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An automatic gypsum powder production line is designed to convert raw gypsum ore into a consistent and fine powder known as calcined gypsum or stucco, which is the primary raw material for gypsum board. Automation is central to this process, ensuring consistent product quality and reducing manual intervention.
The production line starts with the raw material handling system. Raw gypsum rock, sourced from quarries, is first fed into a crusher. The crusher reduces the large rocks to smaller fragments, typically under a certain size, to prepare them for the subsequent grinding process. This initial size reduction is crucial for improving the efficiency of the entire system.
The crushed gypsum is then transported, often by a bucket elevator or conveyor, to a grinding mill. In this stage, the gypsum is pulverized into a fine powder. Modern systems often integrate grinding and calcining into a single unit, such as a grinding calciner, which enhances thermal efficiency. The goal of grinding is to achieve a consistent particle size distribution that is optimal for the calcination reaction.
Calcination is the core thermal process of the production line. The ground gypsum powder is heated to a specific temperature range, typically between 150°C and 180°C. During this process, the dihydrate gypsum (CaSO₄·2H₂O) loses a portion of its chemically combined water and is converted into calcium sulfate hemihydrate (CaSO₄·½H₂O), also known as stucco. The type of calciner used, such as a rotary kiln, kettle, or flash calciner, can vary, but the automated control of temperature and material residence time is vital for producing a uniform product.
After calcination, the hot gypsum powder (stucco) may be conveyed to an aging silo. The aging process allows the material to cool and stabilize, which results in a more consistent setting time when it is later mixed with water in the board plant. Additives can be introduced during or after calcination to modify the final powder's properties.
The final stages involve storage and packaging. The finished gypsum powder is transported to large storage silos. From these silos, it can be automatically loaded into bulk tankers for shipment to a board plant, or it can be fed into automated bagging machines for packaging in sacks. Throughout the entire line, from crushing to packaging, automated control systems monitor and regulate material flow, temperatures, and equipment operation.
This high level of automation helps maintain a stable production rhythm and consistent powder quality. Hengshui Decheng Machinery & Equipment Co., Ltd. specializes in providing equipment and technical support for such automatic gypsum powder production lines, focusing on system integration and operational reliability.
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