(Sanitized)WORK AT LEUNA(Sanitized)

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP81-01028R000100100009-0
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 15
• Document Creation Date: December 16, 2016
• Document Release Date: September 27, 2004
• Sequence Number: 9
• Publication Date: April 21, 1952
• Content Type: REPORT

'FRP,
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COUNTRY .
SUBJECT :
PLACE
ACQUIRED:
DATE
ACQUIRED
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Approved ForReggelOWARtigt-WPAGYReqRCH
INFORMATION REPORT
Germany (Soviet Zone)
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Work
at Leuna
DATE OF INFORMATION
THIS DOCUMENT CON.TA /NB INFORMATION AFFECTING THE NATIONAL DEFENSE
Of TNE UNITED STAY* WI THIN THE MEANING OF TI TLE IA, SECTIONS 793
AND 794, or Toe. o.o.. CODA, AI AMENDED. ITS TRANSMISSION DR RAVE.
LATI?N OF ITS "0E0,14 TO OR RECEIPT NY AN UNAUTHOR I ZED PERIDN IS
PRON 99999 D Of Cal. .TOC. REPRODUCTION OF THIS FORM IS PROHI BI TED.
, .
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NO.OFENCLS.
4LISTED BELOW)
SUPPLEMENT TO
REPORT NO.
THIS IS UNEVALUATED INFORMATION
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Introduction
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This report covers
the following topicsi
1. Organization of Leuna
2. Production of Nitrogen and Oxygen
3. Production of Argon
4. Production of Brown Oxide Catalyst
5. Hydrogen Purification Plant
6. Production of Black Oxide Catalyst
7. Ammonia Plant
8. Production of Ammonium Sulfate
9. Production of Nitric Acid
10. Production of Methanol
11. Production of Ethanol
12. Production of Higher Alcohols
13. Production of Trimethylol Propane
14. Production of Perlon and Nylon
15. Production of SS-Oil
16. Production of Lupolene
17. Production of Pharmaceuticals and Antibiotics
18. Research Projects at Leuna
19. Bottlenecks at Leuna
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DCY 1951,
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Araanisation of Leuna
Production at,Leuna io claosified under a number of divisions, as
follow/es '
(1) Low Pressure Division - formation of mixed hydrogen and oarboe
. dioxide by water-gas shift reaction. '
(2) Nish Pressure Divioion ? oompresmion of mixed'hydrOgen and oar..
bon dioxide, romoval of oarbon dioxide, purificition of hydrogen,
produotion of nitrogen, oxygen, and argon, production of emmonia.
, , ? .
(3) salt Dirision ? production of fertiliserdroudh as amnonium
. fate (formerly, production of nitric acid, fuming nitrio, and
Calcium nitrate).
"(4) Hydrogenation Division hydrogenation of coal and tar.
(5) Arsenio Division . production of methanol - isobutyl 'oil, produo?
tion of methyl amino, and catalyst plant in the north; production
of lacteal, urea, lacquer, msrsolate, and catalyst plant in the
south.
(6) Workshop Division . repair and maintenance
In addAtion to these divisions, there are separate units for purohas-
ins,4410,t control, and the central research laboratory.
It should be emphasised that prooess research is usually conducted at
the plant in the division concerned, rather than in the central re?
search laboratorr 'Whore emphasis is on fundamental reosaroh up to
pilot plant stage.
2s etois....sd.pattsoa
#4. Nitrogen and oxygen are produced at Leuna in Linde equipment.- The by
gen is 90-96.5% pure and must contain no more than 0.4 acetylene for
safety against explosion. The quota of fixed nitrogen production at
Lonna was set for the year 1951 at 225,000 tons, *Yr 700 tons per dors
This quota is to be raised for the year 1952 to 265,000 tone, or 725
tons per day. Ay the end of the five-year plan it is to reach 310,000
tons, or 050 tons per day.
'1),v Aetna], fisurso,for the first six months of 1951 for Peroontags Oonvor*
sift of synthesis gas to ammonias and resulting production of fixed.
nitrogen.. in tons per day, are as followos'?
Metric Tons Nixed
1211.,... Y.;45xasettl vitremlualtim.
...
January
91.6
717
?Ornery
942
725
Narch
92 .6
735
April
93.1
725
)14
93.0
735
June
92.7
74,0 '
2hoinota for-the third quarter of 1951 Wail sot at 715 tpns per (11.71
while tho lest quarter was to provide 725 tone per dsE. pe fulfills
mint of the quota depends entirely on the amount of10i4iiesis44o,
which depends on. the gas 05sProesPrs that haws always been :the bottles
nOok of prTauot.)
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It would seem that the quota of the fiveeyear plan enntot be met
without newor 'additional machinery. Laws has elready oalvaged all
possible old equipment, and new equipment oannot be raised in the
Soviet Zone of Germany. It was announced that throe ovens, Oafish ,
800 gm in diameter and 12 astern high, were stored in the Wept Zone
ready for ohipment, but under preeent oirounstandee it is unlikely
they will be delivered.
Juitauga.avams
a. Argon is not available in the Bast Zone of Germany. It ie needed for
welding oopper and perhape aluminum and other metals whiehrequire an
inert atmosphere. It prevents oxidation and the formation of metallic,
nitrides during the woldins promos., A profemeor at Halle is using
argon for welding experiment's.
b. A project for argon manufaoture is now under way at Lonna. The off
gales frog ammonia eyntheois contain a 30% mikture of argon and
methane, and a 70% mixture of hydrogen and nitrogen. By (Impressing
these off, ga000 to 330 atm, and reacting to sive additional 132120Aill,
the argon-methane fraction is increased to about 401445% of the
residual gas. Lonna propoies-be separate the argon by treating the
gas with liquid ammonia and/or' by liquifying the gas in the oxygen
plant and fraotionally distilling.
e.
The argweeparation project in in the research laboratory of Lonna '
KW 14 and is under Dr Bankoveki. Dr Gross, chief of the ammonia-,
Plant. and Dr /Mute, chief of the Linds.mgon plant, are oollaborat-
, in/ with Dr ?Beafgoveki who MI assured me Lerma will preduce argon on
a full scalo within 1 riwel?
?E909,?19.11-9A-VolfILSX4.40,SettklY0.,
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Drown oxide wotsr-ges shift.reactien catalyst, now being made at Louna,
contains about 90% ferric oxide, 60 chromiaM-mesqui-oxide, and water
and other tm ities. The method of production le as followsL.
Pielpeure (JJ
(1)(1)
, This catalyst is Used to convert carbon monoxide in wator.las to
carbon dioxide and hydrogen by reaction with steam, thereby. in.
creasing the hydrogon concentration.? The carbon dioxidexmn be
removed by abno.fptiom:A whow at 2e0 under a pressure of 23 at.
t Topic aa 4spo3?t Water-Oaefthift
eaction under, Pressure using Fixed and Plutdised Beda2
(2) This catalyst was formerly bought from Oppau._
- (
.37W4441241414191tur. Plaq
At Leuna, the capacity of the hydrogen purification plant is calculated
on the beets of equivalent oynthomie gas, which.eatains three mole of
hydrogen per,iol of nitrogen or 75% hydrogen by'voltme: On this basis
the produotion of the hydrogq.aprification plant is 110$000.120i000
normal cubic meters of synthesis gas per hour. Although .the oapaept7
of the 'Washers Is about 150,000 cubit, meters per hour, the capacity of
the plant io limited to 150,000 cubic meters per haler,. which is the
capacity of the copper solution regenerator, the present bottleneck in
protraction., 4onwersion of synthesis galvto ammonia runs slightly
bettor thwa:92%, which is equivalent to about 720 tons of fixed nitro-
gen per Av.
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During the month of June 1951, the total cosi of running the hydrogen
litrification plant was 470,900 Bast Zona German
112,000 were rental to thA, Soviets. About 30% of the'total dost .
Aght into salaries and wages. It presently takes 000'16 East Zone ,
German Marks to buy one US Dollar, as oontrasted to 4.19 of the West
Gone German Marks.
ei Dig Img Eule is the present chief of the hyArogen purifieatign
plant. Method of production is as follows Liee Enclosure (Ws
4*,
(1) UnpUrified hydrogen containing 11?2% carbon Monoxide and Small
ageOginta of oxygen, hydrogen sulfide, and carbon dioxide is, wasted
to remove carbon monoxide, qxygen,hydrogegvoulfide, and somirof:
. the carbon dioxide in high-pressure cOpper-solutien washers (1)
'Pirating at room temperature and a pressure of about 230 atm.,
The -exit gas is analysed for carbon monoxide content by a con-
tinuously recording "Ultra red analysis scriberras".
(2) The carbon dioxide in the exit gas is removed in a high.lressure
ammonise4olution washer.(2) operating at room temperature and a
pressure of about 230 atm. The entering, solutiOn, containing
about 25% ammonia, is recycled by the ammonia 'solution prefigure
pulps (6), and the ammonium carbonate solution foisted in with-
drawn and piped to the ammonium sulfate produetion plant* The
pure hydrogen, containing less than0.01%, carbon monoxide, is
-piped to thmamMonia plant. .
(3)
( )
The hydrogen purification plant for the hydrogen usedAn Amiga&
synthesis is houmed in Ieuna Bldg ME 106* (I might add that the
hydrogen' used for hydrogenation of petroleum residual fractions
i. purified, in a separate Leuna Bldg, ME 333.) The copper solu-?
tion washers are mounted in a row outside and alongeide NE 106
with their corresponding control panels inside the building.
These Washers are all constructed from a low chromium steel, about
2% chromium, since ordinary carbon steel would decarburise4.714!
the hydrogen*
The washers are all 12 meters high, but of two diameter*. There.
are about .18 "normal washers", 500 mm in diameter having a ompao
ity of 4000-5000 cubic meters of synthesis gas per hour, and
about 5 of the "800-washers", 800 mm in Aisieter, having a ca-,
Witty of 10,000-12,000 cubic Meters of Mynthesis gas per hour*
Tetal capacity is _equivalent to 26 *normal washers"* Each
washer is packed with three layers of sheet iron raochig rings
which are 45 mm, 60 mint and 100 mm in diameter, with the larg-
silt forming the bottom layer* ?
%.?
The oepper solution is regenerated at a rate of 40,000 cubic
meters per hour in the following manner: After passing through '
circulating pump (3) it is reduced from 230 atm to normal pres-
-sure it expansion machine (4). There are four of those?machines,
each. having two cylinders of 700 and 800 mm diameter reppectivelt,
made of carbon steel. The solution thou passes to surge tank (7)
..and on to 114011UM vessel (8) and decomposition vessel (9), beforii
tottering intermediate vegetal (10). These three vessels are all
of carbon steel and each has a volume of 24 cubic meter* .4.isO0M7
position vessel (9) is steam heated and operatec at 40 C. Inter,
,mediate vessel :(10) is connected to a holding tank (11) of 80
cubic meters capacity. Regenerated oopper solution, containing
0.12 mole cuprous and 1.2 mole cupric copper per 100 comp is
tooled to room temperature in heat exchancer (12) and is recom-
pressed to 230 atm by the use of expansion machine (4) pluo
boester. pump (5). There are six booster pumps in the plant,
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) :The carbon monoxide rich gas removed from ?easels. (8)4. (9)4
0,0_(10) by means of vacuum pumps (13) is washed with: ammonia
solution in, washer (14) and piped to the water-gae
,
4
Ulna been observed that the copper solution foams whenever the
. sulfur ocitent of the unpurifted hydrogen gas rune higher than',
11404. It may be that organic sulfur compounds are responsible,
_ ?: ? :,
the lowered surface tension, and flotation affects.
?;,.;;-..' ,, ..: i ,!
1 , .
41. ' Theljeoppar from waste .copper solution is. recovered at the Manifolds* t,...
qopPe* Refinery, in the Ears mountains. .. ... I
,.'
4.._ The, otpaoityof the eopper-solntion washer distal is'preiently
l' 1 being increased by installing. an ammonia refrigerant cooling' ' ?
:.
eyptem for' cooling_ the fresh copper solution to 15.0. Although
'solubility increases, rate of absorptglon decreases as th-ei? **oral!
tur? is lowered. A temperature' of 15 0 le optimum' for' taxiium ? .
'Solubility compatible with maximum rate of, absorption. ' The: coola .
144,installation, when completed in 1952,53, should increase
present ,production to 130,000 ' cubic. !deters Of synthesis gas Per
, ? ?
hour, Which ie ,the goal of the 5oyear.,plan.
., , .
1 i
? ,?
_
' '1..4. I '31nek , Okide ' iiiataiYet for ' ammonia synthesis 46 made at Lonna fand is maialY;
: :..?1*.Ort.XOnideolSith,2%,. alumina pl,'''O' calcium oxide' and 0,5
exide. 4 11464 purity Swedish charcoal iron is used in .iteprepara-; ',...
Htton.Y The :iron 'oxide is in magnetite form, POOA but ie:reduied
,
, i I ? , !Y; . ? ; MO iron ''Oringi the ammonia synthesis. Oryipin frititi4 to re,.!:H
.'-'4*nerate:the, ..black oxide Catalyst.
. , . , ..? .?. ?
I , . . ' ? ? ,.. ,:f''''fr
..T_kimeni11,ant ' . ' ,
?....' '
'1!:Y-1?, '
*- 0- The ammonia plant produces about 720 tone of fixed nitrogen pe' 1, ..? ;,y'
,
Lat.! :The:t0e*age volume composition of the fresh synthesis gas
:? ? / :.? .'.''.
is 4740 h7t7dgen? 23% nitrogen, 2% methane, 1% argon, and 0.01-0,021% ,
.. . earbon Monoxide. The Methane content often rUns higher. Dr.4rose ..
is in 'oharge of the plant.
-
b.
'The method of. production 'is; as follows Lies Enclosure (C)7:
1W The, last treoes of oarbon, monoxide are removed_in,thef.pre-:
liminary contact reactors (1) which operate -a 180-2e0 O I;
and 220-235 atm. There are 3 of these unite, each 1200 mm
- diameter and 12,000 it high, constructed of low chromium
,ateell 2% Cr.. Each reactor oontains about 18.motric tons Of
, -
black oxide ,catalyst whioh is replaced every six Months. r
The capacity of each unit it about 44p00 cubic meters
,synthesis' gas per hour.
*
'0) ;Since these units operate at 180-200?C and .save no facilities
,
. for 4preheating he aynthesie gas to 400-500 04 ..which is re,. ,
.,quired in order to reduce the black oxide catalyst in situ,
the. Oatalyst must be already in the reduced form before
being. charged. For this purpose there is a , single
'7000 OM diameter and 12000 suiV high, made of low ohromium
steel, for reducing the catalyst under Pressure. ; It produoes
' about ' 700kg: of reduced catalyst per week, and constitutee
a 'bottleneck in production. To overcome this difficulty
it is planned to install 'a separate reduction unit 'Which
will work at normal 'pressure. Installation may b4. finished
?by autumn of 1952 at-whi-ch.,-time-the probe:it pressure Unit
.will be used as a producing reaotor.
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The purified synthesis gas joins the ammonia gas stream enter-
ing intg the ammonia contact reactors (2) which operate at .
420-500 0 and about 230 atm. There are 25 of these Xmitst
each 3000 mm diameter and 12,000 mm high, eonstructed of low
ohromium steel. Each unit is equipped with a heat exchanger
and, an glectrical heater for preheating the synthesis 0010
400?500 0. The heat exchanger consists vf 1260 tUbes. 641
mm diameter and 2500 mm high. The eleotrioal heater ha. a
opacity of 305 ITA. The catalyst container consiits of
78 tubes, 67.12 mm diameter and 8800 mm high. These tubes
contain 6 'tons of oatalyst which is active for 20-24 menthe.
The capacity of-eaoh unit is 25.55 metric tons amionia.por
day.
These reactors are started up with an initial flow rate of
5000 cubic meters per hour, which is increased over the course
of several days to 40,000-50,000 cubic meters per hour. As
the catalyst activity decreases the rate must be redwood to
maintain reaction temperature. When the rate falls to
20,000 cubic meters per hour the reactor is stopped, and the
catalyst replaced.
ft* ammonia gas stream leaving each reaotor, at about 410?Ce
passes through cheat exchanger (3) whose shell is 5000 am
diameter and 12,000 mm high. There aro 25 units of two
types; one with 511 tubes, 6-11 mm diameter and 10,850 mm
high, the other with 151 tubes, 14-23 mm diameter and
10450 mm high. The gas leaves these exchangers at about
1000.
The gas then enters water coolers (4), and ammonia refriger-
ant coolers (5) of which there is 1 unit of each for each
reactor. The ammonia refrigerant cooler is 595 mm diameter
and 8000 um high. Its heat exchanger contains 421 tubes,
6-13 am in diameter. The ammonia vaporised from the liquid
ammonia refrigerant is sent from vessel (6) to the injector
unit.
The cooled mixture of ammonia liquid and vapor ,passes to the
high pressure vessel (7) where the liquid ammonia le removed.
and it. pressure reduced in vessel (9) from which the liquid
ammonia goes to storage, and the flash vapor is sent to the
-pressure absorption unit.. About 225-275 metric tons of
liquid ammonia are produced per day.
The vapor from high pressure vessel (7) is recyoled to the
reactors by ciroulattng pump (8), with bleed-off gqing to
the pressure absorption unit. There are 9 circulating pumps;
8 steam driven and 1 electrically driven.
The off gases from the recycle line leaving .(7) and .the am-
monia gas flash from the preesure reducing vessel (9) are
absorbed in Steam ?endow:tate in a pressure absorption unit,
Operating at 16 atm, to produce 1.5%; ammonia solition.
(10,) Thimeolution is sent to the recycle line of .the Injector'
Unit (10) where ammonia gas from (6) is absorbed to produce
a 26% ammonia solution. There are 0 injector units, 1 of
the smaller type, 400 mm diametet and 1295 mm high., and 5
of the larger type, 550 mm diameter and 1840 mm high.' Each .
injector unit consumes about 5000-10,000 cubic meters ammonia
gas perjaour and produces 200-400 cubic meters of 20 ammonia-
"'elution per hour.
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(11) Due to the heat of solution each injector unit is equipped
with 2 water ?colors (11) which reduce the solution tempera-
ture from 32.35 e to 23-26'C. Each cooler is 1800 ma in
diameter and 4000 mm long, and contains 2012' dooling tubes
of 21-26 ma diameter. Water consumption is about 200 cubic
meters per hour per cooler.
(12) The 26% ammonia solution withdrawn from separator (12) is
sent to storage,for use in ammonium sulfate produotion.
(13) The off gases from ammonia synthesis contain a 30% mixture
Of argon and methane (roughly half and half), and a 70%
mixture of hydrogen and nitrogen. By compressing these
gases to 330 atm U.. increase *Le partial pressures of hydro-
gen and nitrogen to ammonia synthesis level, and reacting at
this pressure additional ammonia is produced, and. the anew.
methane fraction is inoreased to about 40-45% of the residual
gas. One unit, 5000 mm diameter and 12,000 am high, has
boon in operation since August 1951 for this *after synthesis*.
It is successfully producing about 6 metric tons ammonia per
day. More of these units will be'installed,as soon as equip..
ment is available.
Production of Ammonium Sulfate
a. The production of ammonium sulfate amounts to about WO metric
tons par day. Sulfuric acid is not produced at Leuha.but is
shipped to Leuna either from Bitterfeld or from Welton.
Production of Eitrie411
About 40% of the fixed nitrogen is shipped es liquid ammonia' t0"
Bittorfeld where it is oxidized over iron oxidei- tungsten catalyst
to fora nitric acid.
4
It is well known, ,}0- course, that nitric acid can be used for the
Production of explosives, and for that reason Br Gross, of.the
amme40:plant atlmuna, was asked to make a radio spepohemphasis?
ingAlit all fixed nitrogen be need exclusively for tho_production
of fertilizers and mining explosives. Dr Gross refused to make-,
the speech.
(14
, ...... :
a. Methanol is produced at Lonna from carbon monoxide and hydrogen.
The higher alcohol fraetion obtained in its manufaotere contains
about50% methyl alcohol, 11% isobutanol, and 40% eight-nine
itodirbon alcohols, mainly of the alpha-methyl type. This raction
is reduced by "after-hydrOgenation", in thepresence of Tienna
itandard. catalyst Re 1930, containing 1.5 mol copper, 0.5 nol
chromium sesqui-oxide, and 1 mol zinc oxide. Lonna produces
about 39 metric tons per month of this catalyst. The "after
hydrogenation" reduces the aldehydes and unsaturates, and im-
proves' the color and odor of the final produote.
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the Soviets
have a projected plan for the production
or methanol-isobutyl oil, probably at Severo-,Bonetek. The methanol_ ,
plant has surpassed its quota for the year 1951 by 130%. In the
.
plant four 500 mm mothana ovens and two 500 mm isobntyl ovens are
in operation.
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14 HProduction of Ethanol ?
1
. Ethanol is also produced-a?Ouna,from Carbon monoxide aid hydra's
gen, but the conversion in only about 15It.
The Soviets *eke ethenol'by'the Libiedrr method at the factories
Of !Wet* and Teronesh4 south of Moscow* elets s1i0 W. -
Paladin* where the alcohol goes into the production of Bulks tub..
;bor. In addition, the Soviets make largo amounts of ethyl al
eohol by the fermentation of potatoes. ,
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no production of butyl alcohol and ecotone by ferment*-
. tion in the USSR.
Produetion of Eloher Alcohols
?s. (This topic has been covered under 10. Production of )Lethanil )
zzamptimaLugiatazaiusinat
a. Tria041101 propane is being made in the Organie Lab at WO**,
,4 4Rd br Dr Probloth. It is made by reacting two moleorles"Of.
formaldehyde with one molecule of butyraldehyde and reducing.
1%* triMethylol propane is used for reacting with, dibaaid &Oita
to etre alkyd resins. It may be used as a substitute for
glycerin in this production. At Lonna, adipic acid is *elicited
with:trimethylol propane to give the alkyd resimNakadyl.
14.0 410.49142&farilla
Lem& makes about 100 metric tons per month of caprol6etam which
is polymerized and then shipped as flakes to Schwarza, Thuringia,
for spinning and weaving into perlon fabric. Drs Niters and
fehaeffler are in charge of this work.
oduotion of SS-Oil
a., This synthetic lubricating oil is made from polyethylene oils by
a batch process in a, small pilot plant at Leuze under the super-
25X1 vision of Dr Leauttke, the Catalyst used ie boron
triflouride. Tho OS-Oil is very stable end is used for lubripat-
int hot bearings and. cylinders.. It ie 'also called 91ot steam
oils.
Production of Lupoleme
14upolehe If (normal) is. polyethylene of 2000-3000 monomers per
chain,: while Lupolene H;(high) is polyethylene' containing abour
10,000 monomers per, chain. Mose waxesare.tedeet:Leune by
co*Prossing ethylene with a trace of oxygen gas as catalyst, to
a4repsure el 1000-2000 atm. A plight excess of oxygen will
produce an explosion in this process.
1
. -Lonna produces pare-amino-salicylic said, known 48 PASS (pars.'
amike-Galioyl.peuer) in Germany and as RASE (kara.oemine,saliorl-
Alslote) in Ruspia. It is a relatively new drug which when need.
with penicillin is effective against tuberculosis.
Before 1946 no pontoillin oould be purchased in Moscow. During
that year three US plants for penicillin were erected .in. Moscow.
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By 1947 penicillin of US quality was available in drug Stores
there. By 1950 the supply was plentiful, and the cost of
300,000 units was only about three-four rubles.
eseareh ProJects at Leuna
The period was actually too short for
detailed observation on present research at Loma.
(1)
A cooling installation for the copper solution washers is
being ereeted in the hydrogen purification plant in order
to increase their capacity. Actually it is,not the copper
solution washers, but the copper solution regeneratore which
comprise the bottleneok to production, and the regenerators
are already running at almost full oapaoity. Dipl Ing Buie
chief of the hydrogen purification plant, is not interested
in researohl
An after.synthesis regenerator is already operating success-,
fully on one half of the off gas from one of the 25 ammonia
Synthesis reactors, producing additional ammonia and a
richer argon-methane fraction.
Dr Bankovski of the Research Laboratory, Dr Gress, chief of
the ammonia plant, and Dr Punks, chief of the oxygen plant,
are working on a project for the production of argon. ;
Dr Walter Gross of the ammenia plant is working on a'-de-
rusting agent and a rust-proef base for-ooating metals
before varnishing. /t contains phosphoric acid, graphite,
and fine iron oxide from used ammonia synthesis catalyst.
Dr Gustav Achilles Krajewski from the Salt Divieion is
doing research On fertilisers.
Dr. Otto BankoWski, chief', Dr Roethnig, and Dipl Ing Adolphi
of the Research Laboratery,are engaged in basic research on.
fluidised beds.
Dr 2obloth of the Organic Department South is doing researoh
on problems retarding the present production of trimethylol
propane from butyraldehyde and formaldehyde.
.Dre Eliand Schauer are working. on,a project for the produc-
tion of ao0Yleno.
Alm and Soheuer were still busy establishing their Om
laboratory, south of Leuna Bldg ME 24. The Soviets seem
very interested in this project.
In Leuna,Bldg,ME 15, the Main Work Shop,
a largo bandle of high pressure tubes, used as pre-
heating tuba in' the hydrogenation plant. . These tubes Were
120 mm in diameter about 10 meters long. And were -made of.:
alloyed steel. They were to be welded into hairpins with
butt-welding machines.
In thesame building
vertical lathes were being
ipecial.orders. I
for propellor shafts for ship*.
used
4-5 large
exclusively. for Soviet
Ithe ordera were
One of these'shaftshad
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I diameter of about 15 om. The orders are rseslifed'direetly
fro* the Soviets, and the workers are paid high bonuses if
they finiet the work within the deadline. Therefore these
.orders are in high favor with the workers. ,
/dialene9k, at PrX3211
Qt. Bottlenecks, epos:lino to the production of a given produot have
ar0114, been presented. More general items follows H.
0
Compressors constitute the most !serious bottleneck at Loma.
All departments depend OA the oompronsors, moot of whisk are:
1.917 models, and in constant need of repair. In October 1951
the production of Lonna was endangered because One of the
oompressors in the hydrogenation plant, ileum& Bldg XX 165,
needed a new cylinder head, and it was impossible to get a
replacement In the Soviet Zone or in any of the satellite
conntries. Melly the LOU= workshop aucceedet in making
One just before the danger became critical) The alimonia
plant had toeork overtime in order to make up the loss of
production and fulfill the quota.
Materials for high pressure inetallations comprise another
serious bottleneck. High pressure tubes of 6-10 mit diameter
are very scam, and high pressure.jaokete for the 500'and.
SOO mm reactors are praotically unobtainable..
Steel tubes for steam and cooling units are produoed at
Riess, but are practically worthless because they an net '
have the oorreot measurements, or are of a faulty material,
or badly welded. In the ammonia plant the last tubes for
000ling units were built into a broken cooling unit in
.0otober 1951. Since that time the ammonia plant has been
without reserve in' this item.
iSheet iron is very scarce, and whatever is shipped to
Leung is of poor quality. The sheets are rolled at liana.
They are non-uniform in thickness and frequently cannot
be used.
(1)
Cables for conveying coal to the gas plant are:th short Ow-
'ply and almost oaueed a, breakdown of all Leuze prodictimi
in September 1951 when tho plant needed a 1500 meter,lengtha
whioh.was procured only in the last moment'.
The oxygen and air blower of the Winkler gegeratortiite
operetiug without a reserve. There ars five such generators.
atjAnna, of which four were derusted and remodeled during
the:Summer of 1951. In October 1951 generator o4 was
still out of operation while the four otherimMrg
day and might. Eaoh'of the goneratore'hae a oapieity of
60,000 oubia Metera of gal pertourc and opnoumes.750 tons
Of raw soft coal per day.
Asbeetve insulating string for the electric heaters for the
ammonia ovens is very scarce, and almost caused a ohutdown
of the ammonia plant-in Ootrlov 1951.,
The_reeervee_of sulphuric) acid are kept dangerously lot.
,There had been a rule at Lonna that. 1200 tone should allays'
be in reserve. However, in a conference of-theimOdUotien
chief. of 5 Oct 51 it was mentioned that only 500 tone were
available at Leuna, and that the ao At Weiseeneee ineisleC
that this amount be further cut to 300 tone, whioh-.004104,
tut* about half t monthls consumption.
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Another critical shortage at Uwe is that of trained person-
nel, particularly those with academic training. The researeh
laboratory, for instance, which.formerliemployed a staff of-
25 aoademioally trained soientisteois now down to six. The
same is true for the production departments. Tho ammonia
plants for inetanoe, hns only one chemist lefts the chief of
the plant, Dr Walter Gross. The hydrogen purifioation plant
has AO chemist on its staff; the chief, Dr Eules Lean en.
gineer.
(10) Not only is the number of professional personnel small and
in many oases insufficient, but the average age io very high.
There are few scientists left at LW= younger than 55 or
60 years of age. The same is true for the trained non-
academic peroonnels Women form about one third of the entire
Lonna personnel. It is the policy of Ileum, under the'diree.
tic* of the BED, to hire women almost exclueively, for two .
regimes
(a)
The Soviet administration wants to force women int? the
production proms. This im done by refusing tennis*
such social benefits as use of kindergarten's hospitals,
etc., unless the woman and the man are both working.
(b) The salaries are in the long run lower for women than
for men, as demonstrated from the hourly wages at
Lima, which by the new oollective contract ares
0.78 DK for unskilled workers
0.88 DM after a probation perioa
of three months
1.02 DU after two years in the same
production plant- _
1.22 DM according to the joint
1.32 DU recommendation of the
1.38 DI--- - --------------- union chief of the plants '
1.48 DM tthe foreman, and the plant
1.58 DM (ahief
Since in general women change jobs more often than 11034
the women stay in the lower salary brackets, and this
saves money for the plant,
11) As subetitutes for the professionally trained personnel, the
SED at Lima and the union are slowly introducing into the
plant a new type of employee called the *plant assistant
(Betriebsassistent). These plant assistants are members.of
the PDJ (Preis Deutsche Jugend), and operate somewhat. as
Communist supervisors, but at the same time are trained to
learn the operations of the individual plants.. So far,
know of two snob plant assistants, OMA of who is in the
Doonomic and Production. Control Department (A11gemeine-
Wirtsehaftlichkeitsprafung) as an *assistant* for Dr Klock.
pann. The two plant assistants were prewent_at the last
two genern1 production oonforencees at which only the pro-
duction leaders are normally present.
(12) The plant assistants are becoming a general institution in
the Soviet Zone. It is hoped that they will work their way
into the various plants to be elle later to direct the
SECILI7!
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Approved For Release 2004/19/ni ? BROXP81-01028R1001001000a6g
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operations of the plants. They repeat, at Leans, a tread"
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area* knowledge or understanding of the 0n0AnntiandLandl,
.14461mdat and without anY aaadiale trainlag la seleaam,'
14?101/11rOs (4) ,notaition of Drown Oxide 00470
(0) Eybog. Cox srioi.104 Paritleatioa Pleat.
:(4) Await Allanyasaa
SWIET
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