made of teams of anode operators showed that un.
satisfactory utilisation of work time was due to lack of transportation
equipment in crews engaged in manually pulling out pins and in manually
raising the pins.
- 40
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
1
In crews engaged in shifting oontasts there vin ineffietest
uao or w=k213,13 time beeauee or the leek of standardlzatien in metal
sms?
In crews engaged it raising the anode frames there were as
instances of idle time (approximately 17% of working time) caused
by editing for hoisting mechanisms and frames.
The lack of solid production standards for 'operate operations
caused insufficiently intense work under the indireet piecework
wage system.
Photographs Of the working time of leading !porkers showed a
high percentage of the working day utilised with exceptionally
productive labor. Leading workers revealed the causes of enormous
losses of time during the vox* day., led a persistent campaign to
eliminate then and achieved considerable results in improving the
use of working time.
Active working time among metal tappers reached 94%, along
autoclave operators 94-98.94, and among decomposer operators 11%,
while the remaining time vas spent in auxiliary and opening and
closing operations. Among workers in the grinding section and the
evaporation /action there was also a, highly efficient use of the
work day.
inee ?AkUm4...mAxma 4x
M M7Wg MMWA, Viami 4404. ANX ww4mAix. modwiw a.air wwwjew wwwwwwww mom
extraction cverations at the Northern Ural Bauxite Nines aimed
that work time losses for reasons of organisation ar technology
rushed 22.64 (leek of oars, timbering, electric power, compressed
airs, faulty operation of machinery, waiting for blasters, lateness
on the job and leaving early).
The elimination of losses in working time for reasons of organi-
sation or technology among stops brigades in extraction operations
weld make it possible to increase the number of cycles during a
24-hour period.
An analysis of the use of work time at the Northern Ural Bauxite
Mines shoved that idle time and losses of work time for organisational
or technical reasons among stopo vorkers of leading brigades in
extraction operations (Lyuts brigade) were 13.74 as compared with
22.6% for the mines as a whole.
In the auxiliary divisions inefficient use of time results
from idle time depending on the workers themselves and idle time for
4b1 41 4.
1522*
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
11
causes of an organisational nature. Idlo time depending on the
workers result fron a lack of tight enough produation standards
in these divisions which reduoes the efficient use of the work
day as yell as from insufficient control over production and in-
sufficient instruetion from the foremen during the shift. Idle
time of an orgenisational nature in the auxiliary shops results
from insufficient precision in the organisation of the work such
ass failure to supply spare parts and tools, transportation equip.
sent, leek of preparation of materials, parts, late delivery of
drawings to the site of operations (in the machine repair shops),
defects in operation planning and in production preparation.
At the Ural plant the use of the work digy increased to 68%
but at the same time idle ties due to the workees themselves
remained high at 7.2%.
At the Stalin plant time losses through the factory were 18.7%
including those due to the workers 11.3%, those of an organisational
nature 1.3%, and those of a technical nature 63%.
At the Bogoslovskoye plant time losses throughout the factory
ran to 12.34%.
The increase in the efficient use of work tine at plants
during the postwar years was helped by improved prodnotion organisa-
tion, mechanisation and the combination of separate occupations.
Filling up the working day in basic and auxiliary divisions
is one of the really important objectives tithe alaninum industry
for the purpose of increasing labor productivity still further.
Maximum efficiency in the utilisation of the work day Inv tz
assured by improving production and iabor organisation in separate
sectors through the introduction of upwtou.date work, methods, by
the mechonisation of difficult processes, by providing the necessary
amount of transportation machinery, by preliminary preparation for
production processes, by *operating auxiliary and subsidiary opera-
tions from basin peocesoes, by improving the system for supplying
material and equipment, by combing occupations and the operating
of several units, by greater instruction, and through the establish
cent of just production standards.
An analysis of the use of work time and the status of technical
standards at enterprises in the aluminum industry has shown that the
introduction of technically based standards which take into account
the aohievements of leading workers makes it possible to utilise '
great potentials for further increasing labor productivity.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
???
The current introduction of new equipment in the aluminum
industry and task' in a fuller mastery of the latest equipment
make increased demands oath* skill of workers.*
Mastery of the latest equipment, and raising -the tschetoal,
political and cultural level of workers open greet poseibilities
for developing their diverse capaeitise and ereatireg a new type
of worker distinat from the laborer under capitalism* Engels
pointed out that under soelallan wthe matiagement of productiom
by the forgoes of satiety itself and the resultant new expansion
of produstion will call for oompletely :new people and will
create them.' Diotes 1.11,rx end P. Engels, rialigittLInekits
vol?5, ;44/11, 1929 editi0
The Communist Party and the et-ate have given= exceptional
*mount of attention to the prdbIem- nf raising the general and
occupatioaal level of the Soviet worker*
Alomg with the system of state labor reserves which provides
a constant large..scale supply-of skilled pommel for socialist
production, the training and provision of advanced training for
workers in being carried out syetematioally through various forms
of instruction on the job*
At plants in the aluminum industry mew personnel is instructed
through courses and by assigning individual apprentice, to highlro
skilled workers and by retraining working personnel through a
oimboot of technical instruction, through schools giving instruoi.
tion in the latest workmetheds, by training in a second ?coupe.
tion, by oeurses in a specific subject, and by advance training
for engineering and technioal personnel*
The number of workers encompassed by all typesOot-produotion
and teohnleal instruction is constantly izereasing* -
Iiieonnection with the introduction of the latest equipment,
the improvement of produetion methods, and meehanisation and
automatisation in production processes -during the postwar years,
greater ettontion, has been given to problems in production and
technical instructiori for workers in the elusions industry* The
amebae of workers oovered by the various type* of instruct ion is
eonsiderible* reaching 3050% of the total =Aber of workersat
some enterprises*
1.3
1
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
ii
*
Training in a second occupation has bosoms widespread* Instrue..
tton isL7elatad eccucations alms at comblning bath basic smd mr/I4n-7
occupation. iii the sane person* For instance, the following basic
occupations in the alumina shopa are compatibles classifier and
miller, charge firer and operator of lime furnaces. Combinations
of basis and auxiliary oecupations takes place intim following
pairs* technician and mechanist +evaporator and pump operators,
foundrywen in the foundry 'hop of electrolytic seetions haw the
rigid to ?pirate overhead eonvoyorei tfthnicianil in the elumine
mutation have the right to operate windhes, eta*
In electrolytic sections schools dealing with up..toNdate work
methods Imre organised in *lodes with poor productivity indexes
(failure to fulfill the plan on the basis of current unit, power
unit, low-grade metal produation)*
The schools were directed hy highly skilled brigade leaders
and crew chiefs who demonstrated the most efficient methods right
on the spot*
Theme schools also had *annuitants free among the engineering
and twiftieal personnel* Along with the school direeter the oonsul*
tent observed the work of those receiving instruction, and pointed
out shortcomings in their work*
The restate of instruction in these modern-methods schools
an be Amen by comparing work factors before and following
imstrustion* The **bole ewes to exchange information between
the best brigades and to introduce the best work methods*
Instruction fathoms schools have given exceptionally good
results* In Table 27 we have data showing the results of instruc-
tion in a brigade of workers in Building 4. at the Ural Aluminum
Plant*
TABLE 27
VORK INDEXES FOR A BRIGADE AT THE IiiiitALUMUM PLANT
WHICH TOOK =MOTION AT TREMODERIWEETHODS SCHOU
Percentage Per current Output Grade of
of plan unit, % supra, aluid.ma in %
rairmarnt gramAnt/hr, Grade AO Grade Al
Before instruction 78.4
After instruction 100.3
72 54?5 4.9 57.7
82.3 5717 82
44
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
p.
S.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
Comrade Boyovolinla brigade (Bldg. )Io.1) met produstion stand-
ards by 115-118% following instruction in the school 'withoutput
per unit of currant 86.0 and output ot blew- grades or metal. to
99.6%.
At tha Voikhovakoye Aluminum Plant production loaders; ilectro-
lytic worker' Morey and Mogutow, after succoasfully finishing
the school for foremen gave instructions in their work methods to
a group of olectrolytio workers.
Ae a result of instruetion, the brigades of Colorado* Tinashev;
Karlin and Volkov markedly increased output based on current and
snore. Zlootrnlytio brigodo leadereilooenkow and PakhlisteklY
taught their weak methods to heretofore lagging brigades of Calvados
Morookov and Xegorov. Yellowing completion of the school the latter
increased production per eurrent unit from 69.2 to 9005% and output
per- snow unit trot 59.44 to 60.24 grals/kilowattibmw?
There has been groat expansion of schools for the colleotive
experionco of leading workers mod innovators.
In theme aohools a study is mad* of the oxporienoo of individual
leading vorkere. Loaders and innovators of the ostablishment* get
acquainted with now achievements in min** and technology and with
progreesive practices in the field of alumina production and. eleetro-
lysis,
Dp-tesdate work methods are also studied in interfactory schools.
Tor inatamoe; in 1956 at the Urea Aluminua Plant to interfactory
schools were conducted for the Thal a. Dogoelovakoye Aluminum' Plante
on the repair of oloctrolytic cells and for steel foundrynen of
plants in the city of lamenak-Craltiklys
Schools for loading workers and Innovators assist workers in
acquiring production Skills and in mastaring highly efficient ldhor
methods *Lich &sours an increase in the production of high,
goods.
In *courses for appoints purposes, studies are made of separate
types of operations and separate seaters of production.
The topic nake-up of acorns for specific purposoe is nest
divers*, for Instant:No; servicing and operating sZollyw filters; for
Derr apparatus operators and filter operators in the alumina section.
- 0 -
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
With the orreat nuAbar of =kers at forminuid plata eneaged
in study through the technical minimum courses, echools Rev leading
lockers and the study of a second occupation, insufficient ettention
UI given to problems in providing advanced training far engineering
and technical personnel.
The aluminum industry is faced with a greet objective, that of
dimming the theoretical knowledge of engineering and technical
personnel eh* have spent a long time in industry but have not finished
technical echools and of further increasing the extent of on the job
training.
2011111.1101911.10MIN
Along with the potentials already discussed for increasing
labor productivity in the aluminum industry there it the importanos
of a correct organisation of wages.
Up to 1940 there was a marked inequality in pay for workers
in the nonferrous metal industry.
The existence of a great number of soales led to an equalizing
of the pay far skilled and unekilled labor.
The poor organisation of labor and wages bad a particular effect
on the unsatisfactory operation of the mining industry.
With the aim of meeting the labor productivity plan the People's
Commissariat for the Nonferrous Metal Industry in 1940 nada a ravirg
of production standards and the wage gyetem4 lege scales mere re-
vieved for workers in all branches of the nonferrous metal induatry.
Az. adjustment of the wage system at this time amounted to tightening
up on wages of workers in the basic nonferrous *total productions
and in separating workers in the leading occupations as well as
workers in underground, heavy and mining operations.
It 'would be pointed out that the wage reform of 1940 did not
eliminate as shortcomings in the wage system, There remained a
great nuaber of scales differing in their scope.
During the Patriotic War in a number of branches of industry
and in the coal industry and the nonferrous metal industry In parti-
cular, there was a sharp increase in 'ages. Although wages for
workers in the nonferrous metal industry increased over the prover
level, it was not as much as in other branches of industry.
46
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release
?
50-Yr 2014/03/21: CIA-RDP81-01043R004000180001-3
ro.4,Libie7.2..b3g -theipt of tito =farm= 61:46,1 ineirait,w
in the national eaonowr and la the Illations1 defames, by the deems
of July 6, 1944 aimed at *waging the material statue of workers
in the nonferrous indurtly and in adjusting the mew system, the
governmgat greatly Increased the wages of workers and engineering
and technical personnel.
In carrying out the decree of the government* considerable
work
was done Ira 1944 in the nonferrous metal iniustry in adjusting
the wage symteig.
For mining enterprises a uniform 10?eategory pay seals was
established aid for the metallurgical and metalworking indwitries
an eacategery scale.
Within the limit* of the wage system for.saining and metallurgi-
cal enterprises daily wage scales were established which provided
for a differing** in wages for workers in the key jobs, other piece
workers ani employees on tine basis* 4.11 the enterprises lore
siabdivided on the tosses of pay- wises mining were divided into two
awl metallurgical. into three groups. Within ene pay scale six rates
were established for mining enterprises and nine different rates
for "metallurgical enterprisees
further increase In Magi* was carried out in 1946. This
rear the wages 'ere mimed twice. The first raise was put through
in wardens* with a &ore, of the Council of Ministers of the IISSR
for workers employed in aiming and heavy jobs in metallurgioal and
mining divisions ae well as in loading and unloading operations at
enterprises in the Urals, Siberia and the Tar east. Weiss far these
workers were inereased 20%. A second raise use put through in
wardene* with a governmental decree on a bread miplement for low.s
pay markers and employees. Theme supplements were included in the
fixed portion of the wages and introdueel into pieeekirork pay rates
with the result that the maw of pay males ourrent at gatterprises
inereaseddrom one to three (where the 20% lacrosse did not apply)
aid to six (where the *0% Increase did apply). The total :number
of p.vsualits for all three groups of enterprises resehei 18.
In addition to the formation of a amber of pay wise which
ocmplieated the ocaputation of wages at enteerrises, these changes
lad to a disruption of the established permute:ft uniform ratios
between wage coefficients. The inclusion of supplements of rations
in the wage *tale led to raising the wage **efficiently of the lower
eategoriee and to bringing the first ani highest categories closer
together.
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2014/03/21: CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
177M?:::*
P t
Comsat pay esalee, in order to ellainate equalisations in
the wages at workers of different -dive's of skill and la eater to
stimulate corkers to enquiring greater skill* met guareatee a
more preoccupied increase in pey ehen saving from the lacer eater:is.,
is)* to the higher ones. The latter eau be anhieved extemilag
thi degree of inorease In ply in the higher eategories. Date skew-
ing the Inereese in Iltypos in the pay scales In effeat are 131ustratod
in Table 18.
&sales then in effect did not nest the requirements for a
occreet organisation of wages mined at imeramit labor productivity tgy
giving *soh worker a monetary advantage In laireasing his skin.
Far imstausse, in the male with a 204 supplement the differenee
between eategories Thr kay plow corkers in oategeries 2 to 4 is
33-16% and la category 8 it is 8.7%. Ia the male for other plan
mockers the breaks betceen oategaries in passim drops from category
4 to 5 froa 16.2 to 14.7% and trot category 7 to from 16 to 9.1%.
TABLE 3.8
DIFIMMTIAL BM= ADJACENT CATEGORIES
(31 % OF THE FRECEDING CATEGORY)
Category
II ru XV V VI 'III VIII
Far workers receiving 20% eupplaseist
Icy pleat corkers
15.0
16.5
15.0
17.0
15.5
8.7
3.9.9
Other pima starkers
31.0
16.2
16.2
1447
16.2
16.0
9.1
Time
23.0
12.4
15.0
15.9
144,3
17.1
15.9
corkers
For workers not reoeiving the 20% supplement
Key piece workers 11.0 16.2 16.2 13.4 36.5 36.0 8.7
Other pies* workers 13.0 12.5 19.0 12.5 13.5 17.0 16.6
Time workers 12.0 143 U.S 14.7 15.3 34.9 17.3.
In the *WA for wars ca a time basis we find shines in
the differentials between eater:ries of a sporadic nature (drop in
*drawing to III from 17.3. to 15?9%). An analogous pint** is
observed in scales for workers chi do not reneive the 20% suPPlismento
:Another shorteasing of the pay *sales vas the feet that they
did not auras a oceateat ratio in the pay of plane scrims lad
workers kr the haw.
Thus the lacrimen in the pay males lea! to a ~tails leveling
in pay conditions latish was the names of a peculiar apalising of
wages*
48
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
I.
Declassified in Part - Sanitized Cop Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The tee?eategory soles in effeet at mining catermief...e of
the Industry as wal so the eight..onteejogy Deolez of riatal
Ionise. plants did not provide fee a oonetamtly inereasing difference
in pay between oategoriz,i. from the lowest to the highest.
Pay males 14 afoot mince 1946 lagged greatly behind the Imo
level achieved )sy workers shish led to the use of lower, untemoded
produetion standards and hindered the imams* in labor prednetivitr.
Pa based el the mule amounted to 5C?40X of the total Ing?el of workers.
In aceordanae with this dimes or the Central Committee Otitis
CPSU and the Council etanisters of the USSR of Auge,f36 10 190
ocmeersing the intreduetion of ? Shorter working dayAsts pay
rotes for verkers, employees and aeglmeering end Ae4he?,, pereommel
in the menfOrrems metal industry between Avast 3.90'.qit., Deptember
1519* there has bee* a gradual 'hitt in emterprices oftlim aluminum
industry to * uniform meven.oategmry pay scale effective both in
aiming amd metallurgieal emterprieesi At the mama time new mere
secure*o pp male manuals are being introduced* reflecting ebonies
in the oeaupational ocmposition of the labor force caused by' the
development of maim's* and technology and anticipating am. rate
for all categories.
In earlier seales there was no *semen** of filling the lower
eategories? Pay scales were different depending en the funetions
porforinel (far workers employed In underground alining. for production
workers In coserldt operations, for workers in shop sections and
divisions with hot, harmful and diffidult working eonditiens in
metallargioal and ethisioairitallavy prooesses, ore oomeentration
and agglomeration* in, the produstion of carbon and graphite electrodes*
for workers in other divisions in these types of graduation* for workers
in auxilliwydivisioaa and auxiliary sectors *fibs basic divisions.
etc.)
In this case workers sepaoyed in the basic production promises
were sub4eat to no difference between the rates of gime and boor
workers (as had previously been the case with mr rates); different
pay rates are introdueel for workers in auxiliary divisions and
auxiliary sectors of the maim divisices; plume "whets in hot,
heavy and harmful Jobs, piece workers working in thecold and per
dime workers in hot* heavy and harmful Jobs and for per diem eorkers
in cold operetione*
The sew pay seals anticipates a uniform diffaronoo in pay from
the lowest categories to the highest mhieh is an affective stimulus
to increasing the skill ?towbars.
- 49
nprlaccifiPri in Part - Sanitized Copv Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3 ?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Another Important lever in organ124tion or we la the
gysteas whioh regulate the amount pia out depending ow quantitative
and qualitative work festers.
Intl* aluminum induatry the following we, Aystems have been
used* pion work, 2) progressive work, )1 mwmorkoboaus gates,
4) per diem, 3) per diewbonus.
In basic divisions the pieftwork system is the principal form
of pay. As of Jarasat7 1, 1515 this wystesapplied to 72.2% of the
workers through the entire alorUmmtindusMrywith 76.0% at the
Ural plant, 66.7% at the Stalin plant, /3.0% at Sogoalovakoye,
7246% at Vo3.kbov and 754% at the Dneprovik plant.
The proportion of pieeeworkers has declined somewhat lament
years. For example at the Stalin Aluminua Plant plesework vas done
by 65.4% of the workers in 1933 and 37.0% ill 1956.
The rather high proportion of per diem workers omn be explained
birth* prepense of a large number of workers in servioes performed
by.rotation who are paid an a time basis.
Under the direst prieeework wage system are auxiliary workers
in thebasio divisions and workers in auxiliary divisions. la
the elostrolytic shops those paid by pieclowork are siphon operators,
pourers, decanters, chlorinator opsrators, i.e. basic but not key
ootrupatiohs.
Approximately 23..30% of the workers in aluminum plants are
paid on a time basis. Tins-based pay is more widespread in the
auxiliary divisions where it 4040UAS for 40050% of the total.
lathe basic divisions the tinso.based often of wages accounts
$.13% ?tithe total. Time payment is used for workers in
tecihnioal oontrol aid for workers emgaged primarily in services
performed an a rotating basis where it Is not possible to ergotism
an accounting !system for the labor employed and to establish produo.
tion standards*
In the oleetrolytio shops of aluminum plants workers operating
the travelling *ranee and the anode system, i.e.- depending on the
amount of metal turned out by the building it.
The progressive piecework pay 'Wimp used in decisive areas
of production in basic divisions, has stimulated the increase in
labor productivity* The oomputing of progressive rates starts
with the first peroentage of overage of the standard up to the
highest rate obtained.
.Attr
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
1"..aaa Pivr?nown?ril:
scalas of progremsive rates.
At aluminum enterprises a nuaber of bonus provisions are in
operetta*.
As a result of a largo number of factors conserning the grant-
ing of bona.* the per of electrolytic operators has been composed
of numerous stratifications asking wage moots nor* ecoplieated
ant not readily understood ley the workers.
For tartan** the wages of workers in the elsetrolytic divi?
sions of the Ural plant has been compoeed of the following elements:
base ploy seal*
progressive additions for **seeding standards
bonuses (.30A of base per) for exoeeding production standards
bonuses for laigber grade motel
brews for winching the planned output of octal
bemuse for savings in electric pow.
In the abed= notices seekers have been wanted bonuses for
aeonemising on steam Awl for returning the condensate to the heat?
power electric' statics*
The treating of bootees to workers paid on a tine basis vas
dole at amino" plants =Abe basis of 19 prineiples. Characteristic
w?Z VW-sift Or- WOW* -tiO 'W W * time boas Is CA fast
that balms intones ooincide with the direct -obligations of a worker
In his prineipal Job and have the 3cature of a guaranteed supplement
to his 'sieges.
A large part of incarnations on the awarding of bonuses aro
quite ineffeetive from the point of view of improving the quality
of work aM tweeting labor productivity since these instructions
on bonuses ant their application directly and cometimee irdirectir
do not depend on those granted the bonuses.
For Inatome, current bonus regulations in a number of cases
have served only as a means for a mechanical Lwowe in es,ges
and have been converted Into * brake on the further growth of
labor productivity. An adjustment of the bonla crates Is an urgent
necessity.
tc. aft ta.ezviilf."024wrzt
In the *login= industry wages have Increased constantly*
All. ohmage* In the isbganisatiem of wits during the Great
Patriotio War aid during the fourth fiv?year plan in the aluminum
51 di
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
-Afe:TP
'1174AEV
,
'industry wero directed at improiring the monetary participation of
workers in the results of their labor.
The average yearly pay of workers in the aluminum industry had
increased by 1950 to 271% of the 1941 level.
During the fifth five?year plan than. was a farther increase
lath* worn* rieriti m.o. For instance, at the Ural Linda=
Plant the average yearly wages inereased by 124% from 1950 to
1955, hi 34% at the Stalin Plant, by 12.4 at ircakbov, by 1605%
at the Dneprovik plant end 12% at the Ianaker plant.
The high rate of ingrates in the average yearly wage. in the
aluminum Warta reflects the policy of the Party and the govern?
neat aimed at stimulating the devolopeent of this beano*.
In eome years in this branch there have been unfavorable
ratios between labor productivity and wage Inareases. Labor produc-
tivity has increased more slowly than the average wee*.
On the basis of inatructions from the Party and government
measure* were adopted to increase labor productivity and regulate
wages with the result that at the and of the fourth fivo?year plan
a favorable ratio between the increase in labor productivity and
the inarease in wawa had been establiahed. For instance, the
overage output per worker increased 10.2% in 1949 and the average
wage increased by 5.7% over 1948. In 1950 labor productivity
increased 7.9% and the average wage 1.8% over 1949.
In the fifth five?year plan the increase in labor productivity
outstripped the increase invites. During the fifth five-year plan
labor productivity increased 64.1% while wages lac:reamed 1% whioh
was one of the. factors making for a reduction in production *oats
in the aluminum industry.
At the Ural Aluminum Plant, starting with 1942, the rate of
growth in the average wage outstripped thereto of growth of labor
productivity which led to an inorease in the portion of the cost
of one ton of aluminum due to amps (Table 19).
At the Stalin Aluminum Plant, as at other plant., in 19450 1946
arid 1947 the increase in labor productivity, lagged behind the increase
in wages (Table 20). (See Table 19 end 20 on following page.)
-52-
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
TAKE 19
CHANGES 331 LABOR FRODUCTIVTIT AND AVERAGE WAGES AT THE URAL KART
Index
Average output
per worker inl
a 1940
% of prooed-,
ing year
Average wage
per worker in:
% of 1.940
% of px.eoeding
year
1940
1941
1942
1943
1944
1945
2946
3947
1948
1949
1950
3.00
1'T7.2
155.5
156,2
1790
1800
1574
187.4
201
206
226
100
177.2
87.7
100.2
1144
100.6
87.4
119.1
107.5
3.02.4
109.6
100
105.4
106.5
120.0
148.0
168.7
177.2
236.4'
100
105.4
101.1
312.6
124.7
115.4
102.7
122.1
108.0
10507
1014
TABLE 20
GRANGES IN LABOR PRODUCTIVITY AND AVERAGE WAGES AT THE STALIN PLANT
Index
1943
1944
1945
1946
1947
1948
1949
1950
Average output
per worker ins
% of 1943
100.0
340.0
171.7
161.0
133.0
145.8
164.0
388.8
% of preceding
year
100.0
140.0
122.2
93.9
76.4
118.5
112.4
112.1
Average wage
per workers in*
% of 1943
100.0
124.0
1530
355.0
3.89.3
220.0
218.8
220.3
% of ;regrading
year
100.0
124.0
123.5
101.3
112.3.
116.2
99.5
100.7
53
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
ECY
In 1946 and 1947 labor productivity decreased at almost all
aluminum plant. in connection with the reconstruction of eleotro-
lytie sections and the transition to the normal work day.
Only at the logoslovskaye Aluminum Plant was there a favorable
ratio beteeen the increase in labor produativity and maps. Libor
productivity (with the exception of 1947) increased at a more rapid
rate than average wage..
At individual aluminum enterprise, the rate in the increase in
wages surpassed the rate of increase in labor productivity whish
was the result of the failure to utilise all the numerous potential.
and the lupe of preotioalm,statiwtioal standards in auxiliary divieions,
a different type of supplementary pay and unprofitable males of
progressive and boons minas.
An analysis of the wage level in basin divisions over a number
of years has shown that among workers in the basis production did*.
sions the highest wages wore received by workers in electrolytic
sections.
Among basic production vorkers in tha basic divisions the addi-
tional pay was small by oomparison to the base pay (with the exception
of eleotrolytic workers), Among auxiliary workers in the basic
divisions and the renair sootiest additional pv 108 almost *qua to
base pay *Loh las the result of a leek of intensity in production
standards and a related high degree of overtime,
In the alumina plants repair personnel received higher sages
than workers in basic production which was the result of poor Judge..
sent in establishing standards for repair operations (lack of standards
based on operations, pay on the so-called no-oategory gysten and
bonuses of 30% of the base pay for meeting the equipment repair sohedule
and )reakdown-free oparatica of machinery =Its). The actual staffing
of repair basedes vas actually below at was planned *hi& also
contributed to increasing their individual earning..
As the result of a marked increase in the average earnings of
workers, the wage funds in the aluminum industry increased constantly
and surpassed the rate of growth in the number of employees caused
by the expansion of the volume of production.
The growth in 'age funds was accompanied by a change in their
structures there was an ingrown in the 'mount of progressive and
bonus poyments and payments for years of service, there was a de-
cree.e in the proportion of pnyments on a time basis at the expense
- 54, -
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2014/03/21: CIA-RDP81-01043R004000180001-3
9
a
7??-???-`? ?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
of Ankincrecse in the progressive piecework systen of pan ani
paxclat for oVertim van redueed greatly*
The struoture of the mega funds by different plant, in 1956
is illustrated in TabAc 21.
TABUS 21
RATIO a D1FFEREIT TOES OF WAGES IN THE TOTAL FUND AT ALUMINUM
PLANTS D 19%
Type of pemsent
Payment by babe pieoe rate for
straight pieoework
Payment by base rate for
IN OF THE TOTAL FUND
354 43.8 21,7
21.99 6.17 32.3
41.7
5.19
38.6
19.6
pie**
progressive piece.work
Supplementary poky for pieoe..
workers on progressive rates
4.6
1.5
703
1.5
2.3
Payment on time basis accor&
ing to base per rates
19,3
29.1
14.57
10.3
11.4
Bonuses to pleoeworkers
1.2
4485
0.6
7.6
6.2
Banussa te walkers on time basis
1.4
5.5
3.2
2.7
6.6
Overtime pay
0.01
0.02
0.03
0,01
0.05
Other supplements making up the
daily wage fund
5.4
4.26
4.0
14.6
1+4
Other supplements making up the
monthly me fund
6.6
7.3
7.3
11.1
7.5
Conloensation tar length of
iervioe
4.2
7.5
9.1
5.4
6.35
Total wage fund
100
106----
100
100
100
55
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part- Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The organisation ewes in ti* ;tan 4,.?at
possibilities for inetessing its role In stimulating grovIA in
;Law thio..?rtaires rtAteitv_Uks* pay rates and a
radial r,avision oZthe tv...aae.p tab' ect in =dor. to alizitite the
equalising tandemoies In their structure as sell as to eliminate
the multiplicity of rate tables 4! =eating a =item bees rate
system for U. entire aluminum imiturte7 ami it require. a uniform
bonus *yet= for markers in say tea (*Pupation working under an".
logo= conditions at different enterprises;
estamtsjainz standards and rates CO the basis of a teobsologieal
evaluation in 110001",41100 idth the rising level of teobsologr 11111i
**Movements of leaing ineters and innovatorwl
4improving the standards system for auxiliary operations is basic
and auxiliary divisions in order to include sore worhers in the
ptomain& ogrstion and eliminate overpayment remelting from insufficiently
demanding standards of produation loading to a levelling of pay between
workers in hey occupations sal auxiliary workers)
demeloping a bonus system for waiters on a tine basis based on a
oonsideratioa of the quality of work and peculiarities of specific
individual occupations*
A revision of the wage system will make it possible to employ*
it sore efactively to further * growth in labor nrodustivity
the aluminum industry.
Raising the base pay rates will make it possible to make the
base pay the greater part of earnings and evade favorable comdid?
tions for an extensive introduetion of teohnioally based produstion
memes_t the elinthation of a fietitious pieoework system and the
eradication of eccoonically =justified inseetiwe systems.,
9. listalallatassuntitiaLasUltog
Socialist competition is a poverful soiree for increasing labor
productivity.
The greet fora* of free creative labor in a socialist society
is clearly opgrossed in the diverse forms of socialist competition
and to the mass movement of leading workers and innovatabs?
Mass socialist ocapetitioat the development ot popular initia*
tive and independent activity are a *leer expression of vital Soviet
patriotism', the sour** of the historic yucce's*s of the Sovirt people.
The maireatat of lending worker% ani innovators expresses a new
and higher stage in socialist competition connected vith the adoption
56
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
???????G
of um equipment in all branches of the national 110611W and the
Appowince of mac people mho have arc-gots/7 mastered the =mat-
oatod equit.ment.
The Comunist Party end the Soviet government have boon giving
groat attention to developing soolalist eospetition ani require
from economic. Party aal trade-seal* alginates the elimination of
ehortoomings in the development of =motive initiative and prodeo.4
Um* eetivity among the manses of ecrkerse The administration of
socialist ocepetition must not admit a routine1 formalletie Sr
bureaucratie approech to new progressive manifestations of
time on the pert of the eorkers?
Groupe in all enterprises of the aluminum industry are partici.*
pitting in sosialist emepetitiom *laid At meeting and emseeding pro-
duction plans, at inoreasing labor productivity* produetion quality,
at redwing production coots sad improving other very important
teohnioal and economic fautars?
Along with individual ocepetition there has been widespread
adoption of easpitition between shifts, sooners, divisions and
entire plants* At the same time all establisbaosAs within the alumi-,
nom indeetry or, alma*akin' g part is tillrision Socialist Covatitione
Winners in oompetition botesen seaters and brigades are awarded
each *oath the challenge Red %were of the plant ar sine and the
retention of these banners for three mouths in a row seams clash
bonuses trcu the funds of the enterpries.
Winners in competition among workers in the sane oecupation
and groups of brigades, shifts and mootare for throe months in a
row are given the title *Best Worker in the Occupation*. *Best
Brigade*i "Best Shift*. *Best Soctor?N
Leading workers employ the following diverse type of work
methods:
division of labor in "(Edell it is possible to make maximum
aseigieent to each worker on the basis of his knowledge and train..
ing;
reduction of idle time and idling of machining and ineressing
the efficient use of equipment on the basis of a *caplet* study of
meehanisms, apparatus, technological prooesses ani mastering products.
tics techniques in their own sector;
improving technical promises, introduction of onrthe?spot
improvements or unocepliciated nature to facilitate operation;
- 57
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-;
_
eambinimg related jobs and _vender, a :terse F=ehlne4
tools and apparatus;
better organisation of thelexiLtig site;
Lv.i.,0-4-131. toeing getup aathcda rral parts =chilling (ohamge
in tha mhapaarthe matting tool, drill, eta,)
improvement in labcr organisation (efficient distribution of
the labor faros, organisation (Calmed brigades)/
oombining the mainteasnee of different prodestion sectors and
freeing umweeesary labor faros.;
assuriag haymow in operation of separate produstiom mite
an mestere;
imireduelmbearly mad shift?de, work sebedulee;
competition for entstamding production quality and a high level
of produsties;
creating aimed brigades of inventors and officious/ promoters.
An important feature of socialist competition durimg meant
years has boa the matiomalmovememt for making a better use of
intoreal production petunias., striot economy, general soviet of
materials an!the ?ratio* of aommulated steaks in emcees of the
plan; for getting theme:dams produstion from existing dignipmemt
and produetiaa WOW fir meeeleratiag the turaever ofworkieg
**pita; for introdusing the best work methods of leading mortars
and innovator' and the adoption of them* =Abode by all -workers;
for meeting the produstionaseigement of maiih shift.
The movement of leading workers and production innovators has
booms widespread in all establishments lathe a/mnima isdoetry.
The number of oompetime workers at elumieve wImmte end ba=ito
mines is isereasimg frail year to year. In order to *tire* a large
number Ow:eters lute sooialist oompetition maciallet aerologists
have beem drawn up *avow brigades, seaters, mimes, divisiome and
individual agreements between individual werkers, and produstion
confiremoes have been arranged between leading vorkers and immove..
tore at which leading methods are studied and analysed treatise
point of view of general application,
The *restive Initiative of mortars in produetion is constantly
giving birth to sewer methods of labor organisatiom,
As as example of progressive methods in drifting operatioms
we have the work of sized brigades engaged in high?speed drifting
operations,
58
4.
neclassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81:01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The speed of opening operations in mining are of partieular
importanas aod for this ]rant-L prabIttz In Igatz mnr,nnitinn of
drifting operations were given a great deal of attention during
the very first years of the exploitation of the deposits of the
Northern Ual Bauxite Nimes.
Up till. 1943 the rate of drift opening at the Northern Ural
Bauxite Nines did not *nosed 2040 linear meters per month. Start-
ing vith 1943 higbmipeed drifting vas organised and carried out
by. mixed brigades. Engineers and teebsicians of the Northern Ural
Bauxite Mines took an active part incoming out high-speed drift-.
ing operetions.
Tunneler* (drift vorkers) Minsaripov and Proniohkin were
ners of the Stalin Prise.
As we oan eels from the data cited below, during the very first
high-speed drifting operation organised in 1943 by Sibirorts
gado a rate was achieved exeeedieg 2.5 times the usual drifting
rate at the Northern Ural Semite Nine'.
The principal oonditiom *deb mud* this high.cspead peseiblo
vas simultaneous performanoe abuts drifting operations (drill-
tinbering, clearing out reek). The combination of operations
made poesible-three cycles in each 24 hours.
Although drifting speed increased 24 tlmoa over the usual
rate, it ;load have boon still higher* Drifting .= boing dome
vhile builders were putting the mina into operation so that there
were standstills in supplying oompressed air. In addition, webers
of the high-speed brigade wore still inexperienced in the operation*
Nevertheless the results obtained by Sibirovts brigade served
as a. turning point in the farther iwovement ofhigh..speed
drift-
ing. Other brigades began to follow Sabirovts exemple.
In 1944 Simegulints brigade composed of 15 men (5 men per *ma)
reached a drift rate of 90 linear meters. The rote vas increased
by compressing operations in the *yule*
In 1945 Soseyees brigade made one *tope 1624 linera motors
long. As distinct from previous drifting operations this vas
done in 4 shifts. Five men worked in each shift. One cycle of
drifting operations vas done in each Shift. Thus the another of
oyeles vas brought to four*
59
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Starting with December 1945 loading maohines were used in
hith,ierIM drift_ngi accalmmto tho removal of the E f 1.4-,)0.40
rocks.
In 1946 Minsaripov's brigade made a drift 172 *eters long. In
addition to using loading machines for rook removal there was the
new feature of using deeper blast holes than in previous operations.
In Table 22 ma have the technical and economics features of
high-speed drifting operations at the bauxite mines in 1943.4956.
The best results in high...speed drifting were achieved in sub..
**pent years. As we i.efrom the data cited in Table 22, the depth
of the bleat holes was again reduced in 1936 but high indexes ware
produced thanks to the use of more powerful explosives and a more
efficient placement of blast holes, to the constant improvement in
labor organisotion, the increased use of maohinery in the drifting
cycle, and the use of improved equipment. Another feature of high..
speed drifting operations in 19474956 was the adoption of multieyole
work. For example, 153 cycles 'ere married out in drifting in October
1947, 171 in Mareh 194$ and 231 ill Yebruary 1956. This increase ill
the number of cycles was achieved through a further vo.?p,o.poion of
drifting operations and their simultaneous performanse.
Further success in high...peed drifting operations was also
furthered by the use of eleetrio locomotive transportation which
replaeed the earlier manual operation.
As we see from the data in Table 22, the increase in speed vas
also accompanied by an increase in labor productivity and the prodno.
tiiitsiapasity of the, loading equipment. Labor productivity in drift-
ing quadrupled fran 1943 to 1936.
There was also a considerable increase in the productive capa-
city of the loading equipment. The proportion of mine opening opera.-
tions effected through highspeed methods at the Northern Ural Daum..
it* Minos increased constantly throughout the fifth five-year plan
which mode possible increased speed in tunneling throughout the mines.
Ths proportion of nine.opening operations carried out by high-speed
methods increased fron 354% in 2950 to 59.3% in 1935.
The average monthly rate of gangway opening increased 74.8%
from 2952 to 1953 (overage speed in 1932 was 36.9 linear metore
and in 1955 it was 64.5 linear motors per month) while the average
monthly rate of inclined workings during this period more than doubled
(22,7 linear esters in 1952 ani AS in 1953.).
- 60 ...
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
It is meeossary to point oat the follewimg very impertemi fac-
tors width determined the possibility for high-speed mimawaning
cps-rations,
TABLE 22
TIONNIOAL AND WON= MATURES OP laiNk3PEND MUTING OPERATIONS
DURING TES PERIM 1942.1956
Year 1943 1944 1945 1946 1947 1948 1949 1950 1936
Ninthly advance
of stops in
linear asters 73 90 162,4 172 181.4 203.4 254 268.6 302
Orme seetion
in square motors 8 8.5 8.5 8: ' *48.90 9.9 9.9 9.5
Timbering on the
Pretodiyakonav
scale 5-6 5-6 6.8 6.8 6.8 6.8 7.9 7.9 6.8
Number of bleat
holes per stope 18 18 2,3 22 26 18 41.01$ 27
Average depth of
blastholes in
meters 1.13 1.25 1.63 1.87 1.44 1,49 1.66 1.79 1.4
Average consump-
tion of explosives
per ot . meter of
rock, in kilogram 1.9 1.95 2.05 3 1.93 1.347 1.73
Method of rook
removal Screw Scraper Loader Loader Loader Loader Loader Loader Loader
Advame of stops
per am/shift
in linear meters 0.163 0.187
Number of cycles
per month 82 87
Labor productivity
of drift worker in
shift in cu. meters/hour 1.3 1.5
0.262
0.278
0.313
0.349
0?450
0,496
0.361
119
121
155
171
184
174
251
243
2.36
2.86
3.15
4.48
4.74
5.15
II
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
i*
Or
?
3* Total neobsaieetion et difficult processes* drifling
bcriag mIhtn,q: olo=bim by loAderst timbering brought to inelixmod
drifts by paeuaatic wimbes# cars drawn aloag driftm 147 elite:W:4
locomotives and oaths aortae* ibr pneumatic latches, oars switched
tr pneumitie oar movers*
2* Operations on a cyclic production schedule based on simul.
taneous operations*
3* Correct organisation *flops tar drift vorkers and servioe
personnel*
4.* Prompt delivery to drift morkers of all neeessery material
and tools thanks to detailed ;reparation of all drifting operations.
As amostimple ef progressive work methods in extraction we
have the work of aimed brigades and mixed ?revs n higtb.produostion
blocks*
After August 1947 nixed brigades started operating IA high-
prodution brigades at different mines which 'as an important factor
in increasing labor productivity in extraction operations*
Mimed brigades aohieved very good results* The productivity
of the mining bleak Increased 2.3 tines*
Libor productivity of the stope worker also great4 =needed
the normal.
In 2955 at the Northern Bal Bauxite Wines there ens an average
lA mob...production blocks in operation*
Labor productivity of stope workers of leading brigades exceeded
the mine overage by more than 10 time s:(4.55 cubic meters/man/eh/ft
and 2.4 cubic motereflaantshift)*
Thus work in high.production blocks was characterized 'by the
following factors!
mechanization of production processes
maxims utilisation of work time
operatioa on a. planned cyologras
;comae of a permanent working site and increased skill of stope
workers
total use of the stope group of 'Porkers in basic production
maintaining tools in good condition
providing the stops brigoida with a line of reserve 'topes as a
guarantee against unforeseen seeideuts and the inoperability of
stapes for geologieel reasons
the use of ineemtive "age systems for exoesding production
standards and the Job assigned*
62 ?
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 ? CIA-RDP81-01041Rnn4nnn1 Rnnn ,z
4 J..
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
At almitinma plants competition by occupations has been wide4
adopted. Forlinstanoe Individual electrolytic section workers,
anode operators, autoclave operators, deeompoacr speratorsi toasters:1
mixer operators, mechanics, machinists, forgers and others have been
in competition.
Competition conditions have been worked out for each profession
and for separate sectors,.
On the basis of individual obligations groups of plants have
assumed obligations tovard the government to increase produetion,
to complete the state plans ahead of time, to increase labor produc-
tivity, to reduce production costs and to accumulate stocks in
OXCesi, of the plane
Uost ex-bon/Ave has been the movement of leadizg production
workers at aluminum plants 'lathe form of general improvement in
production techniques and organisation.
The movement of leading workers and innovators in electrolytic
sections divisions leads to exceeding production standards, to
increasing output (on the basis of current, energy and oell-d.7),
to savings in electric power, alumina, fluorine salts and other
materials and to the production of better-grade metal.
For instance, Petrov's brigade (Ural Aluminum Plant) produced
93.6% better grads aluminum, including 82.5% of .4.00.
The methods which assured Petrov's brigade this *nooses are
the following* the brigade worked with cells with thick side and
bottom crusts. The thick side crusts prevent current leaks and the
oontamination of metal by admixtures from the side lining. Incrusti.
tions by compressing the metal raise its level and a high level of
motel is an important factor which determines stable end cold
operation of the cells which is necessary for producing highograde
metal.
In Petrov's brigade the cells operate on the cold process,
the temperature of the electrolyte does not exceed (with rare excel,.
tions) 950?. The average operating voltage of the cells does not
'speed 4.2 volts.
The top level of the metal in the baths is maintained at 20-25
centimeters after tapping.
-63-
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 ? CIA-RDP81-01043Rounnn1Rnnn1
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
N:74'-AFre
,
_
Au6tia aw 'Ora't offec4 t!it *-1?44vmeritt_ or the
bath. The number of leffellts Or bath aL:?er 24 hours else
047 0--* 4- 4-4P-4-10 3-sga batmen tiVrallsn: (tau 4-f.0.47 equals
148).
The anode effea,t a ;MILL% no longer than 5-6 idnutes in order
to avoid overheating the electrolyte and losing eleotria fraergy?
Overheating of the electrolyte during the anode effort is not
permitted* The effect is extinguished by a *media rod. The sills
do net remain' damped, but are oomPletely tiverhanled. The feam is
carefully removed from the electrolyte.,
In order to assure giod 0111 maintename in all shifts, the
brigade leader *Mellott; to distribute the work load between ehifts
as evenly as possible.
The average number of overhauls per shift is 3.5 (With wad
without anode Wefts)*
Man the raw satorial is being *barged the brigade saes to it
that impurities with recirculating 4114'0003,7U and foss do not get
into the ar?24 Tka ad rooka wy?s---`4-...ior. of tho
tors IA 00101:` to 5v013. the falling of iron and copper mule into
the bath when the contacts are being cleaned.
A- logo amount of alumina is dumped in for 16?18 hours of oell
operatico. %be alumina is sprinkled in evanly over the entire our-
fA016 oft*, at after the 4441 has been Ifteked over
Cryolite and aluminun fluoride
eruct (usder_the alumina) after the
order to. maintain a high quality Of
are malt frequently compensated for
in the \master ?ells.
are sprinkled onto the electrolyte
bath has been worked over. In
the metal, eleotrolyte looses
by liquid electrolyte refined
Progressive work methods in electrolytic divisions are based
on establishing specific parameters of alkalinity of the electrolytes
a specifis level of metal following tapping, in maintaining 4" eamitaust
temperature in the ells during hot wad cold porica xi in establishing
an exact crier for servioing the baths (working over cells after
anode effects, oharging the *baba, preparing oeni for tapping,
prevention of anode effects).
Leading technioal ivorkers master related auxiliary occupations
'hick makes it possible to radon the number of auxiliary workers
Declassified in Part - Sanitized Copy Approved for Release
?
50-Yr 2014/03/21: CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
tkia ibia eitriai= igrvitzee t.411.4 corzlitiori of Tatt
inecisseh as workers in the basic occupatinue heA the graft-test
intermit in the good operation of the equipment shich they are
re5i14ft4ning.
These progressive IMMO of labor organisation have bemuse
widespread in the *ludas sections which has sada it possible to
reduce the number of attending personeelty,
At all aluisinua plants a study- is being sad. of the 'Mk of
leading brigades and los this beeds of a general analysis of their
overiesce inetrustions ars wetted out oonesisIng progreseive
methods for ~doing the eleotrAyte oells and other units. Per
example* in 1956 alone* on the basis Of studyisg tad analraing
progressive woe* methods at the Datoprovsk plant* materfal was pub.
lished stitch provided for a general arpplioation of an up4osdate
electrolytic promos with a minimum cryolits pimento. of 2.02.02.53
work practises of anode operators ?adorer sad toe is shirting and
cleaning barvin -contacts; the practise of 'amide operators Shatilor
and Rausivanav in palljag pins trout the esedes of eleetrolyte *ells
with the 8.2 plasmatic apparatus; tie praitice ofltradiug Uf4
Or Coaled's Machuraihviliji Pope,* sad Grieehetakty in introducing
up.to.dotte techniques and ergiudsidios of labors
At the Stalin Ablation Plant in 1956 'studies and analyses
war* made of tip4e.date week nethodsof brig under ades und Dasidar and
?.iiwdi, iii1........4.2aurisve e minmawurrues.J1141% i.v.w..4toitacriAti4Mt
*inked is3sow being introduced along argWo operators the Monti*,
keg brigade's imoders methods in misting 'timbers has already been
pat into operation* As a result of the istrodustics of this isthod
allow id:mbar easter., pre:tuition quality has isprovedii vast* has
been reduced sod it hes team possible to out to tons per boar
instead of the previous 1?5 tom*
1n alumina coot/one of the Ural Plant the stub,' of
progressive 'amities* Sad the seleetion of the best sack methods
has resulted in instrustioss on progressive setheis for working
with evaporatirig apparatus* thickeners and sills* The Instructions
on the operation of sills included as eippliostion of the method of
Cosrute Terabukis who determined that oontinuity in the operation
of sills is a nest tupertant condition for ersintainin,g constailey
of the gives vele* Charecteristie of his method is a striatly
&Upraised order tor earrying Ott operations in maintenance *Loh
aseures eystamatie inspection and strict oontrol over the COUrile of
the teohnical premiss*
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
in 1956 a CtlAY MS made follotod by the introduatirn or
urto?date praatices of operators of primer hydrate filters whidh r
made it passible to establish more advaneed teibmologieel eenditions
for filtering priaer berate, to increase the productivity of the
filters and improve the quality of the filtrate:
The work of brigades in the seda caustifieation *sotto:thee
also been adopted generally*
Most widespread has been the combination of jibe wag auxiliary
workers in the basis divisions* the mogul* is also *forger, the
electric welder is also a gee welder, the forger also works with
'heat metal, the lathe: operator is also a scilling machine operator,
the scales operator is also a crane operator.
Leading workers in machine repair +replay in their work methods
used in servicing now machine tools (work on two vertical lathes).
However, the possibility of operating several machine tools is limited
by the individual nature of operatioss to repair shops of aluminum
plants (dissimilarity of spare ports and attaohnents being meds).
Lien enterprises engineering and teehnieal personnel have
taken an active part in atudyingo analysing and transmitting ;regres-
sive practices.
At mines and plants of the aluminum industry a large arm" of
innovators has arriimg iii i iatatiuxamplca At ;regret:elm
work methods and Whose names are knowo-not only at plants lathe
alumina' industry but beyond its *anapest drift brigade leaders
Iiinaaripay and Safutin, stop. brigade leaders Lyutft Shock, Chemtyuk (Northam Ural Bauxite Mines), Mikhalev? Usnetser (Ural plant)
Koyylysyev, Syutkin (Bagoslovikeye plant), Mogutev, Vyactskiy? Xara.
banov(Velkhov plant), Popravka (Dneprovsk plant) and others.
The decisions of the Twentieth Congress of tho CPSU pointed
out the necessity fa* n all,roued extension of the mass movmment
of effioioney promoters, inventors and innovators as well as for
assuring extensive publicity and introduction ofvputcoidate practiocs.
During meat years the movement of inventors and efficiency
promoters has become eidespreed at saterprises in the aluminum lodue-
try. There has been aeceleration in studying proposals submitted by
efficiency promoters; Photogrephic eXhibits of the best efficiency
promoters and their proposals have been organized; the best proposals
have been given systematic publicity in the local and factory press;
monthly enlarged sessions of shop ocenittees consider achievements
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
4 ?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
with the awarding of first places for the but evidenos of efficiency
premotion in the emterprimel there is a quarterly summing up of
efficiency vork at 0114.factory meetings of effieency promoters;
*bottle necks* in mines, Shope end separate plants are analysed and
pointed out to merkers?
Participation by workers in efficiency promotion in plants has
greatly increased. For instanos, at the Ural plant the number of
efficiency promoters In 1956 was 851 as against 756 in 1955; at the
Tikhwin plant 743 in 1956 as against 326 in 1955; at the Masker
plant 160 in. 1956 as against 244 in 1955; at the Tolkhowikeye plant
470 in 1956 an against 392 in 2955. The number of suggestions adopted
and their economic effootimess has slim Ikereesed (Table 23).
TUVE 23
OROWIli IN THE NUMBER OF EFFIGBNOT PROMOTION SUOOESTIOIS
AT ALUMINUM PLANTS IN THE PER/OD 19554956
Plant
/ear
Reoeived
Adopted
Ural Aluminum
1955
1467
692
1956
3.496
783
Tildtvin >Alumina
1955
383
190
2956
2134
639
Sumgait Aluminum
1955
89
34
2956
150
94
Kanaker Aluminum
1955
315
173
1956
420
231
Volkhow
1955
676
297
1956
762
381
The adoption of efficiency promotion suggestions contributed
to incoving the operation of equipment, reduced standards for
the consumpticu of raw and processed materials, lightened labor
and reduced production cost.
For instance, at the Ural Aluminum Plant there was a nominal
741107 saving of 4335 ruble, In 1956 from 377 riggestione alone.
Economies in raw and processed materials and power from, proposal
adopted consisted of;
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Blectrie pe usr 1:400000 million kilowatt
hours
Steam 56930 megeoslories
Caustic 352 tons
Bauxite 88,040 tons
Ferrous metals 136 tons
At the Dnepr Aluminum Plant the nominal yearly savings from 156
adopted efficienew proposals les 2748000 rubles in 2956 including
20,000 rubles SA MS' materials, 321,000 rubles in metal, 66,000
rubles in electrio power* 880,030 rubles in eages Iv reduction in
the labor farce* and 532000 rubles in fuel.
At the Xanaker Aluainum Plant the nominal yearly savings figured
OA the basis of 30 adopted efficiency proposals amounted to 1,192,200
rubles in 1956?
Consolidating and improving torus of socialist competition,
esnlysing and making available to all the valuable =pertain* of
leading workers* encouraging initiative in, all was? raising laggers
to the letel of loading workers* using every mans to extend the
mass aovement of immentors and effioiemy promoters and innovators,
all this constitutes one of the moat important goals of workers in
the aluminum Industry.
Asejor role in the further development of the movement of
leading workers and innovators is played by the dreative 000peration
of workers in science and produetion based on the joint work of
Soviet scientists* lending workers and engineers. This eopperation
helps workers in industry to better utilise the achievements of
metiers seism, and helps scientists to enrioh science with the prao...
tic* and experience of leading workers.
The Central Commdttee of the CPSS and the Council of Ministers
of the USSR in a decree of August 7* 2958 "On the Conversion to the
Sevenrand Sim.aour Work Day and the Regulation of Wages in the 1102$..
ferrous Metal Industry" pointed out that carrying out measures on
adjusting 'ages with a simultaneous reduction in the length of the
work day is inseparably connected with the necessity for improving
the utilisation at en eaterprises of all available potentials, for
strenuously adopting up-to.dato practiess, new equipment and modern
technology* far keeping equipment at more nearly full operation, and
for improving industrial and plant management
- 68 -
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_/
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The observance of the xkinciple of tying wages in with a
constant increase in the pro ciliation of raost..ous r.r.tas,
growth in labor produstivity, the improvement in quality and
reduction in production ?oats must be the dail,y cower** of 110.41b?
Party and trade-umioa organisations.
1.
CHAPTER IV
PRODUCTICX COSTS Iii THE SOVIET ALCM= INDUSTRI
:"
121
Production cost is a wet isqxotant indication of the quality
of operation of an industry, its branches and individual enterprises.
This indication expresses the level of consumption of labor represented
by living persons and material in enterprises and branches of industry
per unit of production. It reflects the level of technology and
production organisation, the efficiency and insomnia effeetivocess
of the use of +equipment, labor force, raw and proeeeeed naterialas,
fuel, electric power, loss control and unproductive expenditures,
the efficiency of the raw material supply, and cooperation. An
unvarying reduction in expenditures per unit of production, its cost
and production cost are most important fectors 'hi* characterise
the degree of profit in the operation of an enterprise.
A necessary condition for solving the magnificent objectives
in the svslq.ant of a Comauniat society is the continuous growth
of accumeated capital used in expanding socialist production.
A redaction in production cost at enterprises of the Soviet *Imbues
industry contributes to increasing accumulations within the industry,
and leads to a reduction in ovara3.1 production expenses in the pro-
duction of aluminum aixl its alloys with the result that there is a
reduction in with* prioes and conditions are Greeted for a still
greater use of aluainum in the various branches of industry whore
the previous high price or aluminum had limited the range of its
utilisation.
In this connection a study of production costs at enterprises
of the alusaintse industry is of groat interest for it sakes it
possible to detect the basic factors each determine the level of
production costs and to discover possibilities for a reduction.
Among the divers* factors 'blob effect the production cost
level the principal ones are: a growth in labor productivity to
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
0,41-r,t a.a
_
azoead tho -or.,th in everase asset; a reduction lathe .an con-
sumption of raw and processed =aerie:LI, fuel and electric power;
improvement in the utilisation of waste products; a. reduction in
lonrdistanae transportation of produetion tools and finished pro-
ducts, the utilisation of local rosouroes, improvement i. the
utilisation of fixed assets; * reduation in administrative ;214
trade costs and the elimination of unprolustive expenditures&
In various branches of the industry the role of the different
factors governing the reduction in production cost is not the
same and depends on the structure of production expenditures. For
the aluminum industry *lob includes wining eaterprises, the produo-,
tion of fluorine salts, electrodes, alumina and metallia aluminum,
all the factors mentiomed above are Important but the degree of
their effect on production cost is determined by the structure of
expenditures in the different production processes of this broach
of industrY. A dharacteristio feature of the aluminum industry as
a whole is the great consumption of power lathe production of alumi-
num. This is refloated in the structure of the aluminum prime cost
where expenditures on electria power constitute 15..00% of the cost
prioe. The specific proportion of power expenditures (atom, fuel,
water, elootrioity) in the cost price of *Lain& is approximately
24.-200.
At mining enterprises a decisive factor in the reduction of
prime coat is the growth in labor productivity which is achieved
largely through mechanisation of extraction processes and the
*election of soft effective systems for exploiting the deposit
under the sdning and geological conditions prevailing.
The level of the prima coat as well as the struoture of en*
penditures at enterprises of the aluminum industry turning out
the same product are not identical. Thay. depend on the techno-
logical levels technical systems and the equipment in use, the
specialisation and cooperation eystma of the enterprises, the
degree of utilisation of production tools, the else of the ester-
prises and the distance involved in the delivery of re* and pres
ceased materials.
During the period of 19404950 there was an increase in the
primp coot of raw material for aluminum of 49%. But this bereave
in the prime cost does not refloat the real increase in aluminum
production expenses sines a viatica lathe wholesale pries for
raw and prourdised materials, railroad rates and pgy scales makes
it impossible to compare the production cost for individual years.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
correction has been made for the 1950 produstion cost by
individual plants in encordance eith sonditims for the bee*
periods and this shorad that tha produetiom *est of one ion of
raw aluminum in 1950 elm 54% lees than the prewar level at the
Ural Plant, 2.7% less at the Volkhar plant and 17.4% less at the
Bogoslovskoye plant.
In 1947 and 1948 the aluninun production coat at the Ural
plant vas reduced. In 2949 produetiou *est at teeterreese tithe
aluainom industry increased ever preceding year* incomneetiom
with higher iholesale price,' for row and processed notarial.,
fuel and electric power rates.
lbr oonversion to 1948 petted the 1949 production cost was
1.3% less at the Ural plant, 4.3% less at the Volkhav plant, as
well as at the Stalin and other plants,
During the period 1947-1950 production cost was reduced
thr-gh increasing the volume efprodustice, reducing the sone-
tics of raw and proeeesed material and electric power. During the
feurth fivewyear plan as &Aisle the production cost of raw aluminum
(in terms of comparative prices) dropped 21.8% at the Ural plant,
12,7% at the Stalin plant and 17.4% at tbe logoslovskoye plant.
In 1946-.1947 at the Stalin Aluminum Plant the increase in
the aluminum pr nation eost was caused by wear on the cells with
oval Shells mach bad been installed during thmtwar years Ihich?
in eombination with SA irregular electric power supply, led to
overoonaumption of raw arsi prod-eased materials and electric power
and to a lower level of labor produstivity. U3904949, follow..
ing the replactement of oval by reetangular *hello. labor producti-
vity increased, the consumption ofmeterial and electric power
decreased and the cost of altutinumss reduced.
Following reconstruction at the Volkhov ;dent the cost of
aluminum dropped from 1946 to 1948 but rose in 1949 as the result
of higher wholesale prices as well as the utilisation of its own
alumina from nephelines, the production of ehich was only then
being adopted.
The lowest aluminum production coat was at the Ural Aluminum
Plant,
Alumina is the basic intermediate product of the aluminum in-
dustry* Expenditures on alumina make up 35040% of the production
coat of raw aluminum.
Declassified in Part - Sanitized Copy Approved for Release
50-Yr 2014/03/21: CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
Conversion to proociasing Northern tEral bauxitos by the Baer
Method bronext on a sharp reduction in the preduetion coat of alumina
in 1941.1942 as against this prewar period when bauxitos from the
Tikhvin deposits we being proeessed.
The production cost level for alumina was lower in 1945 than
1940 vim Tikhvin bauxites we extansivaly tamed at the Volkhovt
Dasprovsk and Tikhvin plants. The conversion of the alueinum Indust-
try to operating with Northam Ural bauxites contributed to a rodueo-
tion in the production cost of alumina below the prewar level.
For Instanoo,,, in 3.948 the cost of producing one ton of alumina
was 22% less than in 1940.
Comparative data on the cost of producing OM ton of alustiza
at plants during the period 19404.950 are given in Figure 3.
The increase in the production cost of alusdna in 3.949 and 2.930
was due to higher wholesale prioes and not production expettliturss.
The production cost of alumina in 1949 dropped *7% below 1948 at the
Ural. Plant sid 29% at the Begoslovskoye plant. At the Ural plant
lamina product ion cost was 15.3% 1ounr In time of comparable
prices in 1950 than 1941 and during the fourth fivo-yoar plan alumixia
production cost at this plant dropped by 24.5% of the 1945 level.
Alumina prod:ration at the Bogoslovskcys plant did mat hem=
a normal. operation until 1946 after which throe was a constant
reduction in wine cost.
For instance, the adoption of up-to.date methods during and
after the mar contributed to a reduction in the production vost of
alumina and conaequently in the production price of alumina.
1 A *semi most important factor in reducing aluldnun production
costs was the conversion of electrolytic plants to cells with a
single self.baking anode operating on higher current instead of the
low current (29..34 kiloasperes) used by maltianode cells during the
prewar years.
A Change in the design of electrolytic cells contributed to
reducing the unit consumption of electric poor and the basic materi-
als and to a growth in labor productivity in the aluminum industry.
During the fifth fivei?year plan there was a further reduction
of 30.5% in the coot of production inters* of comparable prices with
the cost ot,ons ton of aluminws dropping 22.4% at the Ural pleats
72
--- Declassified in Part - Saniiized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
v
d
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
k
32.5 at the Stella pl*mtp 39% at the Volkhov plant, amd 43.2%
At the Dawavak plant whilo at the Kaneko? and Kandeleksha pla%e
production *oat in 1953 iss one half that of 1955.
The most of produsing one ton of *lamina dropped 29.2% at
the Ural pleat end 524% at the Bogoelarskeie plant. At the Volkhov
plant the feet of produsing Gee toe of alumina had been 6.6 times
pester in 1950 than 1956, reduction roeulting from the adoption of
the ower?all prooessing of nephelinea?
This made it poasible far the government on Jame io 1955 to
reduce thaw ourrent *anal* primer for abadnun *Joh is now
cheaper than oopper ani lead. The visolesale price of abatis= vaa
107% of the abolesals prime of oopper in 1940 est 86% in 1956,
with respect to mina it was 289% and 144% rospectively, with respect
to lead 345% and 69%.
Thum during the past 15 years the reduotion in the /reduction
?oat of aluminum Ma advanced more rapid] than the reduction In
the most of sapper, sine and les&
UP to 1935 the output of aluminua at the best alumicass plants
did not *mooed 50 grams per kilowatt hour. In 1940 this ratio
increased and at reticent imiividual allsainum plants have reached
an output of 604.2 grew per kilowatt hour.
In 1956 the lowest ooneumption of electric power in elactro.
lytic cells with self-baking anodes was obtained at the Ranskor
Aluminum Plant (16427 kilowatt hours per ton of aluminum) as well
as at the Kanialaksha, Dneprowsk and Nadwoittry plants.,
2.
? 11
ib? ? -
t V 'IL t
Bxpendituras on bauxites oonatitute 27625% of the cost of
alumina and 7610% of the production cost of aluminum.
Up to 1948 the working of deposits oft)* Northern Una Bauxite
Manes took plat)e slaultanoously by opeorkpit and underground method,
the ratio batman them being an ieportant determinant factor of the
level of coot of extracting bauxites in the mines (Fig. 4).
Data given in Fig. 5 illustrate change* in the allimins cost
at the Northern Ural mimeses a, whole during the period of 19414950
and ay open-pit and undorground mining in comparison with the propor-
tion of undorground work in total extraction.
73
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
With the increase in the percentage of underground operations
the ?oft primp of bauxites increased. During the period 19414950
the cost of bauxites at the Northern Ural Bauxite Mines more than
doubled.
The Imre*** in the production cost of *bauxite las caused not
only by the inereased proportion of underground operations but by
the absolute increase in the cost of bauxites in both open.pit and
underground operationiu
During the period from 1941 through 2947 the coat of bauxites
inereased oonetantly, reaohing in 1947 153% a the 1941 level for
oPeandt abaft and 196% for underground extractions Since 1948
the predustion most has declined as the result of a marked increase
in labor productivity connected with nechanisation, the extension of
modern methods and the reduction in the volume of mine-opening opera.
time (working out the upper portion of the deposit).
The Jammu's in proluetion *oats in openvit and underground
operations has both commode causes and those speoifie for each type
of operation.
Among the causes of a general nature are* Increased cost of
timbering and explosiveo, increase in average wagon (in connection
with tbe my rate reform of 2944 and 1946 on, the basis ether govern.-
meat decree increasing the wages of workers In the Urals, Siberia
and the Far East and the increase in wages at the and of 1947 *Used
at equalising the ears of workers at the Northern Ural Bauxite Mines
with those of workers of the Far North).
The increase in the average wage caused a marked increase in
production cost in pSnleg enterprises where the structure of product-
tion costs Is characterised by the large percentage of expenditures
for labor. In the oost price for extracting bauxites at the Northern
Ural Bauxite Mines the proportion of expenditure* on the per of produc-
tion workers slop) is 20%. The increase in lieges in an increasingly
expensive factor for the so-called nominally constant expenditures,
divisional and all-mine, 'shish include items such as wages as an
element of expellee.
The shift to sore cimaplaz mining conditions caused an increase
in expenditure"; for mine opening operations and increased the amount
written off as production cost and caused enincreased consumption
of material and labor.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part- Sanitized Cop Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Since 2947i despite the increase in the average vases the
amount of the it ?wages of pro4oction workersg hae diminished,
thanks to the rapid growth in labor pmluotivity.
The increase in labor produotivity was aehleved by the extension
of up-to..dete methods and total mechanisation of open...pit operetiOns.
*met important article in the produetion cost of bauxites
in open..pit mining is liming the cost of preparatory worst/one"
(removal of overburden); this makers up 50% of the production-cost.
The increase in expenditures for opening operations, pointed out
for 1944, bad a great influence on raising the general production
cost level.
Thus the principal causes in the inerease in bauxite cost
in open.Tit operations vire the higher cost ailing openimg operations
*N. under poorer mining conditions and an increase in the amount spent
to pay for the preparatory operations.
The cost of bauxite in open*pit operations increased 70% from
2941019504.
Tho change inprining conditions vas an important facto: in
increased production toot. In 194 only the upper horisons of deposits
were being mined, i.e. above the level of tuatergrotubd waters.
The shift to the lover horizons caused additional expenses in
increasing the volume of mining operations and lumina drainage.
In additions the greater herdmeas of rocks in the lover levels
increased the consumption of electricity, explosives* compressed air
and other materials as well as increasing the anoint of manpower used.
Wage expenditures approximately doubled. The else of this ex..
penditure was determined by the level of labor productivity and pay
rate conditions.
After 1945 thanks to the adoption of an improved gystem atop
slicing as compared with the hitherto employed longwall system and
the organisation of hisfrproduation blocks (19474950) labor produc-
tivity increased.
In connection with the increasing complication of nietng
tions there were increased expenses for preparatory operatices. In
1946 they made up approximately 5% of the total expenditures bat in
1950 they were more than 15%.
- 75 -
77
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 ? CIA-RDP81 nzv;Pnnannn szt-Inn ,)
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
An Important teeter in reducing the productive wet f bamettel
ttalevuotwi eporatimo vas the inorwAto in labor Two. tluotMty and
the increase in the voluie of or extraction*
As early as 1950 the level of beirdte production cost at the
-
Northern Ural Bauxite Nines was determined by the oast in underpround
operations.
The growth In labor productivity, improvement In the mini*
system, meohanisation of produetion proceseess adoption of myrite.,
date methods in the organisatim of produetion ate labor assured a
reduction in bauxite production oost at all mines of the almeinam
industry*
Ta 1955 the produetice east of one ton of bauxite dropped 7:7
over that of 1950 at the Northern Ural Bauxite Nines, 12.5t at the
Southwn Ural netudta Mines *pi 420% at the Tikhvin Bauxite Mines.
3*
%A.. ? 1 41
0, a
A
? t
Of the plants in operation before the ler the highest e.00t of
aliatina production was found at the Dneprovsk Aluminum Plant awl
the Tildrvin Alumina Plant*
The high production cost at the Deeprovsk plant was determined
by the great expenditures for raw materiels through the utilisation
of bauxites hauled a long distance from the Tildrvin deposits and
slags from metallurgical plants.
Tiklyvin bau:dtes are proeessed into slag in advance In Nigmet
furnaces. The electrothermal amthod of producing a/nem, employed
at the Dmeprovsk plant sae eharacterived by great oonsumption of
raw ',Aerial and of electric power.
In rig. 6 we have data on the structure of the cost of eltseina
in plants in existeno4 in-1940.-19.41.
At the Tikhvin plant exposit:tures for raw material sere tame.
than at other plants due to the nearness of-the plant to the acurce
of supply. All other expenditures* however, were higher 'Moil was-
In part due to the small degree of eumina production at this plant
and the less effective sintering method as compered vdth the Beyer
system*
At the Ural plant expertlittrre2 on bauxite was one of the most
important items In the production cost of alumina (approximately 351).
76
neclassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The level of expenditures on baaatea in -Um cant price of
4 single ton of alumina has changed comparatively little. Thera
was a sharp increase in expenditures only in 3.949 and 3.950 in
connection with the increase in eholesale prices for bauxites.
There was an absolute increase in expenditures for bauxite
only in the period of 19414944 after which the consumption of
bauxite per too of alumina decreased.
The reduction in the consuaption of bauxite per ton of alumina
was accompanied by an inareasa in the proportion of bauxite at the
Northern Ural Bauxite sines with a higher A1103 content (51.6."53.1%)
and improvement in its detection. The specillo conaumrtion of bauxite
is detereined by the alumina content in bauxite and its extraetion.
The extraction factor effects the production cost of alumina not
only as an item of expenditures for bauxites but as a nominal constant
expenditure since the volume of the extraction determines the utiliza-
tion of production capacities already available.
All losses of alumina in production at the Ural Aluminum Plant
may be divided into the following types&
14 Losses of elumina in leaching, determined by the physical
and chemical conditions of the leaching process and the admixture
content of the bauxites (principally
24 Looses freti hydrolysis. In thicRening and mantling the red
slurry there takes place a spontaneous hydrolytic decomposition of
the solution with deposition of amine hydrate in the red slurry.
3. L04448 of alumina in evaporation, i.e. looses with the
illuminate solution carried away by barometric water and condensate.
These losses depend on the degree of capture of drops of solution
carried any by the steam from the separators oft)* evaporation
apparatus.
44 Losses with flue gases from oaleinationnfurnaoes. The size
of these losses depends on the degree of dust recovery in the gas
cleaning erste%
5. Other mechanical losses. This type of less includes pulveri-
zation of bauxite and alumina, api3lieg of solutions.
In Table 24 are given data characterizing the amount of alumina
losses in production at the Ural Aluminum Plant during the period
1941'1956.
Starting with 1947 losses of alumina in leaching decreased
sharply. Other types of loss also declined with the result that
extraction increased.
77
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
A basic factor determining the in yield from bauxites le
eztraetira in leach:log. Losses in leaching depend on the quality
of the bauxite and the 8i02 it contains.
The current eitardard for bauxites did not foresee the maximum
amount of calcium oxide present In bauxites in the form of carbonates.
At the euti of 1943 the fectOry started to receive Northern Ural
bauxites with an increased carbonate content which had a bed effect
on the management of the technical moons.
A second factor determining the demo of leaching is the
observation of oend.itions for cooking In autoolavee. The degree
of leaching is directly proportional to the concentration of Na20
caustic In the b.peas solutions. This concentration depends to
a conciderable extent on the amount of carbonate soda in the solus.
tions which is formed from the GO 2 of the air and calcite* intro-
duced with the bauxites, limo and caustic.
TABLE 24
EXTRACTION AND LOSSES DI ALUMNA PRODUCTION AT TEE URAL PLANT 111
1941
1942
1943
3.944
1945
1946
1947
1548
1949
1950 1955 2956
Extraction 70.37
68.07
66.58
67.59
70.27
71.74
76.86
79.28
80.82
8240 86.9 86.5
Loosest
in leaching 23.15
26.81
26.31
25.03
23.14
20.59
18.10
16
16
15.57
in hydrolysis 2.36
2,00
1.19
1.51
0:92
1.59
0.47
94
34
-
in washing 1.29
0.80
0.93
0.95
0.80
0.72
0.55
0.4.3
0,32.
0.76 -
in steaming 0,35
0.45
0.47
0.58
0.48
0.43
0.48
0.31
0.30
0.30 -
in oalothation 1.03
others and
mechanical loss-
es 1.45
0.60
1.27
1.13
3.39
1.39
2.95
1.89
2.50
1.36
3457
0.89
2.65
0.84
2.20
0.80
1.42
0.82 -
0.52
Total losses 29.63 31:93
33.42
32.41
29.73
28.26
23.14
20.72
19.18
17.79 13.1 13.5
During the second half of 1943 and the first half of 1944 the ratio
of Na20 caustic to Na20 total vas 14-15% and the amount of Ia20 caustic
in the bympass solutions was 260?270 grams per liter; in 1945 this
factor in Shop No. I stood at 10.643.8% and in Shop No. 2 at 10-12%.
The excess amount of carbonate soda in the bypass solutions caused
a reduction in tho productivity of the evaporation station ani increased
the oonsusaption of steam in connection with the formation of scales
on the heating surfaoes of the evaporation apparatuses. The design of
the evaporation apparatus was not adapted to operating on solution
-
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?411,..ells. rat.
yielding precipitates. Tho excess amount of carbonate smashed a
harmful offset on tha grinding of the charge due to the high vieeosity
of the hykvass solutions. Tne poorer charge *Ming aua the reduction
in the concentration of caustic soda in the byopass solutions led to
e reduction in alumina yield in leaching.
In order to eliminate difficulties in the technical prceess
caused by the high calcite content of the bauxites the following
measures were takent
the Northern Urals Beuxite Mines started preparing different
*barges with ores from differamt workings and made a more careful
screening of overburden limestone;
in *lumina divisions in 3944 the torpass solutions were heated
up in order to separate soda from them and Shop causticisers were
installed. In addition a special causticising installed ves fitted
out.
The separation of excess carbonate soda was complicated by the
-excessive ecoumulation in the mystem of large quantities of organic
substances introduaed largely with Sokolov bauxites. This caused
the for=tien of instable vete** (by-pass solutions supersaturated
with sods), which disintegrated under heat and delayed the settling
of the separated crystalline soda.
In addition the high organic content of the solutions compli-
cated the meshing of the red slurry *doh caused increased loss of
caustic and reduced the concentration of Na20 caustic in the solu?
tions with the result that there was a reduced yield in leaching
(especially in 1943-1945).
As a remit of these measures losses in leaching have decreased
markedly in recent years.
The reduction in alumina leases was also achieved through
improvement In maintaining the production process and carrying out
a series of measured aimed at improving separate stages in the techni-
cal process. ,Among these measures were the introduction of a new
method for removing the red slurry from the Dorr washers (gravity
chute) vhichmade it possible to take the Doer Co. pumps out of use,
improve the mashing of the slurry and reduce caustic losses;
the introduction of a :nevrmothod for mashing the evaporation
units making it possible to itIMMUSO the concentration of bywpass
solutions and increasing the productivity of the evaporation station;
improving the grinding of bauxites in Shop No. 2 by the instal-
lation of graders in all ball sale;
increasing the revolutions of the mdlls in order to improve the
quality of the grind;
79
Declassified in Part- Sanitized Copy Approved for Release 50-Yr 2014/03/21 ? CIA-RDP81-01043R0o4nnn1Rnnni_q
Ammfflopy,
Lugs
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
cutting off 64:rubber s from the ealcinntion furnaees and the
installation of multicyclones ally gas purification).
In recontiorm the extraction of alumina from bauxites has
greatly inorea . Considerable work has been done at the plant in
introducing new equipment and improving processes and apparatua, in
installing further afitomatio control and regulation of production
processes.
A continuous method has been put into effect for leaching bauxites
in autoclaves, the limestone furnaces have been redesigned, filtra-
tion of aluminate solution in Nally sheet filters has been adopted
with the use of waste paper instead of binder canvas (block No. 2),
hydrooyolones have been introduced for grading bauxite during milling.
By partial modernisation of alumina calcination furnaces their produc-
tivity has increased 20 over 'hat had been planned. waek has been
done on over-all automation in grinding (block No. 2) and centri-
fuging (bloat No. 1) and new automatic devices have been introduced
in various sectors of alumina production.
Imre/teed extraction and the reduction in the unit consumption
of bauxite are related to further improvement in the technology and
apparatus used in alumina production.
Approximately 25% of the expenditures in the cost price of
alumina are due to caustic sola. The material index of this type of
raw material is not great. The great proportion of this item of ex-
penditure in cost price ia due to the high cost of caustic soda.
In Fig. 7 aro data characterising the variation in the amount
of expenditure for caustic soda in the cost price of alumina at the
Ural Aluminum Plant during the period 19414956.
In 1942.4943 standards for caustic commotion increased due
to the sharp increase in the carbonate content of the Northern Ural
baurltes.
As the result of an improvement in washing the red slurry
(Change in the method of removing the red alUiry from the washers)
losses in NaOH have docremed yearly since 1944.
In 1956 losses of caustic soda had decreased 142 kilogram from
those of 1941 which was achieved through the high level of removal
of bauxites, reduction in possible overflow, loam!' of solutions and
pulp.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The reduction in expondituros for and processed List-m.411s
was furthered by the use of slurry produced during the production of
alumina*
Red slurry is of practical use in making structural materials
such as tiles, clinker, and cement*
Expenditures for steam made up more than 20% of the cost price
of alumina* During the ear years the increases in steam *assumption
were connected with difficulties in the operation of the evaporation
batteries developing from clogging with carbonate soda and the redue-
tion in beat transmission, as well as in additional heating of bp-pass
solutions in order to eliminate precipitation of soda*
After the adoption of the caustification unit in 1946 the con.
sumption of steam startod to decrease,
Improvement in providing alumina sections with steam and better
quality of maintenance, stimulated by special bonus payments for
savings in :steam, contributed to reducing its consumption*
In 1950 there mas a further reduction in steam consumption at
a pressure of? atmospheres by the substitution of *operator steal
for heating solutions in oaustification, expanding the soda eaustifi-
cation unit, and impromingmilling quality*
During the fifth fivevear plan stem consumption vms reduced
from 6,4 megacalories per ton in, 1950 to 54 megacalories per ton
in 1955*
Wages of production workers with supplements nada up approxi.
4041y 3% of the cost price of alumina*
The increase in labor productivity contributed to reducing the
amount of man hours per ton of alumina and the amount disbursed for
wages.
Despite the significant growth in the average yearly 'ages of
workers in the alumina section, expenditures for wages took a lessor
proportion of the cost of one ton of alumina, thanks to the growth in
labor productivity and Improvement in production processes and in
1956 were only 760% of the level of 1950*
In Ilig* e are given data describing the change in the amount
disbursed for wages for alumina production at the Ural Alusdinva Plant
during the period 1941-1956.
81
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
El
Expewittres for pecoluotion netnagement nndraiii?ttonence accum a.
larga pwtioa oftha ?oat pieloo of alumihaf approximat06,4 14%, inalnd
km sectional expenditures /1%, and alIiiplant expenditures 3%. Ms
changes in sectional end allvlant expenditures in producing one ton
of alumina ars given in Fig. 9.
The Increase in expenditures represented in the cost pries of
one ton of alunbsa, despite the increase in the output of alumiaa,
vas caused by the Jeerers* in administrative end managerial expendi?
tures, expenditures for mainteaanee and others. Sinalfioation of
the managerial apparatus and increasing the output later centributed
to redwing expenditures for managessent and miasma**, end sectional
expenditures represented in the cost price of one tom of alumina were
38% lower in 1956 then 1950 while expenditures were 2?5
tines greater in 1950 tbsIA 1956.
One of the most important sources for reducing cost pries is
the fuller uti3.1sation of production capacities.
A decisive factor in improving the operation of equipment in
alumina sections is the organisation of tinely high...grads ailatiausos
and overhauls. Tardy and faulty repairs lead to rapid wahine war.
The &tawny greater tins between repairs than forseen by the
plan has been the result of failure to supply the neeeesary spars
parts, repair material and qualified repair personnel. Faulty
repair led to a reduction in the period of operation between repairs
and decreased the effective use of equipment.
During the postwar yews the coefficient of time of use of equip-
ment inoreened, the quality of work in maintenance has impraved greatly
anti the cost of repairs has decreased.
11.1:04o.date repair methods have beams widespread. For instant*,
the repair ere, wader Coen& Nononow worked out a new system for
repairing oentritugal pumps and reduce repair time to one-third.
As the result of the extensive use of modern methods in alueina
zectionc, the better utilisation of equipment beth with regard to
tine and capacity, the introdustice of new apparatus, intensification
and improvement in the technology of separate production sectors, and
increasing the skill of maintenance pommel, the output of abligifill
had increased greatly over 1950 by 1956.
Nevertheless the alunina sections of the Ural Plant still have
potentials for increasing alumina production further. In 1956 alone
Declassified in Part - Sanitized Copy Approved for Release 50-Yr 2014/03/21 CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
alumina production at the Ural plant inereased 10.8% over 1955
due to the imtanaia.41matical cpwation of eatooltatg.2. tank-m-4ml
deeomposers and evaporating apparatus. Durin* g this porlea the
duotivity of the continuous leaching apparatus inereased 16.6%s
the leaohing promos was shortened by 0.3 hour and decomposition
by 4.8 hours III block No. 1 and 2?7 hours in block No. 2. The
sauMant of aluttina produced per cubic meter of deoomposer volume
increased 0.6 in block No. 1 ani 1.6 kilograms per day in block
No. 2.
The increase ip the production capacity of alumina production
at the Ural Aluminum Plant as well as the reduction in the amount
spent for raw autt proeessed materials ani the abaolute sloe of mrs...
penditures for different items of sectional and allpplant expendt.
tures, in conseetion with simplifying the structure of production
management (commiolidating alumina sections into one and ooneolidc?
tine sectors in this section) and inprovenent in repairs led to a
reduction in production oasts. A marked reduction in production
cost also took piece at other alumina enterprises in the aluminum'
industry.
The cost of one ton of alumina at the Volkhat pleat decreased
28% between 1955 and 1956. At the Bogoslovskoys plant the cost of
ens ton of alasina was greatly reduced and at present this plant
produces the cheapest alumina in the couitry.
4. realt-Pri90 or avian.
A ?caparison of the oast price of raw clumintma and an analysis
of the dYnsnics of the different mi.venditures makes it possible to
determine the most favorable ooeditices for production and potentials
for lowering production ?oat.
In 19504956 all technical factors isproved at aluminum plants
'which contrfbuted to :clueing the production cent of aluntnea. This
was achieved through intensifioation of produstion by increasing
current in the electrolytic series, the use of acid electrolytes
with a minium number of anode effects, and a reduction in the produc..
tion cost of *lumina.
For instance, the prime cost of one ton of aluminum in 1950 was
2.4 UTAH greater than in 1956 at the Xansker LULUS= Plant, 2.2
times greeter at the landaleksha plants approaleately twice as great
at the Dneprovsk and Volkhav plants. 1.75 times greater at the Stalin
plant and 1.4 tines greater at the Ural plant.
11
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
At the Velkhow plant daring the firet year; of its rasorAruomi
tion the production cost of alumin= vas reduced. Rovevers In the
roxt yuara of tha fourth five-year plan, in connection with the
gradual Shift to its own alumina obtained fraa nephelines *ere
production ems not yet mastered and the coat of this alumina still
exceeded the cost of imported alumina, there was a sharp increase
in the cost of aluminum.
At all plants there was a higher cost level during the *axial:-
lation period which cannot be considered a normal phenomenon.
The higher production cost level Is the consequence not only
of difficulties in adopting new capacities but in organisational
shortcomings in putting aluminum plants into operation.
The conditions attendant on mastering the postwar capacities
of the restored electrolytic section at the Dneprovsk plant were
complicated by poor hearth blocks which had bean used in assembling
the cells. This circumetance was the cense of the high aluminum
production cost at this plant in 1949.
Expenditures on alumina as represented in ths cost price of
aluminum at the *operate plants are given in Pigs. 10, 110 12 and
13 for 1940.1956.
The lowest level of expenditures for alumina during this period
existed at the Ural Aluminum Plant which is the consequence of lower
consumption and the lower cost of alumina production at this plant.
At the Bogeslovskore Aluminum Plant there was a constant drop In
expenditures for this item based on a systematic reduction in alumina
consumption and production cost. The lack of a local raw material
supply for alumina production at the Stalin plant -causes the high
cost of alumina in the production coat of aluminum.
At the Dneprovsk plant the great expenditures for alumina were
also caused by an incomplete period of mastering the newly introduced
capacities during the period 1949.1950.
At the Ural plant the expenditures for alumina represented
approximately 36-31% of the production cost of aluminum.
Expenditures for this item rose 21.7% from 1941 to 1950, largely
because of higher prices.
In 1956 expenditures for this item decreased due to the reduc-
tion in the proportion and production cost of alumina, being 36.4%
less than in 1950.
84
npnlassified in Part - Sanitized COPY Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Ai thiStalin plant in 1950 there ma smirked Inc:ream, in
expenditueee for alumina over 1943 (gemeral inerame 32.34 made up
ofules,5% for higher prices and reduotizain 0011SUEptia of 6.2%)
while from 2950 to 1956 expezditures decreased 47%.
The reduetion in the oansumption of alumina at plants vas
aohieved by impreved operation of cells, reduction in lessee from
pulverisation and alumina transportation, oarrying out measures
for improving the oonditioe of floors in aims ehich made it poesi-
hie to utilise alumina swooping', alteration in the design of
bunkers and the welding arias to the cells to prom* spillage
of alumina (Stalin Aluminum Plant), replaeement of earn louver and
the power supply.
The inoreased *assumption of alumina ems alum' by inaaffiolent
hardening in the alumina fUrnaCes. Considerable losses in alumina
took place in transportation for long distances beaus of poor.
grade containers.
Discontinuity in the consumption of *lumina at different
plants and the achievements of the Ural Aluminum Plant testify to
the presence of ocesiderable potential for a further reduction in
expenditures under the item *alumina' in the production cost of
aluminum.
At the Volkhov plant the consumption of almainavas lower than
for 1940 and 1930.
At the aluminue plants the potentials for reducing expenditures
for the it.. *alumina* are connected with improving the Poor suPPAY,
hardening and crystalline structure of the alumina, further extension
of upiwtoodate methods in economising on raw and prooessed materials
in all corps and brigades of the electrolytic sections, improvement
in working conditions and increased Skill of vorkers? improvement
in 144AS of transportation within the factory and in hauling for
long distanoes.
Expenditures for fluorine salts make up approxinatel,y 4-6% of
the cost price of raw aluminum.
During the period under consideration (19404956) expenditures
for fluorine salts became a smaller item in the production cost of
aluminum,
Starting with 1949 factories started using calcium fluoride
which is much less expensive than cryolite and aluminum fluoride.
- 83
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Additions of calcium fluoride contributed to reducing the eonsump.
tion of cryolite. Calolum fluoride roduced the mailing point or
the electrolyte and contributed to the stability of the preduotion
process.
Tho reduction in expenditures on cryolite at the Ural plant
was due net only to the reduction in consumption but to the increase
i
in the proportion of flotation cryolite in t' oonsumption of
oryolite from 7.4% in 1941 to 52% in 1950 and '956 (Table 25).
The proportion of flotation cry:aft* in the totalocnsumption of
oryolite increased during the fifth fivryear plan at other plants
also and stood at 57.4% in 1955 and 63.14 in 1956 at the Stalin
plant, at 57.7% in 1955 and 52.5% in 1956 at the Dnoprofik plant,
and at 40% in 1956 at the Volkhov plant. The ruination in the
consumption of aluainum fluoride in 1955 and 1956 can be explained
as lesser utilisation in acid electrolytes.
TAUB 25
PROPORTION OF FLOTATION aRYOUTE IN TOTAL CRIOLITE CONSUMPTION
AT THE URAL PLANT, IN its
Consumption of flotation
ox7olite as a proportion
of total oryolite consump-
tion
oryolite as a proportion
of total cryolite consump.
tion
1941
1942
1943
1944
1945
1946
1947
1948
7.4
5.8
34.08
32.9
32.0
34.4
43.2
43.5
1949
1950
1956
46.7
52.0
52.0
The increase in the consumption of aluminum fluoride during
cortain years was caused by fluctuations in the power supply at
aluminum plants, wearing of cells and the increase in the alkalinity
of the a/umina. In 1936 the lowest consumption of cryolite per ton
of aluminum was obtained at the Kandalsksha (313.5 kilogram.) and
the &maker (28 kilograms) plants. At other plants where oryolito
consumption per ton of aluminum was higher there were great poten-
tittle for reducing expenditures for oryolite.
The greatly increased consumption of flotation cryolite in 1956
at the Ural and Stalin Aluminum Plants can be explained as the entry
into operation of electrolytic collo of the various corpe following
their redesigning. Figur*. from the Volkhov plant on the consumption
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
On,
of aluminum fluoride during the prewar years were lower than during
the poster years which confirm:, the pm:ability of a further lomr-
ing of expenditures for fluorine salts,
Possibilities for reducing expenditures for fluorine salts
must follow the line of reducing the production cost of the crib-
lite used which requires the organisation at all plants of special
installations for =wilts flotation and the recovery of fluoride
exhaust gases an well as by reducing the consumption of fluorine
salts.
Expenditures for anode materials make up 9-11% of the cost
pride of aluminum. At all plants during the period 1940-1956
there were great flucutations in theee expenditures, caused by
changes in consumption standards and prices.
In 1949 wholesale prices for anode materials and anodes were
increased. The increase in prices was the main cause of the in-
crease in expenditures for this item represented in the coat price
of aluminum. There was a reduction in expenditures from the point
of view of consumption. A certain increase in the,00nsumption of
anode materials during various years was due to iaereased ash,
reduced porosity and a tendency to crumbl.,
At the Dial plant after 1949 there was a marked reduction in
the consumption Of anode materials related to the now system of
shallow immersion of anodes in the electrolyte. At the Stalin
plant the consumption of anode seterials was greatly reduced follow-
ing the institution of an anode materials section which resulted in
a reduction in losses during transportation.
In 1956 the Unaker and Undalaksha plants occupied first and
second plsoe (485 and 520 kilograms per ton, respectively) in the
consumption of anode materials.
At the VoIkhov plant this item of expense reflect the specific
features of the designs of multianode cells with baked anodes.
Expenditures for anode, were 1.5 to 2 times higher than for anode
materials.
The consumption of anodes at the Volkhov plant was constantly
reduced due to an improvement in quality and greeter mastery of the
electrolytic process. In 1956 consumption was 28% lower than during
the prewar period and reached approximately the consumption level
of anode materials at other plants. A further reduction in expendi-
tures for the item "anode materials" was obtained by reducing the
production cost and by reducing consumption ihrough assuring a uni-
form poor cycle, improved anode maintenance and better quality of
anode materials (reduction in ash content, reduced porosity, in-
creased mechanical strength).
- 87 -
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Expandituree for olootrio power fluctuate betweon 15-30% of
the production coot of aluminum and depend principally on the cost
of the energy employed which can be seen from data provided in
Figs. 14, 15, 16 and 17.
Expenditures, for electric power represented in the production
cost of aluminum reflect directly the efficiency of the geographical
location of the aluminum plants, their closeness to the power supply
and its quality.
This statement can be confirmed by the level of rates for eleetri-
city. The Dneprovsk plant operates on cheap paver from the Dneprovsk
Hydroelectric Poser Station which is in the immediate vicinity.
The Xandalakaka, Nedvottwy and Nenaker Aluminum Plants also
operate on cheap hydroelectric power as can be seen from data cited
in Fig. 16.
The consumption of electric power also has a real effect on
reducing the production coat of aluminom. During the period under
consideration the oenaumption of electricity has declined from year
to year. For instance, the consumption of electricity per ton of
metal dropped 2149 kilowatt hours at the Ural plant, 4811 kilowatt
hours at the Stalin plant, 3418 kilowatt hours at the Volkhov plant
and 1663 kilowatt hours at the Dneprovek plant.
The Vcakhov plant made the best Showing on the consumption of
electricity in 1956 (Fig. 19). ?
The ccosumption of electricity per ton of metal depends on
many flu-Aare, among them the most important are cell design and qual-
ity of inatallation; power cycle; quality of maintenanos.
Let us consider each of these factor. separately.
Cell design and installation quality. In view of the differences
in deeign of the different (sells, the separate series operated on
different electric power patterns. Cells with oval shells operated
on lower current than rectangular @ells due to higher beat transmission
since with higher current they became overheated which led to disints.
gration of the lining and leaking of the electrolyte.
In a corps where different types of cells were installed current
was maintained approximately as for oval cells.
Se
1
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
A comparison of power factors of different 'arias calor a
sualer of ya&Grad tha nal:me:ages of restangdar aells without
butts vibieh aseurad a higLor output per cal r-vr, de y and a louvr
consumption of electric power eveniduna operating on lower ourrent*
The Stalin plant had the first installations of oval oells.
Defects in the oval design with poor-Trade installation led to
their being out of operation in a very Short time. The electro..
lytie section of the Stalin plant vas redesigmed with the replace..
mem* of oval mils by rectangular ones which assured a lower ?amorally.,
tion *ram:trio poser and improved other teahnicel and economic
aspects of the operation of the minim* Work vas dome at the
emterprises on replacing obsolete cells with worn shells by more
modern cells.
Measures were also carried out on reducing resistance in cfr..
cuits of electrolytic oells: leads yore strengthened, anode and
cathode contacts waded, bolt *contests of bars and pins were replaced
by wedge contacts. In order to lengthen the service of the cells
worn channel bar shellemms replaced by shells of sturdier design,
short shells replaced by longer ones, cells assembled with Joint
overlap.
Pager system. The main power faotors determining the operation
of electrolytio cells at the Ural Aluminum Plant are cited in Fig* 20.
During 1942 and 1943 at the Ural plant the current flnotuftted,greatly
whieh led to a reduction in outpgt per current and to an increased
consumptioa of eleetrie power* In 1944 the current vas ceeparattvely
stable, voltage was redrased and the consumption of eleotricityde..
alined* In 1945 and 1946 there were emsiderable fluctuations in
the electric power supply to !notaries, however, thanks to raising
the level of the metal in the inns, it was possible to 'liberates
output on the basis asts dwrent and energy and reduce the consump-
tion of electric power.
After 1948 the current was stronger which resulted in an in..
creased output on the basis of current and energy* Raising the
level of the meta 'nth* *ells emtributed to increased output an
the basis of current ems with loser current* The introduction of
mirtomdats method of work emtributed to redueizgvoltsP lathe
cell. The reduction of losses in electric power was furthered by
the introduction in 1950 of simpler and more rapid method for
quenching anode effeats with wooden rods instead of ladles as had
bemused. Thus, beginning with 1946, power factors improved from
year to year and there was a ecrreeponding reduction In electric
power consumption*
89
1!
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The redesigning of cells in the first and sioond corps ehioh
took place in 1946494$ med. it possible to raising output per unit
of electric power in there corps from 78 to 81% end higher. The
replacement of worn out shoals with nmones in other corps* the
replacement of oovers of oprilamkin 1: j')'? the addition of ealciun
fluoride to the electrolyte* contributing to a reduction in current
losses through the side lining* all this led to increased output
per unit of current and reduced the consumption of electric power.
The reduction in the voltage in the cell and the ooneumption
of electric paver were also encouraged by measures carried out in
1950 an cleaning contacts of cell leads and the initial welding of
cathode contacts and the reduction of the depth of anode immersion
by 100 millimeters (in corps No.1).
At the Stalin plant after 19480 following the replacement of
oval shells by rectangular ones* current increased greatly and all
power factors were improved (Fig. 21).
improvement bathe power supply after 2949 assured inprovesent
in all operational factors at the Stalin Aluminum Plants increased
current* increased output per current unit and reduction of voltage
in the cell. Improvement in technical factors in 1950 was achieved
as the result of mastering operation with thick aids and bottom
deposits.
At the Dneprovsk plant the power cycle in 1950 did not reach
the 1eve1,ce1940-1941 as regards output and was lower at the Urs1
plant (Jig. 22).
Theft/eduction in the consumption of electric power at the Yolk.
hov pliant was acocmpanied by an increase in current which exceeded
that'planned and by increased output (Fig. 23). The increase in
output per unit of current was determined bys raising the level
of the metal In the cells even with some increase in the diatoms
between poles; improvement in the power supply; increased skill
of operating personnel.
Power factors at the Yolkhov plant during the postwar period
vastly exceeded the prewar factors *WC* indexes Of the Dneprovsk
plant* also operating with cells with baked anodes.
During the fifth fivevear plan there was further improvement
in aluminum production processes continued growth In the produc-
tivity of electrolysers with a simetaneous reduction in the ow-
sumption of electric power per unit of production. A basic trend
90
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
in eleotrolysis VW/ providing far the operation *foals on more
aoid electrolytes and with a reduced nueber of anode effects and
inoreaeed current density.
The oryolite portion of electrolytes at aluminum enterprise*
dropped te ar the end of 2955 as against 2.0*3.0 in 1951.
At the Ural plant the cryolite percentage was redueed from 2.52
in 1955 to 2.45 in 1956'1 tram 2.46 to 246 at the Stalin plant,
from 2.39 to 2.38 at Kandalaksha and te 2.2 in 1956 at the Volkhov
plant.
Thanks to raising the level of metal in the cells and improvement
in the power supply the number of anode effects in the **II during
a 24-hour period was reduced at the Ural plant from 1.31 in 3.955
to 1.0 in 1956 and correspondingly from 1.2 to 0.77 at the Stalin
plant, from 1.07 to 045 at Xandalaksha and to 0.99 in 2956 at
Valkhov.
The greatest sweeps in this field was achieved in 2956 by
personnel of the Xanaker plant. The frequency of anode effects
at this eeterprise in 1556 reaohed approximately 0.19 per day and
0.12 by the end of the year. The great reduction in the number of
anode effects made It possible for the plant to increase the current
and the production of the electrolysers without increasing the con-
sumption of electric power.
During the period under consideration current density in the
eleotrobvers of all aluminum enterprises'inereased constantly,
by 20% at the Dneprovsk plant, by 16% at the Ural plant, ail 16%
at the Xanaker plant. In the second electrolytic aeries at the
Ural plant anode current density increased from 0.695 amperes/sq.cm.
in 1946 to 0.863 amperep/Sq.em. in 1956, i.e. 24.2%. At the Kanaker
plant current density had reached 0.914 amperes/eq.ond by the end
of 1956.
The Velkhov plant, operating on multiancde cells, has high
output per unit of currents 924.34% in 1955 and 91.21% in 1956,
which vas assured by operation on acid electrolytes at high current
density (145 Kam.), maintaining optimal voltage, oonstancy
of current in the series and careful servioing of the electrolytic
cells. Paver factors by' plants in 1956 as compared with the Ural
plant are given in Pig. 24.
The quality of servicing of electrolysers plays a great role
in reaching high metal output and in reducing the consumption of
electricity. The quality of cell operation improved continuously
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
ith.167-to=nt: tochniq=; of 'Ayes and 4_swealiti1
skill of perscatnel.
During peetear years the ski.U. of the workers improved acortantly.
Increasing the skill of natintenence personnel and the reehanisation
of hard Jobe (treating ell* with pneumatic hosiers" mechanisation
of anode regulation) contributed to inprovamat in eon servicing
emit consequently, to redueing the ecomptiaa of eleetric power.
The reduction in electricity consusgtion leas tint hared by the
campaign among loading workers for savings of elestrie poor,
Assigning permanent groups of cells to week crews coatributed to
reducing the average voltage in the oell and to reducing electricity
*consumption.
Further mechanisation in managing the anodes And treating the
oeU,inpranneent in working 'conditions* the popularisation of
up-to-date practises within the plants and between plants will make
it possible to ensure a higher quality of operation and, consequently,
a ruction in the consunption of fasetrioity and ;rammed smterials.
Expenditures for wages of production workers nede up 6-9% of
the produstion cost of *badman*
The encent of expenditures in this item depends first of all
en labor productivity* the average wage level* the bkill of workers,
and the organisation of work.
Expenditures for wages during the postwer period Were consider-
ably higher than Viol* of the prewar period which was related to
the increase in the average meg* in the tannin= indnetri AIM the
introduction of a lege system for key Jobs in electrolysis "birth
stiadiated the output of alumina and improved its quality kr giv-
ing largo supplements to the basic pay rate* Starting with 1948 the
average wage increased markedly as the result of payments for length
of service and bonuses for higheri,grade metal.
Por instance at the Ural plant the average yearly sage of workers
in the electrolytic divisions increased 2.8 time. from 1941 to 19500
Characteristic of the urea plant in the continuous inerease in wro
pabditurea on wages. While this item of expense was 3.66% of the
cost price of aluninun in 1944 it had reached 7.0 in 1950 erd 8,2
in 19%. In recent years expenditures for wages at the Talkhov
plant have started to drop in connection with the rapid inereese in
labor productivity as aospared with the increase in the average wag**
- 92 .?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
NIL
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
At the 8telia plant expenditures tor sages inoraaged through
1948 which was caused by the rapid rice in pay and unsatisfactory
labor productivity under difficult factory conditions of working
with Erma oval cells.
The redesigning of the electrolytic section on the basis of
rectangular cells contributed to the rapid Increase in labor produc-
tivity, following which there vas a drop in the peroentage of the
aluminua production cost represented by wages.
The lomat level of expenditure* for wages lathe itemised
production cost of aluminum-sae reached in 1936 at the Stalin
plant ehich can be explained by the high labor productivity achieved
through the operation of powerful molls and the up-tos.date work
methods adopted by the ?Tomb:1301w majority of the factory's workers,
The higher level of veva at the Ural plant is the result of
higher pay rates and the bonus incentive system.
The level of expenditures for wages is determined by the growth
in labor productivity. This factor in turn depends on the design
and capacity of the cells, the improvement in the teChnioal aspects
of production, efficient labor organisation and the electric power
supply system. Where there are marked fluctuations in the ampere
load over a 24-how period and an insufficient supply of electric
power labor productivity is reduced.
Workers in the main occupations under a system of uneven
electric power supply were paid on the basis of corrected output
standards as related to current. Such a situation led to an in-
*ream, in the percentage of production cost spent on wages for the
wages per ton of metal increases ilth lower current. Consequently,
,ane of the meet important rectors in reducing expenditures for
wages was the guarantee of a regular electric power supply.
Another important potential for reducing expenditures on wages
is a readjustment of the pay scale and current system of payments,
the elimination of indirect piecework and the creation of bonus
scales aimed at making them return a profit both from the point of
view of nonoverdisbursement of the wage fund and from the point of
view of increasing production oost.
Potentials for reducing expenditures for the item ".ages of
production workers" are also related to improvement in labor
organisation.
93
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
diszer.Amticu. of maaticea of looLvtrit? =taro nithin.
the elestrolytia plants and between the ThrieOS enterprises is a
powerful factor in increasing labor productivity and, consequently,
in redwing expenditures for wages.
Expenditures on managennit and aeintnnwe make up 13..20% of
the production coat of aluminum.
The size of such expenditures depends to a great degree on
the sue of the establishment.
Changes in divisional expenditures as represented in the pro..
duction cost of ow ton of aluminum are given in lrig. 25. At the
Ural plant we find an increase in expenditures on management and
maintenance up through 1946 and a constant &areas. in subsequent
years. The increase in these expenditures leas socompanied by an
increase in metal output and ins the oonsequenee of adding new pro-
duction capacity, attended by large additional expenditures. The
sharp immune In divisionia expenditures in 190 reflected increased
reserves for amortising expenditures for electrolytic cells. A fur-
ther reduction in divisional expenditures was caused by a rapid
increase in metal production..
At the Stalin and Volk:how plants there ins a constant reduction
Lu sectional and ell-plant expenditures in the produetion cost of
alimainme, thanks to an Increase in the output of metal.
At the Dneprovsk plant the level of sectional and all-plant
expenditures was raised in 1930 as the result of putting new
series of electrolytie wills into operation as well as the leper..
feet utilisation of available capacities during the course of the
year.
The lomat level of divisional expenditures was at the Ural
plant in connection nith larger scale production and better pro-
duction organisation than existed at other enterprises.
During the period under consideration estimates of sectional
expenditures increased as the result of higher wages for auxiliary
wcrkers and engineering and technical personnel and increased ex.
penditures for routine repairs.
Potentials for reducing libation' and all.plant expenditures
are related to increasing production output, primarily through a
better utilisation of available equipment both from the point of
view of capacity and time In operation, and to en absolute redue..
tics in their total dimensions at enterprises. Reducing the total
4.6 94 -
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
eum of sectional expenditures is connected with reducing amortise-
tion expsnditures for electrolytic cells.
The increase in the average length of service of cells makes
it possible to reduce amortisation figures and consequently reduce
the production cost of metal.
Reducing the percentage of aluminum production cost reprellemted
by sectional expenditures should follow the line of reducing the
coet of repair operations carried out in basic and repair divisions.
The high cost of operations in the machine repair shops can be ex*
plained by shortcomings in the organisation of productions high per.
centage of defective work, many bard job* are not mechanised, a
whole series of production standards are established by the practical-
statistical method and not by a technologically based system# and
not all factories make studies of the length of service of parts and
units subject to rapid wear.
The else of seotional and all-plant expenditures per unit of
production may be reduced oonsiderably by increasing the utilisation
of the capacity and operating time of equipment, i.e. increasing the
smelting of meta.
A most important indication of the utilisation of the capacity
of electrolytic cells is the output of metal per cell-day.
An indication of output per cell per day is the synthetic indica-
tion of the operation of the electrolytic sections which refloat the
power pattern, the conditions of the cells and the level of maintenance.
During the war and the first postwar years the power supply fluctuated
greatly, there yore breaks in the polar supply, 'worn out equipment
was kept in operation, and repairs were not of a high ealiber. All
this caused a reduction intim output of aluminum per cell per day.
After 194 there was an Improvement in all qualitative indications
of the operation of electrolytic sections thanks to improved and
intensified production processes, the replacement of worn equipment
by improved types, improvement in the power supply and in moll main-
tenance.
A systematic study and general adoption of u*.t&date work
methods by the entire body of workers in electrolytic sections nust
assure a further increase in output per cell per day.
The period between major repairs can be lengthened by the more
extensive use of the unit repair system.
al 95
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Reducing the idle time of Dells for repairs and incroaeing
their length of service will increase the production capacity of
the elootraytie geatione.
The reduction in all-factory expenditures may be attained
first by eliminating nonprcduative exponditwes.
At the Dneprcvsk plant in 2930 nonproduction expenditures
mado up 36% oft)* total sum of all-plant expenditures, at the
Stalin and Ural plants 25%, and at Volkhov 17.4%. Nenpreduction
expenditures are to a largo degree *annotated with railroad d.-
rage charges. In 1930 demurrages at the Ural plant averaged 1147
hours as against a standard 6.5 hours.
The elimination of nonproductive expenditures in paying fines
comes through better financial discipline and Improved operation of
transportation divisions in the area of better meohanisation of
loading and unloading operations, providing satisfactory unloading
frontages at sectional and all-plant warehouses, and improvement in
the organisation of loading and =loading operations.
The reduction in production cost he* taken place not only by
reducing /material empenditures(raw and procesood materials, electric
power) bat by reducing expenditures for maintenance and administration
through bettor produotion organisation and a simplification of the
structure of enterprises. For instance', at the Ural Aluminum Plant
two alumina sections were consolidated into one. Six production
sectors were formed frontwelmy than existing. All this node it
possible to simplify managesient, increase the operating factor and
reduce expenditures for administration through the elimination of
superfaSons echelons.
Expenditure* on mamgement and mminteaanae at the Kandalaksha
Aluminum Plant in 1956 Niro reduced considerably through modifying
the organisational structure and the use of a divisionless system
of administration.
Through the elimination of superfluous echelons in the adminis-
tration, expenditures on the maintenanee of the administration and
managerial apparatus at this plant were reduced by 2,800,000 rubles
per year *tile the number of engineering and technical personnel
and 'hits collar workers decreased 130 men.
The reduction in administration and managerial expenditures
should aim at further efficiency in the managerial structure and
the reduction of enceesive staffs.
u, 96 -
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Sltaueous with tho roductien in expeuditnrom ftr materiel
and power and iarer in tho utilization of the production
capacity of electrolytic sections vas the improvement in the quality
of aluminum melted.
For inetance, the output of high-grads 400 and AO aluminum
vas 73% at the Ural plant in 195160 Fa% at the Stalin plant, 75%
at the Dneprevek plant, 412% at VOlkhov, 71% at Nameker, etc.
The movement of leading workers and innovators which spread
among workers la the basic and auxiliary occupations has played
an enormous role in reducing the production coot of aluaimum.
deoisive improvement in qualitative indexes, the liquidation
of losses from umeconomic and nonproductive expenditures, the intro-
duction of economic accountability within the plant, the increase in
labor productivity based an a further adoption:of the lit, at achieve..
ments of science and technology, improvement in the forms and methods
of production and labor organisation and the all-round study and
dissemination of the upp?taidate practices of innovators are the
necessary prerequisites for &further reduction in tha production
cost of aluminum'
Chapter V
PROSPECTS FOR THE FURTHER DEVELOPMENT OF THE
SOVIET ALUMINUM INDUSTRr
# .
I 1 ?
witalivaTY Aszgx&satealtaL
Plans for the-future devalopement of the aluminum industry are
determined by the reqiired scale and rate of developetent of the
national economy and its overate branches.
As indicated in Comrade Ihrusbohovis addrese delivered at the
Teenty*first Congress of the CPSU ca target figures for the develop-
ment of the Soviet national economy during the period 1959..1965,
aluminua has in recent years been acquiring creator and greater
importance as a metal for diversified use in industry and construc-
tion.
The seven-year plan aims at a 24.13 fold increase in aluminum
production.
Any substantial increase in aluminua output must be based on
the construction of nee planfut-
- 97
immmw
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
31/
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
The location of anterprisan in tbo *lamb= industry is
determined by a number of factors characteristic of all industries
requiring large energy consumption. Among them are predominant1y
branches of heavy industry which play an important role in strengthen-
ing the industrial and oommercial potential of the country, ispeeifi-
?ally the aluminum, zinc, synthetic rubber, magnesium, and liquid
fuel industries, etc. Their expansion OM be assured by an enonsous
increase in the production of electric power.
The current sevewear plan is a decisive step in carrying
out Lenin's concept of the over-all electrification of the country.
In 3.965 the production of electric power will increase to 50D-
520 billion kilowatt hours, is. from 2..2.2 times greater than in
1958; the established capacity of electric power stations will more
than double.
In this connection considerable importance is attached to the
problem of the effective location of the powers.consuming industries.
The location of the different branches of industry is influenced
by the nature of the technical processes involved.
The nature of the technical processes involved in the different
energy-consuming industries is not identical.
However, it is possible to isolate features common to all these
induetriest a high consumption of different types of power per unit
of production; the great portion of the cost of power equipment
in the total coat of the fixed emits; the large peroentage of
power expenditures in the production cost; the high level of power
requirements per worker.
The relatively great expenditures for power among the production
expenses of industries using a great deal of electric power renders
most important the presanoe of major sources of cheap power in deeiding
on geographical location. The transmission of power over long distances
leads to increased production cost and excessive transmission loads
which reduces the possibility for expanded production in the national
*canopy.
Where there is great consumption of power the quality of the
power supply acquire. enormous importance since even with a slight
difference in the coot per unit of power (1 ton of ideal fuel, the
first kilowatt hour, 1 ton of natural fuel) the production cost
changes markedly.
- 98
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Tho small consumption of labor in the power-consuming Indus,
tries per unit of power capacity has exceptionally great importance
in thoir location in naa areas.
, 14 must 48.ft out not only from the eharaeteristics of the
specific power sour** but take into consideration its plate in the
total paver belanee of this or that area of the country, in clam
connection with the economic specialisation of the area. ?redia-
posing factors for the location of power-consuming industries must
be considered against the paver potentials of the aria as a whole,
in relation to their structure, and with consideration for the time
needed for assimilating available power supplies and technical and
economic factors of the individual power *cures* and the satire
power system of the area (individual capital investiments in the
construction of new power supplies, the production cost of power,
the degree of regulation, the cost at obtaining fuel and power
transmission). The power supply of an soonomie region is determined
by the balance method against the prospective development of the
basic branches of industry which define the speelalisation a' the
area and of other power consumers within a given area.
/nlocatingapower-oonstmiing industry we must atart with&
consideration of the industrial and mowed* complex of this or that
area.
The location of industries requiring considerable supplies of
power, subordinated to the principle of the nearest possible location
to power souroes, must start from party directives on the preferential
construction of new enterprises in the eastern areas of the country
where the richest power resources-are found as well as with the aim
of deconoentrating and evenly distributing industry throughout the
country yet keeping them clone to sources of raw material, fuel and
areas of consumption.
In the location of energy..consuming industries their structure
and the quality of electric power sources is of particular importanoe.
The production cost of electric power obtained from heatispower
and hydroelectric power stations reveals vita large fluctuations,
depending on the following ciroumstancess
natural conditions (size, shape and depth of coal seams and the
quality of coal, nature and quality of water and power resources -
regulation of rivers, pressure, eta.).
technology of power resource utilisation (production systems,
mechanisation and automatic control of processes, the adoption of
improved technical methods for utilising power resources);
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3 ?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
V
the size of the electric pc-irr. stations;
the level of organisation of proluotion at central electric
power stations;
the possibility of using secondary sources of power-waste from
coal preparation).
The location of power-consuming industries within the limits
of a eelected power system with positive economic features cannot
be (serried cut arbitrarily. Under these circumstanoes es cannot
omit ocasideration of the transportation of the basic types of
raw material or the possibilities for loading new centers of
ooneumptian or *enters with a labor supply. We must also take Into
oomsideration the technical possibilities and the economic feasibility
of electric 'power transmission.
Ebere transmission costs are high industries consuming consider-
able electric power are located near sour'ss of eleotrio power,
electrie 'entrel power stations, sinoe an increase in the cost of
electric power increases the cost of production in the industry
which uses the power.
A qualitative description of the somroe of electric power must
meet the requirements of the electrie power consumer with relation
to the pattern of the electric power supply during a 24-hour period,
a month and a year.
2.
? ? ?
The specific nature of the location of the alumina industry
is determined by the characteristics of the raw material being
processed, and by the structure and nature of the technical processes.
The aluminum industry includes three main production links:
the mining of bauxites or other raw material for aluminum; the
production of alumina; the production of aluminum by the electro-
lysis of oryolitralumine melts.
Subsidiary links in the production of alumina are the extrao...
tion of raw material containing fluorides and limestone, the produc-
tion of fluorine salts and the production of electrodes.
In the production of alumina great quantities of boat are con-.
mimed in the fora of steam for reheating and evaporating by-pass
solutions, for cooking the bauxite pulp in autoclaves and for re-
moving silicon from aluminate solutices.
100 -
Declassified in Part - Sanitized Copy Approved for Release
?
?41111/111ff
50-Yr 2014/03/21: CIA-RDP81-01043R004000180001-3
?
yobow
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
lasetrio pow is used at alumina plants far power purposes.
Sinai it requires steam of low and mediva potentials, the produc-
tion of alumina provides an advantageous sitmtion for the combined
production of heat and electric power,
The value of the location of the fuel supply as a aouroe of
industrial fuel and steam acquires great importance in the location
of alumina production since expenditures for power make up a rela-
tively large percentage of the production cost.
At the same time, under all methods of alumina production, the
material index:for ooeparison fuel is below the material index for
raw material and limestone take together.
The predominance of expenditures for raw material over expendi-
tures for power determines the practicality of locating alumina
plants near the source of raw materials. The greatest consumption
of material and power is found in the processing of a nepheline
conaentrate, thus inclining toward location near sources of limestone
since 10 tons of the latter is used to produce 1 ton of alumina.
When low-calorie fuel is used in processing nephelines, it may
be .quell-as decisive a factor in locating as the limestone aspect.
When locating for alumina production we must take into consideration
the districting of fuel consumption in the country and try to combine
local fuel resources with the beet local raw material resources.
The nearness of alumina production to alwainua plants has a
number of technical and economic advantages. However where favorable
raw material and fuel factors in the organisation of alumina produc-
tion do not coincide with polar tactors this condition is not obliga-
tory since approximately 2 tons of alumina is used to produce 1. ton
of aluminum while the consumption of raw material and fuel amounts to
8-26 tons per ton of alumina.
Where alumina is being produced from nepheline concentrates the
nearness of oement consumers is of particular importance since approxi-
mately 9 tons of cement is produced to 1 ton of alumina. The enormous
scale of construction operations in all areas of our country may
insure the sale of this side product from *luau& production; neverthe-
less in order to have the least transportation expenses it is desirable
to be able to dispose of the cement near the production site.
Thus on. of the most important conditions for effectively loca-
ting aluaina production facilities is the question of sine and loca-
tion of the raw material supply, the degree to which it has been
? 101 as
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
1'
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
studied geologiOally and the level of technology in alumina produc-
tion which determine the possibility for using wollknown minerals
containing alumina.
For this reason an appraisal of the alumina raw material supply
from the point of economic geology is a necessary prerequisite far
planning the efficient location of alumina production in our country.
The production of aluminum is a process requiring high oonsumpm
tion of electricity, making particular demands on the quality of
the electric power supply. The percentage of electric power onpsumed
is approximately 38,000 kilowatt hours (alternating current) per ton
of metal. The electric power is consumed in the form of direct our-
rent for technological purposes and in the An of alternating current
for power purposes. The electric power supply spites must be constant
with regards to current strength and voltage during the normal opera-
tion of the electrolytic cells and somewhat heightened in voltage
and lower in current form, during the period ehen the cell is being
pat into operation. The starting and operating cycle of the cells
le determined by the specific nature of the design of the cells
installed. Breaks in the electric power supply are inadmissable.
Frequent interruptions for short periods disrupt the operations of
cell series, increase the average voltage in the cell and cause an
increase in the consumption of electricity. Long interruptions in
the electric power supply lead to a cooling of the smelted solutions
and to throwing the cells out of operation.
The aluminum plants include large transformer substations which
convert alternating current into direct through mercury rectifiers
or motor generators. The percentage of the cost price of aluainum
represemted by the electric power factor fluctuates widely (15-30%)
depending on the cost of the electric power and the sive and organisa-
tion of the enterprise.
A reduction in the cost of electric pallier by 1 kopeck with
other conditions remaining equal reduces the cost of 1 ton of metal
by 180 rubles and allows the plant to maintain a capacity for 100,000
tons of aluminum per year for a sum of 18,000,000 rubles.
Where aluminum plants require very great electric power consump-
tion, great national importanoe is attached to the assurance of
cheap power resources. The transmission of electric poser over
long distances causes unnecessary expenses in the national econoey.
Aluminum plants must be located near cheap power bases and may
be located at some distanoe from the production of alumina and other
materials.
- 102
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
it
Thus the location of aluminum plants mat be oriented on
inexpensive and extensive po-r supplies vhioh rill assure the pro-
duction of controlled electric power.
The combination of alumina production with the electrolysis
of aluminum is a favorable factor in reducing the coot of the
metal (lamina loofas in transportation are reduced) but it is
net obligatory where extensive sources of *heap power are not
available in the area:shore alumina is produced.
Combination in the aluminum industry has a real meaning since
in this case there is a reduction in the production cost, transporta-
tion is mimed, there are fewer losses in raw, prooessed materials,
and elmifinished products, there is less demand for working capital
and the ums of fixed assets is improved.
Particularly effective is the combination of alumina production
with the electrolytio prams which guarantees*
the elimination of expenditures for special containers, the
transportation of the alumina and a reduction in capital investments
for special rolling stock; reduction in alumina losses from pulveri-
sation during transportation; reduction in the sise of varehouees
for the alumina;
considerable economy IA fUel used in hardening alumina since
where it is used immediately there is no necessity for deeper harden-
ing which is required for alumina which has to be hauled for a long
distance;
savings in capital imesbsents in subsidiary and auxiliary
items (repair, transportation, water supply);
consolidation of the power vete* and increase in its efficiency.
Ihere alumina and aluminum production are combined it is pradtical
to inolade a heat-power station in this complex to provide the neosser
sary amount of steam for alumina production and electric power for the
electrolytic process.
The shifting of a heat-power electric power station completely
to a heat-power schedule is feasible if there is available another
*aurae to provide electricity for the aluminum eleotrolysis and
where there are alumina capacities exceeding the alumina require-
ments of the electrolytic division in the wahine.
Prerequisites for the combined production of alumina and aluminum
may be the following factor's
1. The preeence of an extsusive fuel and power supply with
low-calorie fuel. In this eel* the production of alumina independent
-103-
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
4gst'S'i '"
????
of its methods of produotion (-4th tho =option of the processing
of mph:line concentrate) at be moved near the fuel supply since
la-coca:1=Jc fuel br;flee the fuel index up over all other indexes
in alumina production*
2. The presence of alumina raw materiel (bauxites, nephelines,
aluminites) in the region of the power supply center for the aluminum
plant.
Aluminum production can be efficiently combined with the produc?
tion of the anode material. This combination assures advantages of
a teohnioal nature in tarrying out the electrolytic process. The
reduction in the vinosity of the anode material following its
immediate use has a favorable effect on the electrolytic prongs.
As operations at the Bogoelmakeye and Stalin plants have sheen,
the import of anode materials was accompanied by pulverisation and
contamination of the briquets during transportation and storage
which mode the electrolytic process more difficult and led to a
deterioration in the technical and economical aspects of the cera-
tion of the electrolytic plants.
Under specific conditions, in the construction of enterprises
of the aluminum industry it is essential to take into consideration
the time factor, which can be demanding in individual ones in con-
nection with the necessity for the most rapid development of this
branch of industry, and not establish the whole complex in a single
spot all at once despite the practicality of combination. Under
then circumstances the required combination connections msy be
temporarily replaced by cooperation with already existing enter-
prises where the increase in production will require smaller capital
expenditures.
Practical sises of individual compasses in the aluminum industry
are determined first, by the interests of the national economy and
that of separate regions where the aluminum industry is to be developed.
The effectiveness of decomentrating new construction in a large nulber
of small places or of concentrating it in a small number of large
centers is determined by the following principles:
1. Technical and economic advantages of organising large alumina
or aluminum plants are related to possibilities for improved techno-
logy and apparatus (the use of larger production units) with more
complete mechanisation and automatic control of all proneness in
the basic and auxiliary divisions with len expenditures for admini-
stration and the auxiliary services.
2. A decisive factor in the concentration of the aluminm indus-
try (a complartof enterprises or separate production) in the trend
in the development of the differeot areas of our country. The
- 104 .P
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
finteunivo de-,701*--40,... of industry in the eastern pert of the country
lirlffski before the war has determined the meuesetty for findis: lune
sources of raw materials and power in this region. The priority
of selecting this or that ileum* for exploitation is determined not
only be the interests of the aluminum industry but by a 'bole complex
et objectives in the expansion of the economy of this or that region
(power, metallurgy, machine...building, chemistry, railroad transports.-
Um).
The degree of oonnentration of alwainue production near the
supply oft)* huge hydroelectric) power resources of Eastern Siberia
will be determined not only by the absolute size of the power supply
but by the eise of the develipment of other branches of this industry
and of the national economy as e.
3. Prospects for the Expansion of Alluminum Productipe
The importance of raw material resources in the expansion of
the aluminum industry is exceptionally greet. Oath* correct and
couplets solution of the problem of raw material in the alumiewm
industry depends the eelf.ssufficiency of the country in raw material
in a certain area.
As the result of systematic geological prospecting conducted
by the government in ell districts of the country during the five-
year plans, the raw material supply of the aluminum industry has
expanded rapidly. The Soviet Union occupies one of the first places
in the world with regard torus materials for aluminum. Compared
with 1929 the bauxite reserves in 1933 were 73:7 times greater, in
1936 13.1 times greater and in 1936 tens of tines greater (including
marked increases i high-grade bauxite reserves carried on the indus-
trial balance V).
As distinct from the slow and sporadic growth in raw material
reserves in the capitalist countries the increase in reserves for
the Soviet aluminun industry has taken place continuously. We suet
also mention the more uniform distribution of the reserves territori-
ally, the tendency to a decentralisation of reserves as distinct
from the increasing inequality of their distribution in the oapitalist
countries.
The explatation of separate sources of raw material for the
aluminum induatry and deposits in the Soviet %ion is taking place
in a planned fashion Olathe basis of a umiied econorl plan, in
particular the plan for the territorial orgeniseloa, .ct the winnow
and a oomparative economic evaluation.
105
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part- Sanitized Cop Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
&Name* rpilw illovered dmlng orcepostind Arm&
tions two also boiteg brought into use in a planned, erticiema aria
feshicet.
The increase in reeerras of ebaeinun rem nietoitetal 7,in be c=i
of the basic factors determining the apftific at of exposit* of
the eluninun Industri in the lenrrange plan for the develnyeesett
of the Soviet national ineoacer.
The task of developing the raw material sopply suet be solved
with a view toward assuring the aluminum industry the rssourees
needed for producing the greatest icaouiet of aortal in the shortest
ties ant at the lowest cost in the ecesonically ;referable areas
of the country.
The Soviet Unice poeseesse rioh awl diverse scertes of alusinine
raw material ehieh assure the extensive deve3.opeent of the Soviet
addle= industry. Bauxite deposits have beset dissovered and proem
peeted in the Northers, Central. and Southern Urals, in lenthgred
and Vologda Provisoes, in Central Naesidastaia, inWris4'4i*64011a,
In Krasnoyarsk Territory and in the Ukralee*
The development of a large aluminum industry In the USSR
and the increase in the *sale of aluaina production coonected with
it have required the expansion of the raw material suppli for the
aluminise industry,
Until reoently the basic raw material fcr the production of
alumina was bauxite. This can be explained largely trina the fact
that the 417211Lialli oontent of the 001/11118rell1 grades of bauxite is
higher and the silioon dicalle *content laser then in other aluminum.
ores. However, in addition to bauxites, industry will be able to
use other types of nonbauxite raw material with satisfactory technical
and eviceksio results. Haar types of nonbauxite raw naterial has the
advantage over bauxite in containing in addition to alineinun oxide
other useful elements suc&i as, eadiun and potassium in nepheline,
alkali ani sulfur in *lumina*, etc. Tor this reason the Industrial
proeessing of these ores into aluaina is quite feasible mod quite
advantageous, despite the lower content of aluminum oxide, if the
promising is done by a ocepound method, i.e. not only the alued.raie
codds but the other valuable ?deponents of these ares are also
One of the typo* of raw material for producing alumina are the
nepiielines. The largest nepheliner.sienite deposits in the world are
las
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 ? CIA-RDP81 nzv;Pnnannn szt-Inn ,)
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
loentedin th Kole.Pt7r Iii+ton, .
containing rocks have been found in other areas of the Soviet Union,
in Xrasnoyezak Territory, in the Armenian Set, in the Ukraine-, in
Transbaikalie and other places.
A main, source of nepheline raw material of commercial important*
are at pre*** the nepheline waste fraa the concentration of apatite..
napholine are.
as raw materiel for the prOduction of alumina, are
of a loser grads than the bamdtes (in aluminum adds content) end
for this reason they can be utilised profitably only by compouni
prooassing with the simultaneous extraction of other components.
As the result of years of research in the Soviet Union a 'method
has been developed and adopted in practice for producing aluminum
oxide, alkalies and cement from nepheline..
When nepbelines are utilised the capital investment for the
production of the soda required for alumina is leas inasmuch as
the nephaline processing utilises the alkali coming free the
nepheline itself.
The principal advantages of the Xola nephelines as a source
of alumina sires
1. Nepheline tailings from the apatite concentration fastat'y
exclude the necessity of expenditures for airing, grinding and
2. The uniformity of the chemical composition of nepheline
tailings *assures a constant technologic*1 process in the pro:tactics
of alumina araich to a great degree facilitates production (o,.,
the processing of imuixites)
3. In prooessing nepheline the only additional raw material
needed is limestone *Ile the yrooessing of bauxites requires sods,
lime and other proonaged materials;
4. The yearend* of zakalies in asphalt* makes it possible
not only to do without soda in processing but makes it passible to
obtain caloined soda and potash as by-products'
5. The production of cement frost waste slags in nepheline
processing.
At present nepheline concentrate is being successfully processed
at the VOlkhov Aluminum Plant,.
Tho longwrange plan for the expansion of the aluminum industry
aims at oonstrusting alumina plants in a number of areas of the
country on the basis of the nopholine raw material supply.
107
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Also included in the complex ores are the alunite.; thry are
found in thick and compaot masses along the oerthts ourfoco *Leh
makes their mining in a largo scale by the openepit method muoh
easier and simpler.
The tots' amount of useful components in alunite rook mobs@
50..55%.
The procossing of alunitea for alumiwdoos not require oxpendif
tures for soda as is necossary in the case' of bauxites.
Rxteonsive rooecroh has been done in the USSR on the compound
processing of alunite rook. An the result of research now being
done a method for the compound processing ofZaglik alunite or.
into alumina and other produotm has been selected.
The rapidly growing requirements of all possible branches of
the national economy for aluminise. and aluminum alloys is leading
to the necessity for rapid growth in the production of alumina
in our country. The curront method of producing aluminum by electro-
lysis of oryolite-alumina melts is extremely complex, requires the
consumption of large amounts of *amino, soda, fluorine salts and
electrodes.
Capital outlay for the equipment for alumina plants, transformer
substation and elsotrolytic Shops is extremely high.
All this makes it necessary to expand the aluminua industry
en the basis of now and simpler production methods and now types
raw material.
The greatest amount of aluminum is used in the fora of alloys
with other metals.
The basic alloying natal in aluainum alloys for casting per-
poses is silicon.
Silioln is produced in the Soviet Union by smelting electro-
lytic aluminum with silicon. In this connection attention should
be given to the fact that at alumina plants a Urge amount of labor,
energy and material is expended on silicon removal. At the OM.
time tho silicon must be reintroduced into the aluminum to produce
silumin.
1011
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Thia contradiction is partially or *oily elitlinated zhon
aluminum-silicon alloys are produced by the elsetrotberaal method.
?be electrothermal method for producing silumin is particularly
useful in utilising natural ores containing aluminum and silicon,
through bp-passing the alumina production and Aluminum electrolysis stages. The prehlem of producing silumin by the electro-
thermal method has been worked on for a number of years in the
Soviet Union. However until recently the electrothermal method
for silmato production had not been applied in practice.
Anhievements in the technology and equipment used in elootro,
thermal methods for producing aluminum alloys as loll as progress
in the concentration of raw material are making it Possible to
consider material with a high alumina content as provisional raw
Astoria for the production of aluminum.
As already mentioned the Soviet Unica has very rich reserves
of raimaterial with a high alumina content. Deposits of raw
materiel with a high alumina contest are known in the various parts
of our country.
The use of raw material with a high alumina content in the
;reduction of aluminum will greatly expand its raw material reserves
and make it possible to organise aluminum production in a number
of areas with power resources but without local sources of other
types of alumina raw material.
The introduction of electrothermal methods for producing
aluminum and *Inatome alloys will *inure an increase in metal out-
put, a transition to metallurgical aggregates of greater capacity
with a high coefficient of energy utilisation, a simplifioation of
technological eyeless reduced cost of production and achievements
in higher labor productivity and savings in capital inveatments
through the elimination of the alumina production stage. The
introduction of the elsotrothermal method in the aluminum industry,
i.e the production of aluminum directly from ores by direct reduc-
tion in electric furnaces, assures a reduction in capital expead1r.
tures hymen than a third and a reduction in operation expenses
by almost 20%.
This increase in the production of aluminum in the eastern
part of the country on the basis of cheap electric paver fres large
hydroelectric power stations required the creation there of an
extensive sour** of supply of aluminum raw material.
For this reason great Importance was attached to prospecting
in t4leao areas and to technological tests of other types *free
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 ? CIA-RDP81-01041Rnn4nnn1stnnni
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
tl
sateriali for ol?--ntis with the ain of bringing them into industrial
utilisation se rapidly as possible as had been foreseen br a. number
of +...b.e govorrmontla decrees. In Krasnoyarsk, T.-wit-Grs.
inokbaustible riches of nepbeline granites and a number of bauxite
deposits have been discovered.
Further study of alumina raw material swerves and continued
research on' deposits already discovered in the eastern part oft's,
eountry as well as ?calmed research in the adoption of nonbauxite
processing will make it possible to provide raw Astoria for the
fast?growing demands of the aluminum industry and bring it closer
to power sources thus contributing to the rational geographioal
distribution of the aluminum industryithildh is a, most important
factor in the expansion of the production forces of the Soviet
Union.
During the seven-year plan for the expansion of the national
economy of the USSR for 1959-1965 the Soviet people are fatted with
major objectives in expanding production capacities and in increas-
ing the actual output of aluminum and alumina.
Extension of aluminum produetion during the next years will be
based largely on the use of power from the rivers of Eastern Siberia,
tb. ftal reserves of the Kusnetik Basin and Eastern Siberia, bauxite
deposits of 'Was Easikh SSA. and the over..-all processing of mph...
lines from Eastern Siberie and Yaglik alunites. The use of now
complex:types at aluminda raw meArisl will make it possible to
produce soda products, moment, fertiliwers, sulfUrio Aeid and ethers
along with amine.
Kew enterprises of enormous oapacitibs will be built and put
into operation in the eastern part of the country. The great
growth in the power capacity and cheep electric power of the *astern
areas will create favorable oomditions for the expansion of aluminum
production.
A large aluminum industry will be developed during the new
seven-year plan in Krasnoyarsk Territory on the basis of cheap
electric poser from the Krasnoyarsk Hydroeleztric Power Plant.
The cost of,alumina will be 404 lower than in loading extant plants
in the Soviet Union and the east of aluminum ii111 be 25-.30% lower
than the cost of aluminum now being smelted.
As indicated in the report by. N.S. Khrushohev at the Twenty.-
first Cowes's of the CPSU on target figures for the development
of the natiomal economy during the period 1959-1965, the rolative
role ef the eastern areas will increase to 71% of ths taa tilatbara
production by 1965.
t*.:AIMEAMEVAIIMPF
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
it
Ii
f.
Aluminum plant, plan to inatall electrolyze= of hiel espeel-
tics with cvarhead current load-in and with reehenisation and auta-
natio control of the electric cycle of cell operation.
As the result of new, IWO unifara and efficient placement of
enterprises in tho aluminum industry transportation expenses vill
be greatly reduced.
The reduction in the production cost of aluminum will also be
furthered by. increased compound utilisation of raw material, produc-
tion masts, and better extraction of rare elements found in signings
raw material. The cost of alnminum will drop by approadmately 20-22%.
The lames.* in the role of the eastern areas in the total metal
output sill be an important fainter in reducing the cost of aluminum
since the cost in the factoriom of Eastern Siberia will be oonsider-
ably cheaper than in other Eases due to the low cost of electric
paler.
Along with the construction of new plants there will be an
important increase and improvement in the utilisation of the oapar,
cities of enterprises already in operation. Existing plants must
turn out more than 25% mime alumina.
The creation of a large aluminum industry in the USSR will
contribute to progress in toohnology in many branches of the national
economy, to intensified expansion of branches producing the means of
production, will strengthen the economic and defense might of the
country and l *sealants the move towards oommunime.
/go
O0 *
150
100
so
as,0
0;104' fit fgh3 191,4 111190
Fig: 1 Changes in the production capacity of bauxite mines during
the period, 19414945, in %.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
74 I ,
1941 /94 19.173- Nix rA5 146 i94,7 :yi-rg 1943 19507951 11;!)
/7.73u
Fig. 2 Changes in labor productivity in cubic niters of rock in
vmdergroded operations, 19404945.
4 Per *tope worker 2. Per underground worker 3. Per surface
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Fig. 4 Production cost of 1 ton of bauxite during the period 19414950
by open-pit methods in % of underground methods.
240-
Pig. 5 Changes in the cost of one ton of bauxite during the period
1941?1950, in
1. underground extraction 2. cost by underground method
3. open-pit method 4. average
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Ypanoceua
1 2 3
rj L4 EMI
Nal/Agoura
Fig. 6 Structurs of the Production Cost of One Ton of
Different Planta in the period 1940s.1941, %.
1. ram material and principal preowned materials less
2. auxiliary materials; 3. fuel; h, steam power; 5.
power; 6. water; 7. wages.of production workers; 8.
all-plant expenditures.
musts products;
eloctric
diviCion'and
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
-
?
Fig. 7 Manama in expenditures in caustic soda represented bathe
cost price of alumina at the Ural plant during the period 19414956p
%s 1. expenditures for caustic soda in the cost price of 1 ton of
alumina,' 2. Consumption of caustic soda per ton of alumina; Cost
price of 1 to of caustic soda.
- 11.5
Declassified in Part - Sanitized Copy Approved for Release 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
4r.
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Fig. 8 Changes in expenditures for magas in the oast price of one
ton of altssina at the Ural plant during.the period 19414956, ST
port4to,of alumina coot price devoted to Images
2* aveil ----gely_mage of ivorkma______
1
1
/ I
1, ; -1
i .... .,. ;'': .
1
'- P:-.. , /- :? i i
\ /
iii
i
I \
II *
i "i',..?; ;
I \ '
I \\
! \ \ \
RII ! I
I
I
I I
1 1
1
i
1 i 1
1 i I 1f
I
____L 1
- - I
, 1
_i_
194 I'." !:%411 '::-.:+- - -A IL' -
,.,- - ... _... ...
/lg. 9 Changes in expenditures for managing and maintenanoe
producing one ton of &baba at the Ural plant_ in 19414956, P
1. section. expenditures In producing one ten' of alumina
2. (111-plant expenditures in producing one toi2 of alumina
116 -
to ?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
101
140 r
/2171-
70
/55,6
p.
10.
C4". t.
Rkt
Ylip..-41 I \ti
\ I
gc . I
? ? I It
'743,-- 1 I.
I 11
I I , 1:51
11 I
'I- -1,7 i I
1 1
t
,
i
A-'
IW
?
,
? -
;
1
775
go
dOL
I
I-
---/7',
I i;/
I
1 .
- ,--,-,?-_,
1 .!.."
!;35
5 47, 7- 7 i2Tirr..17157-71.744;
SIR
- - 2
Fig* 10 Changes in expenditures for
lamina as represented in the Fro-
duction omit of 1 ton of aluednum
at the Ursa plant durf..ng the period
194049560 1. oonsamptioisof
alinina per to of alumina;
2. oost.'of 1 ton of altaina 3. or*
pentit*es for a3.untna represented
in the px?oduotion cost of 1 ton of
aluminum.
-- -2 -
1
1.;'4',1112:d.9 /950 ,v55 5.
I
I
Fig. 11. Changes in expenditures
for lamina represented in the
production otost of 1 tom of
al.uminm VICS itakn'a plant
during the period 1940..19,6* %t
1.coneumption of alumina per
ton of aluminum; 2. ooet of 1
ton of alumina 3. expenditures
for alumina represented in the
production coot of 1 tan of
alumina.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
,
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
_
'',?:?:42.4:..., -,?47...-cr-?,,---
IH---"--?-?''
.VOr
1
..-'412;-
1
i
-
4-
li 2.4 a
1 /
I! t
I 1
i 1.1
I222.1 Ili]
I.I i
I 'I'
I I 1
I I !I1
I
I'
I, !
0 I
t t t
t:
1 j
t 1 1
ii t it.
I i 1
.;!
i I ;
.;;. ? ?.. 1 ; i '
o'?, /
'', ?. I . 1,:. I 1! I, '
1251 1
) 1
1 ,?:? _I':"1.? -1 v'.6 1 ; i I I \I
,
8C L_ !!,11:III11877
, . 1 i____i_
L Al S'1717-9-...2 dij IS't4le V-3-7`'.1.???4; .?.:4,Tif:,-,-97sv.,,2
?I -----2----g
Fig. 32 Changes in the expenditures for
alumina represented in the production
cost of 1 tom of alumintai at the Volk..
boy plant during the period 1949-1956p
Ss 1., consumption of alumina per to
of aluminum; 2::,ocat of 1 ton of alum-
Ina; 3. -expenditures for alumina re..
prissented-in_the-Produation cost of
1 ton of aluminum&
- - ?
40i
701
^
/AU
,-"k 134
it%
l
/
Il I
/
,
11
?'
I
I gy PS..i
I
I v.
737
77
19?21.7 4;41 49,4 Igo? 4.946* 1947194S 1.9k9 g O .95.7 :9-fe
Fig. 33 Changes in experdt.
tures for alumina represented
in the produation cost of 1
ton of aluminta at the Dneprovsk
plant during the period 3.940-
1956, %s 1. consuap4ion of
alumina per'tod of aluminum;
2, mist of 1 ton:of alumina;
3: exPenditurei-for.alumina
represented in the4Toductica
cost of 1 to or aluminum.
,
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
_
/pi, /07,7
),
- ? ? 3 ,
-- 1937
925
????. 441
188;
1
N 'i44 /WI ie "-N 7 9 fi 742 /95o Igsr
ra3e,
272
II
.711
II
?.-.. ---2 ---3
Fig* 14 Changes in expenditures for
electric power as repreeented in the
production cost ofone tan of alumi-
num at the Uril plant during the
period 29414936, in %s 1. consuaT,
tion of maestri(' power per ton of
aluminua; 2. coot of 1 kilowatt/
hour of electric power; 3. ex-
penditures per ton of aluminum*
219-
51.4
k95.5
\ T
\:4?11.7 :18;
t7-1-1z.
?
237
\
\ I
\ 52
J417
*93 ?*4 45 , 4e; 997 '34 1953
-1 ---2 - 2
Fig. 25 Charges in expenditures for
electric power as represented lathe
production cost of 1 ton of aluminum
at Stalin plant during the period
194301956, in %s 1. counumptl.on of
electric power per ton of aluninua;
2. *oat of 1 kilowatt/hour of oleotrioitYl 3. expendituxee per ton of
aluainua.
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
9
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
1;. . i
II I \ C?
li ! \
1, ii i ? \
i,. ' 1 \
li !
II \ \
!
1
.... - I. 1
?
. 1
..-----.-.
1
--/' -.... .........../29 % 128 I!
....
...-- .-
..-
.../. -- "-
.--?
----? ..- ..---
V5.4 I!
-
1..
fita,-
E - ? ?T' .J99.2 :
N
99.2
1;1,4 _4? l___L______ __- _ _I . --_
/7275-- .',.. I -/.94'.; iS14./ 1$74-, r.:,5 oil --isi.c, -7.-?,i- .,?,,:;. s.5o 795;
? ----- 2 -- - 3 raid
Fig. 16 Changes in expenditures for eleetrio power an represented
in the produstion cost of 1 ton of aluminum at the Volkhar plant
during the period 19404956, in %I 14 oonmumption of eleetrio
power per ton of aluminum) 2. oost of 1 kilowatt/hour of electricity)
3. expendituresvm-ten-of_aluninua.
I.19:7
/ / ..' '?
. .
. i
1
)133
_.2
Pig. 17 Changes in expenditures for electric power as represented in
the produetion oast of 1 ton of aluminum at the Doeprowsk plant in
1940i 1950, 1956, ittP 1. consumption of electric power per ton of
alumimii4 2c coot of 1 kilowatt/hour of electricity; 3. expenditures
per ton of aluminum.
120
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
I
?????Ir?
? ?
PO)
!
.2 L _?. _____L__L___ L_?____L. I
...1 ,
-, .... ; -.4.- 42
?..
,s. ?????...
??..-1"% '',Ctl. -Is'
.........
k
-5
Pig. 18 Price of 1 kilowatt/hour of electrioity at different plants
in 19% by comparison with the Ural plant*
alz
Fig. 19 Consumption of electric power per to of metal at different
plants in 19% by c caper ism with the Wel Aluminum Plant.
- 121 .*
.g
_
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
-
,
?
?
[
U
'1
V
97
91 :ill 6 g7
?
N. 91.8
824
A .
g?Cfl
50
342 1943 1944
1 2
-
,1224 CO
? ? ?
97?ss7
91 91
8
9r
?
_
_90
; ?
85?5
It
IV5
?1110
11:1f5
,
V71,
??
1.'74
/
/06_
J_
,
i
.120
_
1945 1945
fo&I
1947
P248
191/9
/9$0
1955
?
Fig. 20 Principal power factors in the operation of electrolytic
cella at the Utal.plant during the period 1941,4936p in p
1. currant 2. average voltage in cell 3. output per current unit
4. output per energy unit. 5. output per cell per day
Declassified in Part - Sanitized Copy Approved for Release
?
- 122
50-Yr
2014/03/21 : CIA-RDP81-01043R004000180001-3
;?./
t
?
vkx
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
Fig. 21 Principal power factors in the operation olwelectrolytic
cells at the Stalin plant during the period 19434956, in %$
1. current 2. average voltage In cell 3. output per current unit
A. output per unit of energy 5. output per cell per day
to 123
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
I 77.5.
Z17
_
I -F
? -
5
Fig. 22 Principal power factors in the operation of electrolytic
cells at the Oneprova plant during the period 2941.1956? in %s
1. current 2. average voltage in cell 3. output per current unit
A. output per unit of energy 5. output per cell per dei
141 t / '
I 44,
i ire ,
\\,...: ---....
Z .
:t't
7
i , f
.,,
,1.4)
,I7:.,?-/
-/ 2
'Yr
Fig. 23 Principul power factors in the operation of electrolytic
cells at the VOikhov plant during the period 1941.19564 in %I
1, micros* 2. average voltage in cell 3. output per current unit;
A. output per unit of energy' 5. output per cell per day
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
?
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
t,.
70
_
,\1/2,1
,
/ ...
\ 10S,4,
-- ? "" - 47/1 4711
DM .1241 471
. VV." - - - ----,' -,,--
- _ -?-_ __ _....
v
420 it12 4f7/ i'l
976' /lir* - - -
-..,
/ N,
/ .9:,
?.,
1
? 47,
Si
r
NZZ
cal
rocrileneta Cflat ritrmsaatil Aie/7roxA7fli &Amin:owe Abdecritmuf
HoArkwaxwartal
loocrim
Ural Stalin Volkho: Dneprevik &maker Kanaker Fandaleksha
#advoitsy
Fig. 24 Power factors for different plants in 1956 by oomparison
with the Ural Aluminum Plant, in %;
1. current: 2. output per current unit 3. output per unit of emery
4.4. output per cell per day
Declassified in Part - Sanitized Copy Approved for Release @ 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3
1
gir
?
'I., Ix
7 till
ss,
97,5 ,
i \.' ? 1
\ \
I
1
9(1 \ \\ 1
N \
\ . 1
\
8C
7:$
\ 1
1
\ \
A
513
se:
3- -
Pip 23 Changes in soctional expenditurres as perm:tags' of the
production cost of 1 tan of aluminise.
1. Ural plant 2. Stalin plant 3. Volkhov plant 44 Dnoprovek plant.
5070 THE END
- 126
Declassified in Part - Sanitized Copy Approved for Release ? 50-Yr 2014/03/21 : CIA-RDP81-01043R004000180001-3