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The Gypsum Powder Manufacturing Process is a multi-stage industrial procedure that converts natural or synthetic gypsum into fine powder suitable for construction, plastering, prefabricated panels, and other applications. Understanding each step in the process is essential for manufacturers seeking stable quality, energy efficiency, and scalable production.
This article provides a detailed breakdown of the gypsum powder manufacturing process, including material preparation, calcination technology, grinding systems, environmental controls, and process optimization strategies.
The process begins with gypsum rock (CaSO₄·2H₂O), which may be mined naturally or recovered from industrial by-products such as flue gas desulfurization (FGD) systems.
Remove impurities
Reduce particle size
Stabilize moisture content
| Stage | Equipment | Function |
|---|---|---|
| Feeding | Vibrating feeder | Controls material flow |
| Crushing | Jaw or hammer crusher | Reduces stone size |
| Screening | Vibrating screen | Separates oversized particles |
Proper raw material preparation ensures consistent calcination and prevents equipment overload.
Moisture content directly affects calcination efficiency. If gypsum contains excessive water, pre-drying may be required.
Rotary dryers
Hot air systems
Waste heat recovery systems
Maintaining moisture within controlled limits improves energy utilization during thermal processing.
Calcination is the core stage of the Gypsum Powder Manufacturing Process. During this step, gypsum dihydrate is heated to remove part of its chemically combined water, producing calcium sulfate hemihydrate.
CaSO₄·2H₂O → CaSO₄·½H₂O + 1.5H₂O (steam)
| Equipment Type | Characteristics | Application Scale |
|---|---|---|
| Rotary kiln | Continuous operation | Large capacity plants |
| Kettle calciner | Batch operation | Medium capacity |
| Fluidized bed calciner | Uniform heat transfer | High efficiency production |
Temperature control typically ranges between 120°C and 180°C depending on product specification.
After calcination, material is ground into fine powder.
Raymond mill
Ball mill
Vertical roller mill
Air classifiers are integrated to control particle size distribution, ensuring uniform product quality.
Finished gypsum powder is transported pneumatically to storage silos and then packed in:
25–50 kg bags
Bulk tankers
Jumbo bags
Automated packing systems reduce labor intensity and ensure weight accuracy.
Dust management is critical in gypsum processing.
Pulse jet bag filters
Cyclone separators
Enclosed conveyor systems
Effective dust control protects workers and meets environmental compliance requirements.
Modern gypsum powder plants incorporate PLC-based control systems to monitor:
Temperature stability
Production rate
Motor load
Dust concentration
Automation reduces human error and ensures consistent product properties.
Hengshui Decheng Machinery & Equipment Co.,Ltd provides integrated solutions for the gypsum powder manufacturing process, including equipment selection, layout planning, installation support, and commissioning guidance. The company focuses on coordinating crushing, calcination, grinding, and environmental systems to maintain stable production performance.
Q1: What is the most critical stage in the gypsum powder manufacturing process?
Calcination is critical because it determines setting time and strength characteristics.
Q2: How can energy consumption be reduced?
Using waste heat recovery and efficient calcination systems can significantly reduce fuel costs.
Q3: Can synthetic gypsum be used?
Yes, but process parameters must be adjusted for purity and moisture content.
Q4: How is product fineness controlled?
Through grinding mill configuration and air classification systems.
Consistency in gypsum powder quality depends on synchronized operation between thermal systems and grinding systems. Minor temperature fluctuations during calcination can significantly alter final product performance. Therefore, precise thermal control and stable material feed are essential for industrial-scale manufacturing.
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