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Gypsum Plaster Production Plants


Gypsum Plaster Production Plants

IPS PLASTER TECHNOLOGY

 

Plaster;

 

Gypsum was inherited from the sea that evaporates 20-30 million years ago while land fragments were formed. In nature, gypsum is mainly present as anhydride (CaSO4) or dihydrate (CaSO42H2O). In the last two centuries, the human culture of gypsum has been so developed that more than 100 million tons of gypsum is consumed in more than 100 countries today. Gypsum in developed countries today; 80-85% construction plaster production, 10-15% industrial use (cement production, glass industry, mold making, drilling, animal feed and pesticide production, paint, glue, plastic production, food, pharmaceutical industry etc.) and 25% agricultural used as a purpose. Gypsum; Chemical composition of calcium sulphate is a mineral in the composition of two molycrystalline water type JIPS (CaSO4.2H2O), anhydrous calcium sulphate mineral is also called ANHIDRITE (CaSO4). Although there are beds where each is located separately, these two minerals often coexist.

 

Gypsum is found in 6 ways in nature. These; Natural Anhydride, Bassanite, Gypsum, Albatr, silk Jips and Selenit

 

 

Lime

Sulfur trioxide

Crystal water

 

(CaO)

(SO3)

 

Gypsum

% 32.6

% 46.5

% 20.9

anhydride

% 41.2

% 58.8

-------

 

Both gypsum and anhydrite are never found in pure form. There are two reasons for this. Each of these two minerals can be converted to another. In addition, foreign materials may be mixed with gypsum beds. Some of these foreign substances; Calcium, Carbonate (CaCO3), Magnesium Carbonate (MgCO3) Chlorides, other Sulfates, Clay Minerals or Silica. As a result, gypsum is obtained only in purity between 85% and 95%. The gypsum is generally used with the quality of the quarry and without any treatment.

Gypsum has very wide beds around the world. Countries with large quantities of gypsum reserves in the world United States, France, Russia, Britain, Canada and Turkey. The purity of gypsum found in gypsum deposits in Turkey compared to western countries is very good. This ratio is used in 70% purity gypsum in Western countries is around 95-99% in Turkey. Gypsum is mainly used in construction sector, in agriculture (enriching soils for Ca2 +) and in cement industry (freezing time as regulator).

 

Gypsum Plants;

 

Technological Gypsum Plants designed by our company We offer the most accurate and most suitable facilities for our customers by taking into account the characteristics of our customers, the current fuel type, capacity needs, market targets and facilities, production cost expenses. Our facilities are designed to have a single calcination kiln with a capacity of 100 Ton / Day to 1000 ton / day. The capacity of the plants can be increased by increasing the number of furnaces.

 

With IPS Technology;

 

The facilities are shown to our customers in three dimensions by our project unit.

• Investment plans are prepared according to your future plans.

• You can take firm steps in building sector with the advantage of comfortable operation.

• Easy maintenance and intervention will increase your plant's efficiency.

• With our labor-saving systems, both speed and efficiency will increase and your costs will decrease.

• Factory can be controlled easily with automation system.

• With our special design machines, you can increase your product range and contribute to your R & D work.

Our facilities consist of 7 (Seven) main units;

 

• Raw Material Crushing and Screening;

 

Gypsum furnace entrance size from the quarries (Max. 60 cm) to the factory stone stock area with max. System is broken up to 0-10 mm size. The main machines that comprise this system are composed of polymeric breaker, seconder breaker, vibrating screen and transmission lines. This system allows the gypsum to be adjusted to the range of grains required for the calcination.

 

• Calcined Rotary Kiln;

 

Our rotary kiln designs are designed according to the chemical analysis of the plaster, capacity values and fuel type. The data is carefully examined by our project unit and calcination furnaces with suitable diameter, height and interior design are performed by considering the minimum fuel consumption. In our kiln systems, the tonnage knowledge of the plaster, the temperature values at certain points of the system, the control of the pressure values in the furnace cycle and the furnace, and the production of quality basic plaster in IPS Plaster Technology are provided. The furnace units, which are the heart of Gypsum Plants, eliminate human error with PLC automation control.

 

• Grinding and Seperation;

 

Gypsum Calcite Rotary Kiln units in these systems, which have IPS designs, allow to obtain plaster in the range of grain required for Plaster, Satin and Plaster plate. The gypsum mills bring the gypsum to a range of 0-1000 μ, and 0-100 μ product is required for the satin gypsum after the dynamic separator. Pim mills use different sizes of sieve, long-term pin hammer resistance, different speed adjustment, optional automatic bed cooling and varying sizes depending on the need low energy consumption one-step systems. Our Dynamic Separators allow to separate the 85% of the separable material in the material to be separated and to reach the desired grain size in the range of 50 μ to 400 μ.

 

• Dosing and Weighing;

 

In these systems, Gypsum and Filling Materials (Calcite, Perlite, Lime) are weighed in accordance with the mixture capacity in the previously entered values and the weighing prepared after the mixer process is sent to the mixture. Prescriptions are stored with automation software and both production follow-up is provided and the product that you produce years ago is re-produced.

 

• Mixing;

 

Units that are coupled to your systems as IPS can be implemented in Linear or Rotary Packaging according to their capacity needs. Optionally, our packaging is available with Rotor or Air filling. Our packaging machines are PLC controlled and they carry out the operation with ± 2% accuracy in world standards. PP or Kraft bags can be used if requested. Our Linear Packaging 250-300 bags / hour in single packaging It can reach 2800 bags / hour capacity. Our packagings perform the filling and process completion steps automatically and ensure that the prescriptions for the product are stable in bags.

 

• dedusting ;

 

Each unit includes filter systems with separate capacity, air flow rate calculated according to the application place and dust load. These systems prevent dust leaks in Gypsum Plants and provide recovery to the system. In this way, the working environment is made more favorable to the system.

 

• Perlite expansion;

 

The perlite in the range of 0-600 μ tanel allows for expansion between 17 and 24 times depending on the chemical structure of the crude active perlite in the expansion plant. In this way, perlite air gap structure contributes to the insulation of plaster. Expansion systems of raw perlite can be activated or passivated to Gypsum Plants by designing according to grain size and fuel type. Gypsum plant needs to be designed in excess capacity and the possibility of transportation to different markets can be provided.

 

• Micronized Calcite Grinding and Decomposition;

 

Facilities are designed according to the capacity of the gypsum plants to meet the filling material requirements. The gypsum needs of each type of gypsum found in the Gypsum Plant product range are met. Gypsum is added to give surface hardness, easy mixing and strength. Calcite O (fine calcite) 0-90 800, Calcite 1 (thick calcite) 0-800 90, Calcite 3 (thick calcite) 90-1200 ler is obtained for use in Gypsum plants. Gypsum plant needs to be designed in excess capacity and the possibility of transportation to different markets can be provided.

 

• Micro Dosing;

 

Because chemical additives are low on grams and grams based on prescriptions, doing this process by manpower often leads to errors. These errors are returned to you in time, capacity, labor and cost. Therefore, Micro dosing systems designed by IPS to Plaster Plants will return to you as a profit. Chemicals are prepared for each charge according to the prescription and the mixture time is delivered to the mixer. This process is done automatically with the help of automation does not allow human errors.

 

• Automatic Palletizing;

IPS-FAP Fully Automatic Palletizing Machine, which we designed as IPS for our businesses with our experience in dust and mining sector, eliminates labor and time losses in palletizing process in Gypsum Plants. IPS-FAP Fully Automatic Palletizing Machine will help you to make faster production in your production facilities, to use your stock space more efficiently, to save on labor force and to be in front of your opponents with perfect palette sequence. PP, PE and Kraft bags can also be used in pallet stacking.

 

General properties of Gypsum and Plaster Factory to be produced by our company depending on the characteristics of Natural Gypsum stone;

Particle Size                                    :           0-1000 micron calcined gypsum

 

 

Freezing time                        Early Start            :         8-9 min.

 

                                                 Last Finish           :         22-24 min.

 

 

The energy consumption of our facilities designed by our company; (Based on summer months)

 

Electricity                               :         22 - 26 kwh / ton

 

 

Natural gas                            :         22 - 23 m3 / ton (according to 8200 Kcal / Nm3 calorific value)