Complete Technology Handbook on Gypsum and its Products (Science, Mining, Processing, Transportation, Handling, Machinery) with Detailed Manufacturing Process and Project Profiles

Complete Technology Handbook on Gypsum and its Products (Science, Mining, Processing, Transportation, Handling, Machinery) with Detailed Manufacturing Process and Project Profiles

Book contains chapters on Introduction, Manufacturing Process, Types of Gypsum Products, Plaster of Paris, Gypsum Board, Types and Sources of Gypsum, Different Types of Drywall, Gypsum Products in Dentistry: Types, Uses and Properties, Gypsum as an Agricultural Product, Mining Technology, Preparation of Other Gypsum and Anhydrite, Role of Gypsum in Cement, Technology of Gypsum and Gypsum Plasters, Gypsum Board Waste Management, Grinding and Calcining of Gypsum, Crystallistaion and Dissolution of Gypsum, Gypsum Pelletizing, BIS Specifications, Process Flow Sheet, Plant Layout, Gypsum Utilization in Geotechnical Applications, Photographs of Machinery, Plant Economics of Calcined Gypsum for Plaster in Construction Sector, Plant Economics of Dry Mix Mortar (DMM), Plant Economics of Gypsum Board and Gypsum Wall Putty, Plant Economics of Gypsum Plaster Board, Plant Economics of Manufacturing of Plaster Board Liners (Heavy Duty Papers).

Chapter 1

Introduction

Gypsum

Occurrence of Gypsum

Where is Gypsum Found? 

Chemical Formula for Gypsum

Physico-Chemical Properties of Gypsum Mineral 

Different Kinds of Gypsum 

Types of gypsum products

History of Gypsum 

Gypsum Moulds 

Plaster of Paris

Calcium Sulfate

Gypsum Credentials

Unequalled as a Material for Interiors

Plasterboards 

Decorative Plaster 

Building plaster 

Plaster blocks 

Gypsum-based self-levelling screed 

Gypsum Fibreboards 

Gypsum Products’ Unique Properties

Fire Properties

Fire Resistant 

Non-combustible

Effective in Fire 

Acoustic Properties 

Thermal Properties

Aesthetics and Design 

Ease of Installation 

From Products to Solutions

Chapter 2

Manufacturing Process

Five stages of gypsum production line

Raw Materials

Gypsum Production Process

Dehydration: Rock into plaster 

Properties of gypsum plaster

Production processes

One simple production method is to heat the gypsum on a flat metal plate above a kiln

Crushing the gypsum ensures a more uniform product which requires less energy to heat

A pit kiln is the simplest method of heating gypsum, but it is inefficient compared with other methods

Gypsum Unique Properties in Buildings

Gypsum is Fire Protective

Non-Combined Properties

Gypsum Regulates Sound

Thermal properties

Gypsum equilibrates Humidity and Heat Peaks

Gypsum is Easy to Install and to Dismantle

Gypsum Acts as a Thermal Insulator when Combined with Insulation Materials

Gypsum is Multifaceted and Multipurpose

Plaster board

Gypsum Plasterboard Types

Drywall white board or gypsum board

Backing gypsum plasterboard

Moisture-resistant gypsum plasterboard

Modified moisture-resistant gypsum plasterboard

Blue board gypsum board or plaster baseboard

Paperless gypsum plasterboard

Fire-resistant gypsum plasterboard

Soundproof gypsum plasterboards

Exterior gypsum soffit board

Gypsum Fibre Boards

Gypsum-Based Self-Levelling Screeds

Plaster Blocks

Decorative Plaster

Benefits of using decorative plaster in your home or office

Building Plaster

Uses of Gypsum

Uses of Gypsum Powder

Uses of Gypsum in Agriculture

Uses of Gypsum Board

Other Uses of Gypsum

Chemistry of Gypsum Products

Chemistry of Gypsum Product Formation

Setting Mechanism

Manipulation Stages

Manufacture of Gypsum Precursors

“Plaster of Paris” “Hydrocal”

Properties of Plaster of Paris

Features of Hydrocal

Use Hydrocal

Variables influencing Properties

Manufacturing Variables

Thermo-Gravimetric Analysis and Chemical Composition

Occurrence of Gypsum

Agricultural Gypsum Uses

Gypsum Improves Soil Structure

Gypsum Helps Reclaim Sodic Soils

Gypsum Prevents Crusting of Soil and Aids Seed Emergence

Gypsum Improves Low-Solute Irrigation Water

Gypsum Improves Compacted Soil

Gypsum Makes Slightly Wet Soils Easier To Till

Gypsum Stops Water Runoff and Erosion

Gypsum Decreased pH of Sodic Soils

Gypsum Increases the pH of Acidic Soils

Gypsum Improves Swelling Clays

Gypsum prevents Waterlogging of Soil

Gypsum can Help Remove Excess Boron from Sodic Soil

Gypsum increases the Stability of Soil Organic Matter

Gypsum makes Water-Soluble Polymer Soil Conditioners More Effective

Gypsum makes Excess Magnesium Non-Toxic

Gypsum Corrects Subsoil Acidity

Gypsum Can Enhance the Values of Liming

Gypsum Improves Water-Use Efficiency

Gypsum makes it Possible to Efficiently Use Low Quality Irrigation Water

Gypsum Decreased Dust Erosion

Gypsum Helps Plants Absorb Plant Nutrients

Gypsum Decreased Heavy-Metal Toxicity

Gypsum increases Value of Organics

Gypsum Improves Fruit Quality and Prevents Some Plant Diseases

Gypsum is a Source of Sulfur

Gypsum helps Prepare Soil for No-Till Management

Gypsum decrease Bulk Density of Soil

Gypsum decreases the Toxic Effect of NaCl Salinity

Gypsum multiplies the Value of Other Inputs

Gypsum mcan Decrease pH of Rhizosphere

Gypsum keeps Clay Off Tuber and Root Crops

Gypsum decreases Loss of Fertilizer Nitrogen to the Air

Gypsum can be a Source of Oxygen for Plants

Gypsum helps Earthworms to Flourish

Gypsum can Increase Water Retention in Soil

Gypsum Can Increase Crop Yields

Chapter 3

Types of Gypsum Products

Types of Gypsum Products

Gypsum Plaster

Gypsum Fertilizer

Gypsum Board

Gypsum Powder

Setting of Gypsum Products

Theories of Setting of Gypsum Products

The hydration theory

The dissolution-precipitation theory

The setting Process

Stages

Water/powder ratio

Effect of W/P Ratio

Hygroscopic setting expansion

Mixing

Mixing time 

Setting Time

The hydration theory

Working Time or Initial Setting Time

Final Setting Time

Initial Gillmore Test for Initial Set

Gillmore Test for Final Setting Time

Loss of Gloss Test for Initial Set

Variation in Setting Times

Vicat Test for Setting Time

Ready for use criterion

Control of setting time

Chapter 4

Plaster of Paris

Plaster of Paris Uses

In Architecture and Decorations

In Art

During Burial Services

Medicinal Purposes

Fireproofing

3D printing

Uses in Medicinal and Fireproof Fields

Radiotherapy

Quality Control and Standards

Pollution Control

Preparation of Plaster of Paris

Step 1 - Plaster of Paris Manufacture

Step 2 - Rehydration

Step 3 - Setting

Application of Plaster of Paris

Chapter 5

Gypsum Board

The Chemistry of Gypsum Board

Gypsum Board Manufacturing Process

Advantages of Gypsum Board

Gypsum Board Manufacturing Process

Fire Resistance

Versatility

Durability

Easy Installation

Low Cost

Areas of Applications

Acoustic Property of Gypsum

Drywall White Board

Drywall White Board Gypsum Board

The Manufacturing

Process

Blending of additives

Making the sandwich

Finishing the edges

Cutting the panels

The drying process

The finished product

Applications

Types of Gypsum Board

Regular and Type X Gypsum Board

Regular Gypsum Board

Type X Gypsum Board

Core Manufacturing

Edge configuration of gypsum board

Types of Gypsum Board Based on Edges

Common Types of Gypsum Board

Regular/Standard Gypsum Board

Fire Resistance Gypsum Board

Moisture-resistant gypsum board

Fire and moisture-resistant gypsum boards

Regular gypsum board

Fire-resistant gypsum board

Moisture-resistant gypsum board

Fire and Moisture-Resistant Gypsum Board

Abuse-Resistant Gypsum Panels

 Soffit board is good for lining the eaves

Abuse-Resistant Gypsum Panels

Foil-Backed Gypsum Board

Exterior Gypsum Soffit Board

Foil-Backed Gypsum Board

Gypsum Fiber Board

Glass Mat Gypsum Board

Sheathing

Applications

Backing Board

Chapter 6

Types and Sources of Gypsum

Mined Gypsum

Flue Gas Desulphurization (FGD) gypsum and Spray-Dry Absorption materials (SDA)

Phosphogypsum

Pickle Gypsum

Synthetic Gypsum

Titanogypsum

Borogypsum

Fluorogypsum

Drywall Gypsum

Greenboard

Landfill versus Recycling

Green Building

Common Uses of Gypsum

Markets for Gypsum Products

General Benefits of Gypsum for Soils

Soil Crusting

Sodic or Salt Contaminated Soils

Nutrient Availability

Runoff and Water Absorption

Animal Bedding

Manure treatment

Crops Known to Benefit From Gypsum

Animals

Applicatom:

Chapter 7

Different Types of Drywall

Dry Lining Systems:

Interior Partition Systems:

Performance partition Systems

How to Build a Drywall?

Installation

Drywall Tools

Fixing Tools

Marking Tools

Marking Tools

Basic Principles to Design a Drywall

Key Design Criteria

Height

Maximum partition heights

Thermal Insulation

Benefits of effective thermal insulation make building

Jointing and Finishing Details

Jointing level 1 (Q1):

Different types of Drywall

Jointing level 2 (Q2):

Finishing level 3 (Q3):

Finishing level 4 (Q4)

Chapter 8

Gypsum Products in Dentistry: Types, Uses and Properties

current ISO Standard for Dental Gypsum Products

Chemical Composition

Use of Gypsum Products in Dentistry

Desirable Properties

Types of Gypsum Products

Plaster

Stone

High-Strength or Improved Stone

Other Types of Gypsum

Setting Reaction

Water/Powder Ratio

Setting Time

Definitions

Working Time or Initial Setting Time

Final Setting Time

Measurement

Variation in Setting Times

Setting Expansion

Strength

Wet Strength

Dry Strength

Factors Affecting Strength

Surface Hardness

Dimensional Stability

Technique of Use

Measuring the Water

Measuring the Powder

Adding Powder and Water

Mixing

1. Hand Mixing

Vacuum Mixing

Filling the Impression

Chapter 9

Gypsum as an Agricultural Product

Benefits of gypsum as a soil amendment

Gypsum as a Source of Plant Nutrients for Crops

Gypsum to Improve Soil Physical Properties

Gypsum to Improve Soil Chemical Properties

Effect of FGD Gypsum on the Yield of Cotton

Gypsum for Landscape and Sports Field Use

Other Uses of Gypsum in Agriculture

Use of Gypsum as a Soil Conditioner

Causes of Poor Soil Structure

Recognition of Gypsum Responsive Soils

Exchangeable sodium percentage (ESP)

The calcium-to-magnesium (Ca:Mg) ratio

Clay Dispersion Index

Chapter 10

Mining Technology

Exploration Techniques

Stratigraphy

Topography

Vegetation

Hydrology

Deposit Evaluation

Drilling and Sampling

Methods of Sampling

Grab sampling

Chapter 11

Preparation of Other Gypsum and Anhydrite

Phosphogypsum

Use as a soil amendment

Use in construction and building materials

Processing method of phosphogypsum

Processing and Application of Phosphoric Gypsum

Titanogypsum

Insoluble Anhydrite

Calcination Methods

Schematic diagram of the process

Batch Kettle

The kettle with its hot gas pipes

Schematic diagram of the kettle – the introduced heat is very uniformly distributed

Continuous Kettles

Submerged Combustion Kettles

Conical Kettle

Rotary Kilns

Technical Characteristics

Schematic diagram of the Rotary Kilns

Impact Mill Calciner

Horizontal impact calciner

Hammer mill calcination system

Benefits

Ring Ball and Roller Mills

Technical advantage

Calcining and Drying Units

Boiling Furnace Calcining

Advantage:

Anhydrous and Multiphase Plaster

Hemihydrate Plasters

Chapter 12

Role of Gypsum in Cement

The Effect of Gypsum Solubility

Optimum Gypsum Content

Strength and Volume Stability

Effects of Gypsum on Cement

Chapter 13

Technology of Gypsum and Gypsum Plasters

Gypsum plaster: 9 easy steps

Production plants for gypsum plasterboard

Gypsum - A Natural material that will not bur

Properties of Gypsum Plaster

Gypsum Plaster Specifications

Types of Gypsum Plaster

Procedure for Application of the Gypsum Plaster on the Internal Walls

Surface Preparation and Ground Work before applying gypsum plaster

Application of Gypsum Plaster on the Walls

Thickness Recommended when applying Gypsum Plaster

Recommended Finish for Gypsum Plaster

Storage of Gypsum Plaster at Site

Gypsum Plaster Advantages

Gypsum Plaster Disadvantages

Chapter 14

Gypsum Transportation, Handling and Storage

Solution

Packaging

Plaster packaging for transportation

Expiry Date of Gypsum

Gypsum Storage: Types, Safety Measures to avoid hazards

Gypsum Storage Types

Safety Measures to avoid hazards in Gypsum storage

Gypsum Panel Products

Safety Tips for Handling

Storage

Support Risers

Typical Gypsum Risers

Preventing Sagging Gypsum Panel Products

Incorrect Riser Alignment

Correct Riser Alignment

Note that risers are aligned vertically so that loads are transferred directly to the floor

Suggested Placement of Risers for Storage of Gypsum Panel Products

Manual Handling

Mechanical Handling

Use of Wedges

Stocking Gypsum Panel Products on Job Sites

Loading Gypsum Panel Products

Open Top Rail Flatcars

Flatbed Trucks

Guidelines for Carriers and Drivers

Chapter 15

Gypsum Board Waste Management

Gypsum and Gypsum Boards

Reusing

Recycling

Sustainability Imperative

Gypsum Board Waste and the Management

Recycling process and technology

Policy instruments for promoting recycling

Action on gypsum board waste

CRD Waste Management in Europe

Chapter 16

Grinding and Calcining of Gypsum

Determination of Fineness

Application of secondary grinding of gypsum:

Recommendations for Gypsum Industrial Ultrafine Powder Mill Machine

Gypsum Pulverizers

Gypsum Pulverizers

Dryer Mills

Gypsum Hammer Crushers

Single Roll Crushers

Dryer Mills

Gypsum Hammer Crushers

Single Roll Crushers

Process of calcining gypsum

Calcination Examples

Calcination Process Description

Calcination Process

Difference Between Calcination and Roasting

Calcination Reactions

Limestone Calcination

Calcination of Gypsum

Production of Gypsum Products

Calcination of Gypsum Process

Chapter 17

Crystallistaion and Dissolution of Gypsum

Mineralogy

Crystal Nucleation: The Classical Nucleation Theory

Induction period

Classical and non-classical nucleation theories

Surface energy

Gypsum Nucleation Induction Period and the Surface Free Energy

Induction time measurement and nucleation mechanisms

Sketch of the experimental apparatus used to measure the induction time

Chapter 18

Gypsum Pelletizing

Gypsum Waste

Recycling Gypsum Products

Pelletization

Pelletizing Diagram

Drying

Simplified Pelletizing Diagram

Uses for gypsum pellets

Increased Plant Nutrition

Water Infiltration

Improved Soil Structure

Erosion Relief

Pond Remediation

Applying Pelletized Gypsum Soil Conditioner

Guaranteed Chemical Analysis

The basics of gypsum pelletizing

Gypsum processing equipment

Disc pelletizers

The Gypsum Pelletizer

Rotary Dryer

Front view

Back view

Rotary Dryers

Gypsum Processing Equipment

Material Processing

Pelletizing Equipment

Bulk material handling

Binder

Clamshell Pin Mixer for Limestone and Gypsum Pelletizing

Drying Mined Gypsum

Beneficiation

Drying Gypsum for Use in Wallboard

Pre-conditioning gypsum

Producing gypsum board

Why drying gypsum ore is important

Benefits to drying pelletized gypsum

Improved Product Handling

Product Consistency

The Benefits of Adding a Pin Mixer to a Gypsum

De-Dusting

Improved Productivity

Reduced Binder Costs

Improved Blending

Pelletizing System

Underwater Pelletizing System

Water Cooling Strand Pelletizing System

Under Water Strand Pelletizing System

Air Cooling Strand Pelletizing System

Air Cooling Die Face Pelletizing System

Water Ring Pelletizing System

Chapter 19

BIS Specifications

Terminology

Types

Gypsum Wallboards

Gypsum Wallboard with Reduced Water

Absorption Rate

Gypsum Wallboard with Improved Core Cohesion at High Temperatures

Gypsum Plaster Baseboard

Gypsum Plaster Baseboard with Improved Core Cohesion at High Temperatures

Materials

Gypsum Plaster

Manufacture

Plain gypsum plaster boards according to is 2095 (part 1): 2011

Name of the product Plain Gypsum Plaster Board

Grouping Guidelines

List of Test Equipment

Major test equipment required to test as per the Indian Standard

Scheme of Inspection and Testing

Chapter 20

Process Flow Sheet

Flow diagram of the manufacturing gypsum and analysis

Raw material preparation

Manufacture gypsum

Chapter 21

Plant Layout

Plant Location

Evaluating Location Alternatives

Markets

Factors Affecting Plant Location

Factors Evaluation

Plant Layout

The Production Line

Other departments of the plant

Plant Layout Method

Activity Relationship Chart

Typical Process of Manufacturing Gypsum Board

Raw Materials

Crusher

Grinding Mill

Calcine System

Stucco Holding Tank

Mixer

Forming Station

Typical Process of Manufacturing Gypsum Board

Board Line

Cut off Knife

Transfer Table

Kiln

Chapter 22

Preparation of Other Gypsum and Anhydrite

Phosphogypsum

What is the Difference Between Gypsum and Phosphogypsum?

Summary – Gypsum vsPhosphogypsum

Titanogypsum

Insoluble Anhydrite

Calcination

Plaster mill-rock

Batch Kettle

Batch kettle with four transverse flues, usually oil or coal fired

Continuous Kettles

Continuous stucco production

Submerged Combustion Kettles

Kettle with submerged combustion

Conical Kettle

Conical kettle

Analysis of stuccos produced

Rotary Kilns

Co-current rotary kiln

Imp mill calcination

Ring Ball and Roller Mills

Claudius-Peters ring ball calciner with classifier

Calcidyne Unit

Calcidynecalcining system

Anhydrous and Multiphase Plaster

Conveyor kiln for anhydrite production

Alpha-Hemihydrate Plasters

Autoclave for alpha-plaster production

Chapter 23

BIS Specifications

Terminology

Types

Gypsum Wallboards

Gypsum Wallboard with Reduced Water

Gypsum Wallboard with Improved Core Cohesion at High Temperatures

Gypsum Plaster Baseboard

Gypsum Plaster Baseboard with Improved Core Cohesion at High Temperatures

Chapter 24

Photographs of Machinery

Automatic Production Line of Gypsum Board Machine

Gypsum Plaster Board Making Machine with PLC Control System

Gypsum Plaster Powder Production Line Manufacturers Equip

Fluidized Bed Type Gypsum Plaster of Paris Powder Machine

High Quality Advanced Gypsum Powder Plaster of Paris Making Machine

Gypsum Plaster Powder Production Machinery

Gypsum Dryer Working Process Machine

Conveyor

Crusher

Chapter 25

Plant Economics of Calcined Gypsum for Plaster in Construction Sector

Introduction

Gypsum and its Types

Two Types of Gypsum: Natural and FGD

Manufacturing process of calcined gypsum

Reaction

Preparation of Gypsum

Preparation of Fuel

Reserve Storage

Quality of Plaster Produced

Activities in gypsum processing

Description

Process Flow Diagram

Technicalities, Emission & its Control in Gypsum Processing

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 26

Plant Economics of Dry Mix Mortar (DMM)

Introduction

Mortars

Air-Setting Mortar

Hot-Setting Bonding Mortar

Masonry Cements

Process and Equipment Mainly used in Dry Mortar Plant

Raw Sand Receiving & Storage

Cement, Fly ash and Additive receiving and storage

Mixing

Mixer Discharge and packing

Raw Materials and Composition of Dry Mix Mortar

Formulations

Internal Plaster Mortar

External Plaster Mortar

Masonry Mortar

Quick Setting Mortar (RCC)

High Strength Mortar

Repair Mortar (Mortar For Repair & Patcm Work)

Self Leveling Flooring Mortar

Premix RCC Mortar

Process of Manufacture of Ready Dry Mix Mortar

Working Process of Rotary Dryer

Manufacturing of Various Types of Ready Mix Dry Mortars in the Same Plant

Process Flow Diagram

Ingredient used for the Manufacture of Ready Mix Dry Mortars

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 27

Plant Economics of Gypsum Board and Gypsum Wall Putty

Introduction

Wall Putty

Manufacture of gypsum plaster board

Edge and end profiles

Requirements

Dimensions of gypsum plaster boards

Transverse Strength

Breaking load of gypsum plaster boards

Measurement of Taper Profile

Taper Width

Taper Depth

Sampling and criteria for conformity

Sale of sampling

Number of tests and Criteria for Conformity

Sample size

Finish

Packing and marking

Manufacturing Process of Gypsum Board

Preparation of Raw Materials

Calcining of Gypsum

Preparation of Paste

Moulding in the form of Boards

Drying of Boards

Formulation of gypsum wall putty

Process Flow Sheet

Formulation of gypsum board

Mixing method of wall putty

Manufacturing process of gypsum wall putty

Plant Economics

Land & Building

Process flow diagram of gypsum wall putty

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 28

Plant Economics of Gypsum Plaster Board

Introduction

Gypsum Material Characteristics

Abrasive

Dust and Clumps

Raw Material Description

Gypsum board - a part replacement to wood

Types of gypsum board

Types of Gypsum Board (Based on Material strength)

Gypsum liner board

Manufacturing Technology for Gypsum Board

Machines and Equipment

Manufacturing process

Process Flow Diagram

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum

Chapter 29

Plant Economics of Manufacturing of Plaster Board Liners (Heavy Duty Papers)

Industry Overview

Kraft Paper Unit

Fiber Preparation

Stock Preparation

Approach flow

Head Box

Paper Machine

Wire Table

Press and Dryer Section

D.C. Drive

Finishing

Rewinder

Sheet Cutter

Quality Control

Waste Paper

Local Suppliers

Foreign Suppliers

Water

Air

Effluent Treatment

Plant Economics

Land & Building

Plant & Machinery

Fixed Capital

Working Capital Requirement/Month

Total Capital Investment

Turn Over/Annum