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DCI builds plaster powder production lines from 20,000 to 100,000 t/y on the grinding-before-calcination route. Gypsum rock is crushed to 10–40 mm, ground to raw powder, then calcined in a boiling kiln or rotary kiln, aged and packed. Full automatic and semi-automatic control are both available on a Siemens PLC. Delivered turnkey with installation, commissioning and operator training.
DCI builds plaster powder production lines in the 20,000–100,000 t/y range on the grinding-before-calcination route. Gypsum rock is crushed to 10–40 mm, ground to raw powder, and then calcined in either a boiling kiln or a rotary kiln. Each line is delivered turnkey: process design, equipment manufacture, installation, commissioning and operator training.
DCI builds gypsum powder lines on three process routes, and the route follows the raw material and the product requirement. This plaster powder plant covers the compact grinding-first line. Projects above 100,000 t/y on a grinding-first route use the vertical kiln line; projects that need calcining before grinding use the calcining-first line.
Route | Process order | Capacity |
This line | Crush, grind, then calcine in boiling kiln or rotary kiln | 20,000–100,000 t/y |
Calcining-first line | Crush, calcine in rotary kiln, age, then grind | 30,000–200,000 t/y |
Large grinding-first line | Crush, grind, then calcine in boiling kiln or vertical kiln | 100,000–300,000 t/y |
Gypsum rock enters the crusher and is reduced to 10–40 mm. The crushed rock is fed to a grinding mill to produce raw gypsum powder. The powder is lifted by bucket elevator to a storage silo, measured automatically and accurately by belt scale under PLC control, and fed into the calcination kiln. Heat from a hot air stove or boiler drives off the crystallisation water, converting dihydrate gypsum into hemihydrate stucco. After cooling or aging, the finished powder is packed into bags.
Grinding before calcination means the kiln receives powder of an even particle size, and the mill works on raw rock rather than on hot calcined material.
System | Function |
Crushing | Reduces run-of-mine gypsum rock to 10–40 mm |
Grinding | Raymond mill producing raw gypsum powder before calcination |
Storage and weighing | Bucket elevator to silo, automatic measurement by belt scale with PLC control |
Calcination | Boiling kiln or rotary kiln, hot air stove or boiler as heat source |
Cooling and aging | Stabilises phase composition before packing |
Packing | Finished stucco bagged to the customer's bag specification |
Two calcination systems are available on this line: the boiling kiln, also written as ebullition furnace, and the rotary kiln. The choice follows the product requirement rather than the budget alone.
System | Best suited to | Notes |
Boiling kiln (ebullition furnace) | Standard building plaster, compact sites | Fluidised-bed calciner; heating medium can be thermal oil, hot air or steam; compact, low energy consumption, stable phase composition |
Rotary kiln | Higher whiteness or wider feed size | Indirect combustion; accepts feed up to 30 mm; can calcine powder finer than 80 mesh |
Parameter | Specification |
Annual capacity | 20,000–100,000 t/y (customised by configuration) |
Process order | Crushing, grinding, calcination, aging, packing |
Calcination system | Boiling kiln or rotary kiln |
Control | Full automatic or semi-automatic, Siemens PLC |
Fuel | Natural gas, diesel, coal, heavy oil |
Raw material | Natural gypsum rock (CaSO4·2H2O content above 80%), FGD gypsum, phosphogypsum |
Finished product | β-hemihydrate gypsum powder (β-CaSO4·1/2H2O), no admixture or additive |
Quality standard | GB/T 9776-2008 |
Main use of powder | Gypsum board, plaster powder and putty |
Technical data are taken from DCI's standard configuration for this capacity class and the product catalogue. Final configuration is confirmed against the customer's raw material analysis, fuel and site conditions.
The line is designed around natural gypsum rock with a CaSO4·2H2O content above 80%, conforming to the requirements of JC/T 700 for gypsum rock used in cementing materials, grade 3 or higher. FGD gypsum and phosphogypsum can also be processed; both change the feed preparation and drying stages, so the flow sheet is fixed only after the raw material is confirmed by analysis.Every gypsum factory setup is configured against that analysis rather than from a fixed list.
The division of work below is DCI's standard split for a line of this class. The final scope is written into the supply contract.
Party | Item | Responsibility |
Buyer | 1.1 | Machinery and tools for installation, commissioning and maintenance |
Buyer | 1.2 | Transport equipment: two forklifts |
Buyer | 1.3 | High-voltage power supply, substation and distribution station |
Buyer | 1.4 | Water supply, storage and drainage system |
Buyer | 1.5 | Civil engineering: buildings, equipment foundations including pre-buried parts, silos and pools |
Buyer | 1.6 | Material for machine platforms and supporting frames |
Buyer | 1.7 | Round-trip tickets and transport for the seller's workers |
Buyer | 1.8 | Accommodation and necessary allowances for the seller's workers during installation, commissioning and training |
Buyer | 1.9 | Large tools such as crane, forklift, welder and cutting equipment |
Buyer | 1.10 | Assistant workers to cooperate with the seller's team as required |
Buyer | 1.11 | Usage permission for special equipment |
Seller | 2.1 | Production equipment |
Seller | 2.2 | Installation guiding engineers and technical workers |
Seller | 2.3 | One team leader and one interpreter |
Seller | 2.4 | Foundation drawings and general arrangement drawings within 40 days of down payment |
Seller | 2.5 | Operation manual provided during training |
Seller | 2.6 | Assembly drawings, control cabinet wiring diagrams and PLC programs within 7 days of acceptance |
Seller | 2.7 | Commissioning and training, including full-scale testing and handover to the buyer's operators |
Seller | 2.8 | Free technical consultation within one year of the acceptance certificate |
DCI sends engineers and technical workers to site for full-scale testing, with the buyer supplying assistant staff to cooperate. The seller's team runs the line, explains the operation on site and answers questions from the buyer's technicians and operators. Once the buyer's workers have mastered the operating technique, the running line is handed over and training is complete.
Q: What capacity can this line deliver?
A: 20,000 to 100,000 t/y, customised against the raw material and the required product.
Q: Should I choose the boiling kiln or the rotary kiln?
A: The boiling kiln suits standard building plaster and compact sites, with low energy consumption and a stable phase composition. The rotary kiln produces higher-whiteness powder and accepts a wider feed size range.
Q: What is the difference between grinding first and calcining first?
A: Grinding first gives the kiln powder of an even particle size and keeps the mill on cold raw rock. Calcining first lets the kiln take coarser rock and is used where the product calls for it. Both routes meet the same finished-powder standard.
Q: What raw material can the line process?
A: Natural gypsum rock above 80% CaSO4·2H2O, FGD gypsum and phosphogypsum. The feed preparation stages differ by material.
Q: What standard does the finished powder meet?
A: GB/T 9776-2008. DCI also confirms the finished powder against the setting-time requirement agreed in the contract.
Q: What does the buyer need to prepare?
A: Civil works and foundations, high-voltage power supply and substation, water supply and drainage, large tools and local assistant labour, plus travel and accommodation for DCI's engineers. The full list is in the contract.
Send us your target capacity, raw material type and available fuel, and our engineering team will return a tailored configuration and quotation. Hengshui Decheng Machinery & Equipment Co., Ltd. (DCI)
Email: dci@chinagypsummachine.com | WhatsApp: +86 13930110827 / +86 18203235588
| www.dcimachine.com
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