1. Introduction

The basic fundamental regulations of economical and technological conception for rational use of natural resources: production of environmentally safe and non-waste resource- and energy-efficient technologies for complex chemical processing of carbonate and coal mineral raw materials by using several modules, providing the obtaining the following products on the first stage:

• carbide of calcium, calcium oxide, carbon dioxide;
  on the second stage the products of calcium carbide̕ processing:
• synthetic gaseous and liquid fuel and non-fuel products.

As an example of economical-technological model of production̕ organization the characteristics of electrothermic and plasma equipment complex for production of carbide of calcium and carbon dioxide is presented detailed in this report. The example of using the electrothermic furnace RKZ-2,5 and plasma reactor with capacity 500 kW for the obtaining of carbide of calcium and products after its processing: acetylene, agricultural products, such as plant̕ growth and protection regulators (REGROST and TAKAR) is given here too.

To show the efficiency of application the developed resource- and energy-efficient technologies for carbon-carbonate mineral raw materials processing the comparative complex table of technical-and-economic indexes for investment projects in cement industry, using as main mineral ingredients limestone and black coal also with parameters for production of carbide of calcium and carbon dioxide, products of its processing is developed.

The urgency of the report is determined by the fact that thermo-chemical processing of coals and limestone at newly established or modernized industrial enterprises in Primorskiy region provides the obtaining of materials, products and consumer goods, precious for industry, construction, agriculture and energetics. The technology of calcium carbide obtaining accepts the application of lime or limestone as calcium-containing materials, coak or coal as carbon-bearing materials. Analysis of chemical structure of coals at the deposits of the Far-Eastern federal district shows that, basically, according to its physical and chemical characteristics the coals of black coal̕ deposits are mostly satisfied for the production of carbide of calcium.

2. Tasks and objectives of Research and Advanced Development (RAD)

1. Development of strategy for the production diversification at energetic and coal mining enterprises of Primorskiy region;
2. Conduction of RAD and development of physical and chemical model of industrial process for carbonate and coal̕ processing;
3. Development of high-producing progressive operations for carbide of calcium and carbon dioxide̕ production on the base of mobile plasma generator of modular construction on the whole technical plan;
4. On the base of obtained patents the development of innovative technologies and synergy of technologies for environmentally safe industrial processing of carbonate and coal mineral raw materials;
5. Development of innovative resource- and energy-efficient technologies for the production of synthetic gaseous and liquid energy sources and non-fuel products.

3. Subjects of researches and innovative solutions

1. Energy providers: Thermal Power Plant (TPP), State District Power Station (SDPS), working with black coal (first of all, Partizanskaya SDPS). Opportunity analysis for the carbide of calcium mobile production̕ organization shows that, first of all, the energetic enterprises, such as TPP and SDPS, working with black coal, are satisfied to that purposes. The organization of carbide of calcium̕ production at electric power plants is appropriate also that high-temperature gas emissions are can be thrown off to boiler furnaces, where their heat energy is used and also gases are gone treating in boiler gas duct. On account of it a non-waste technology for carbide of calcium̕ production is provided. Plasma reactors in connection with fast response can be exploited as consumers in night duty - regulators of electric load;
2. Diversification of coal-mining and energetic enterprises for the purpose of efficiency and competitive ability̕ upgrading;
3. Construction of mining and chemical enterprises (CONSORTIUM) on industrial processing of coal and carbonate mineral raw materials for obtaining of competitive products of fuel and non-fuel application (I turn - Primorskiy region) in Far-Eastern Federal District (FEFD).

4. Mineral resources and directions for processing of carbon-carbonate raw materials

The range of limestone deposits is developed in Primorskiy region. There are reports on geological explorations in geofunds of "Primorgeologia» Co Ltd., conducted at the deposits Dlinnogorskoye, Vysokiy Utys, Sukhaya Skala, Phrolovskoye and others. Mineral raw materials of these deposits are suitable for the production of carbide of calcium.

At present time in Russia the equipment complexes for the production of carbide of calcium with output of 1500; 2500; 6000 tons a year are produced by companies Scientific Production Enterprise (SPE) "Energotherm-system" and «Metmash». Calcium carbid is used for the production of acetylene, it is obtained at the special acetylene stations with output from 10 to 80 m³/hour. In Far-Eastern region of Russia the acetylene was used as high temperature energy carrier for welding process and cutting of ferrous and non-ferrous metals.

In chemical industry more than 90% of produced acetylene is exposed to further processing, for a example, on such directions:

1. - acetylene (С₂H₂) - ethane - synthetic ethanol (produced by ethane̕ hydration) - dichloroethane (solvent) - ethylene glycol (anti-freeze), acetone;
                                                  synthetic ethanol;
2. - acetylene - ethyl aldehyde ⁄                                - acetic anhydrate - ethyl-acetate;
                                                     \  acetic acid ⁄
3. - acetylene - vinylacetylene - divinyl - acetylene - synthetic dry oils.

These directions are planned for the development of mining and chemical enterprise̕ construction in the second priority.

In traditional plants for carbide of calcium production' the carbon oxide was wasted into atmosphere and polluted the environment and imposed higher ecological requirements on replacement of this equipment (refer to formula of physical and chemical process). In this investment proposal the plant for carbon oxide' utilization and obtaining of carbon dioxide additionally. According to customer' preference it can be obtained in liquid, gaseous or solid condition. Carbon oxide is widely used in production of mineral water, sweet effervescent beverages, beer, conducting of welding works, for fire fighting and production of dry ice.

The technical tender for obtaining of plant growth and protection regulators on the base of calcium carbide - (PGPR) is newly tested device of reliable increasing harvest: REGROST - for the stimulation of plant growth; TAKAR - for the protection of plants.

REGROST is produced from materials, formed in ground and plants with microorganisms a natural hormone of plant growth and protection - ETHYLENE. The preparations of A and B brand in ground and D brand in fruits are produced for the increasing of ethylene content. The preparations are produced in pills and powders.

REGROST is differed from famous plant growth regulators: gydrene, campozene by nontoxicity, application in all phases of plant development from seed processing to fruit afterripening, efficiency on vegetable, gourds and frumentaceous cultures and also berrylike bushes (gooseberry, currant, raspberry and others). Under processing of seed and plants by REGROST the vulnerability of plants by diseases (bacteriosis, brown rust, stem break and browning, fusarium blight) is reduced in 3-5 times.

TAKAR - new effective product for plant protection from blasts of berry, market-garden, and flower cultures and also fertilizer for neutralization of sour lands. It contains of nitrogen, phosphor, potassium in volumes, exceeding its containing in organic fertilizers (poultry excreta, barnyard manure). As product of plant protection TAKAR is used for destroying of aphids, white fly, weevils and etc. on cucumbers, cabbages, tomatos, fruit trees and bushes. The efficacy is 90-100%. The harvesting capacity of green crops is increased to 20-50%, potato - 30%.

In the report a new environmentally safe method of complex processing of carbon-carbonate mineral raw materials, which is a scientific development of the first turn of mining and chemical complex in Primorskiy region. It is oriented for the calcium carbide obtaining, calcium oxide, carbamide, acetylene, products of acetylene processing, carbon dioxide due to utilization of carbon oxide, calcium hydrate. For the purpose of energy consumption decreasing under calcium carbide production in the plant the thermal treatment of limestone in reactance coil with supply into it and burning of high temperature energy carrier[1-9].

At the industrial complex a preliminary burning of limestone (CaCO₃) with obtaining of calcium oxide (CaO) and carbon dioxide (CO₂) is produced for the calcium carbid' obtaining; a fusion mixture from calcium oxide (CaO) and bituminous coal is used for calcium carbide obtaining (CaC₂). The carbon dioxide (CO₂) and carbon oxide (CO), obtained under limestone burning and calcium carbide production are captured and carbonic acid (H₂CO₃) is produced from that products by the equipment for capture of outgoing gases (CO₂).

Under acetylene obtaining from calcium carbide the calcium hydrate (Ca(OH))₂ is produced, it is used in construction, agriculture. The carbamide CO(NH₂)₂ is produced from calcium carbide by using of nitrogen (N₂). Synthesis of carbamide (calurea) is possible with carbon dioxide (CO₂) application by adjoining of hydrogen nitride (NH₃).

The investment prospects of this project are enough great as far as its realization gives an opportunity to use local abundant and cheap sources of raw materials and on the basis of it to produce a precious goods with high added value and enough high demand stability for different branches of economics and commonly used products. This fact provides increased economical stability of the enterprise in the process of market conditions in any given different segments. The formula of success of the project is a serious scientific and technological knowledge of this direction and very substantive practical learning of equipment' exploitation in such processes. And, first of all, it is necessary to have a team of specialists, capable to solve any scientific, technical, technological and organizational task. All the technologies, used in industrial complex, are tested and guaranteed, general structure of the equipment is not unique - a risk of time lost and efforts for the purpose of balancing and optimization of complex' work is practically brought to nought. Risks of raw materials lack are equal to zero too. The production facility on limestone complex processing foresees an application of reliable, tested by long-term practical activity of electro-thermal furnace RKZ-2,5 with calcium carbide production 2500 tons a year.

The basic technical-and-economic data of project for organization of competitive production of fuel and non-fuel application' goods in Primorskiy region by using electrothermic furnace RKZ-2,5 in conditions of Partizanskaya SDPS and industrial enterprise (ref. Table 1)

Table 1

The analysis of technical and economic parameters production' parameters of complex processing of carbonate and coal mineral raw materials, given in Table 1 shows that the commercial viability of produced goods is enough high and it is changed from 27 to 62% (average value 54-55%) in condition of one furnace RKZ-2,5 using; agreeably from 51% to 60% (average value 57%) in condition of using the production complex, made up from three furnaces of RKZ-2,5 type. In this case the crew size of industry-production staff is from 130-150 to 390-450 persons; average net sales according to all kinds of output products are from 590,0 mln. rub. to 1770,0 mln. rub.; average revenue per one person a year - 4,0-6,0 mln. rub., that is in 2,6-3,5 times increases analogue parameters in cement industry under significantly lower volumes of consumable mineral raw materials.

The cost of equipment with erecting and start-up works comes to 210 mln.rub./7 mln. US $. Taking into account that using of existing territories is supposed the expenses for exploratory design, technological and construction projects, construction unit and electric power supply are not registered. It makes up 28,0-30,0 mln.rub. additionally. Besides, extra charges for device with plasma reactor by capacity 500 kW make up 60-70 mln. rub. The creation of plasma device with reactor 500 kW is appropriate in time frame of exploratory design and processing of technological and construction projects.

Constructional design, construction, installation arrangement and start-up of the first stage mining and chemical complex - 21-24 months from the beginning of project̕ financing. Payback period are 3,0 - 3,5 years.

The basic profit is obtained from realization of agricultural products (REGROST and TAKAR), their price is arranged in 1,5-2 times lower than foreign analogue product. Taking into account the novelty of these products, some measures for preliminary (in parallel with construction of the plant) informing of consumers about advantages of REGROST and TAKAR products in comparing with well-known analogues are also supposed.

A complex table of technical and economical parameters for investment projects is presented in table 2. Work data of Spasskcement Co Ltd. on cement production of different types in 2011 are given in column 4. As a comparison the basic initial index are volumes of used mineral raw materials during a year: in column 3.1. it is shown that 990990 t of limestone ≈ 1,0 mln. t is accepted for calculations in compared variants. As for the second unit - coal for the carbide of calcium̕ production it is necessary about 100 thous. tons more, but it is fully balanced by exception of other mineral resources: politic, gypsous units and etc. in this production.

Complex table of technical and economical parameters of investment projects

Table 2

Data analysis, presented in complex table of technical and economical parameters of investment projects for the production of different types of cement by the example of Spasskcement Co Ltd. with processing of carbon-carbonate mineral raw materials during a year: limestone - 990990 t; coal - 218218 t in comparison with processing of limestone of the same quantity 990990 t and 315315 t of coal according to the suggested innovative technologies by using of electrothermic furnaces and plasma reactors is below:

• - volume of output production, t:

cement - 1415700; carbide of calcium - 450450; carbon dioxide - 630630; by using plasma reactor - carbide of calcium - 450450; carbon dioxide - 616369/492249;

• - commercial production viability, %:

cement - 21,42; carbide of calcium - 29,4 (RKZ-2,5), 41,7-48,0 (plasma reactor); carbon dioxide - 51,7-63,0 and 57,0-66,0;

- earnings for 1 person a year, mln.rub.: cement - 2,61; carbide of calcium - 2,5-3,0 and 4,0-4,8; carbon dioxide: 3,5-5,8 and 5,1-8,6.

Earnings, mln.rub.: cement - 4652;carbide of calcium - 13514-16216; 9460-15766 (RKZ-2,5); total 20898-28522;

Profit, mln.rub.: cement - 959,18; carbide of calcium - 3968-6130 (RKZ-2,5); carbon dioxide - 4888-9933; total: 8856-16063; carbide of calcium (plasma reactor) - 5630-7791 (RKZ-2,5); carbon dioxide - 4204-8160; total: 9834-15951.

The above-mentioned data on the project of carbonate and coal mineral raw materials̕ processing by using resource- and energy-efficient technologies only on the first sub-system (obtaining of carbide of calcium and carbon dioxide) show their high efficiency and just as important - ecological safety.

The technical and economic calculations of newly established device̕ using for carbonate and coal mineral raw materials̕ processing with application of experimental-industrial plasma reactor by capacity 500 kW on all above-mentioned manufacturing chain of output products: carbide of calcium, carbon dioxide, acetylene, REGROST and TAKAR under the same annual outputs of consumed mineral raw materials - 990990 t of limestone and 315315 t of black coal show the following integral parameters of the production:

• investment volume, mln.rub. - 21375;
• volume of output products, t:
• carbide of calcium - 450450/656250;
• carbon dioxide - 492244/616360;
• acetylene - 54000; REGROST - 90000; TAKAR - 144000;
• crew size of industry-production staff (IPS), persons - 10425;
• sales margins, % - 68,9-69,3;
• earnings, mln.rub. - 87043-95359;
• profit, mln.rub. - 60912-65063;
• earnings for 1 person a year, mln.rub. - 8,87.

Therefore, the suggested investment project, providing a rational connection of famous and tested in practice technologies in a whole technological complex, gives a possibility on a base of highly-profitable production to realize the extremely effective in economical way and full complex application of local mineral raw materials and energy with obtaining of profit' heavy rates and with minimum payback times for production projects.

For the key personnel of European scientific and industrial consortium «ESIC», Russian Academy of Natural Sciences we suggest working relationship in further conducting of scientific -research and design-experimental works, development of resource- and energy-efficient technologies and creation of joint mining and chemical enterprise (CONCERN) for the obtaining of high-efficiency and competitive production of fuel and non-fuel application.

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