EPA-600/2-77-023q
February 1977
Environmental Protection Technology Series
INDUSTRIAL!^
ENVIRONMENTAL USE: Chapter 17.
The Gypsum and Wallboard
Industry
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
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RESEARCH REPORTING SERIES
Researph reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-77-023q
February 1977
INDUSTRIAL PROCESS PROFILES
FOR ENVIRONMENTAL USE
CHAPTER 17
by
P. E. Muelberg and B. P. Shepherd
Dow Chemical
Freeport, Texas 77541
Terry Parsons
Radian Corporation
Austin, Texas 78766
Contract No. 68-02-1319
Project Officer
Alfred B. Craig
Metals and Inorganic Chemicals Branch
Industrial Environmental Research Laboratory
Cincinnati, Ohio 45268
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Industrial Environmental Research
Laboratory - Cincinnati, U.S. Environmental Protection Agency, and approved
for .publication. Approval does not signify that the contents necessarily
reflect the views and policies of the U.S. Environmental Protection Agency,
nor does mention of trade names or commercial products constitute endorsement
or recommendation for use.
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TABLE OF CONTENTS
CHAPTER 17
Page
INDUSTRY DESCRIPTION 1
Raw Materials 2
Products 2
Companies 3
Environmental Impact 4
Bibliography 5
INDUSTRY ANALYSIS 6
Process No. 1. Mining 9
Process No. 2. Crushing/Grin ding 12
Process No. 3. Pot Calcination 15
Process No. 4. Rotary Calcination 18
Process No. 5. Pulverizing 20
Process No. 6. Packaging 23
Process No. 7. Blending 25
Process No. 8. Fabrication Plant 27
Process No. 9. Calcination/Pulverizing 30
Appendix A - Raw Materials 33
Appendix B - Products 35
Appendix C - Companies and Products 37
in
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LIST OF FIGURES
CHAPTER 17
Table Page
1 Product Tree 7
2 Gypsum Products from Gypsum Rock 8
IV
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LIST OF TABLES
CHAPTER 17
Table Page
A-l List of Raw Materials 32
B-l List of Products 34
C-l Gypsum and Calcining Plants in the United
States in 1973 36
v
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ACKNOWLEDGEMENTS
This chapter of the Industrial Process Profiles for Environmental
Use was prepared for EPA by Dow Chemical, U.S.A., Texas Division,
under Contract No. 68-02-1329, Task 8. The contributions of
P. E. Muehlberg and B. P. Shepherd in preparation of this catalog
entry are gratefully acknowledged.
Helpful review comments from Gilbert C. Robinson were received
and incorporated into this chapter.
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GYPSUM AND WALLBOARD INDUSTRY
INDUSTRY DESCRIPTION
The industry comprises operations which mine gypsum deposits
and process the mined gypsum rock into crushed or pulverized
uncalcined gypsum, pulverized calcined gypsum (various types
of wall plasters and specialty plasters), and a diversity of
prefabricated gypsum-core board products (wallboard, rock-
lath, sheathing, and formboard). The latter end-product
category accounts for approximately three-quarters of the
total product tonnage and an even greater fraction of total
product value.
The relative simplicity of gypsum processing is evident from
the single flow diagram of Figure 2 (page 7). All operation
except for differences in product mix are similar, employing
basically the same processes in fundamentally the same sequence.
Mining is by open-pit (quarrying) methods in three-quarters
of the operations. Calcining is conducted in either pot-
kilns (usual) or in continuous rotary kilns. The balance of
the operations chiefly involve size reduction and size
separations. Most of the equipment, including that in pre-
fabricating plants, is standardized throughout the industry.
The industry includes a total of 108 facilities (1973) in-
volving either mining plus mechanically processing crude
gypsum rock, or calcining and producing prefabricated
products. Of this total, 36 facilities were integrated
mining-plus-fabricating operations.
The size of a single installation, gaged by the number of
employees, ranges from four persons in a small open-pit
mining operation to between 100 and 120 persons, in a large
facility combining an underground mine and a calcining-
fabrication plant. Total employment during 1973 for the
entire industry was 3,200 persons. In the same year about
19 million metric tons of gypsum products were produced from
12 million metric tons of domestically mined gypsum plus
7 million metric tons of imported gypsum rock.
Gypsum rock is mined in 22 states and is calcined and fabri-
cated in 32. The relatively low unit value of crude gypsum
(approximately $4.50 per metric ton) economically limits its
rail transportation to relatively short, single-line hauls
and accounts for the importation of approximately 37% of the
crude rock consumed. Imported rock was used to supply 32
calcining plants located near population centers in 15
states on all three seaboards. In only five situations is
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domestic gypsum rock transported by rail freight from the
mine to a calcining plant.
The industry has experienced a compounded, annual A 1/2 per-
cent growth rate during the decade ending with the close of
1973. A compounded, annual 4 percent growth rate is pre-
dicted to 1980.
It is believed that none of the operations in the industry
generate on-site power and that steam is generated on-site
in package steam boilers. Statistical information is
entirely lacking.
Raw Materials
Bedded gypsum "rock" deposits form the usual and most desir-
able type of raw material for the industry and are usually
the only type capable of economic exploitation. These may
be either near-surface deposits or lie at typical depths of
50 to 400 meters. This type of deposit usually contains
between 85 and 95 percent pure gypsum. Some bedded gypsum
rock in Michigan contains about 99 percent gypsum.
Near-surface deposits of gypsite (gypsum intermingled with
clay) and selenite, containing as little as 70 percent
gypsum, are of commercial value.
About three-quarters of the existing gypsum mines are open-pit
operations.
Usually, it is not economically possible to beneficiate
mined gypsum ore except by screening. Exceptions are the
gypsite deposits of Southern California and the gypsum mined
in Ottawa County, Ohio, where heavy-media separation is used.
Adverse environmental impact situations arise from the
"craters" and mounds of overburden resulting from strip-
mining methods and from the dust (non-toxic) created during
drying and crushing the mined rock. Quantifying information
is unavailable for both types of problems.
The raw materials used in this industry are listed in Appendix A.
Products
The 19 million metric tons of crude gypsum consumed by the
industry during 1973 were processed into the end-product
categories listed as follows:
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Uncalcined products -
Sold crushed for Portland cement retarder 20%
Sold pulverized for agricultural use
(land plaster) 1%
Calcined products -
Prefabricated board products 67%
Wall plasters ^%
Plaster of paris, "soluble anhydrite,"
dead-burned gypsum for specialty cements,
paper fillers, paint pigment, and others
Total
Prefabricated wallboard products are steadily replacing wall
plasters for interior wall construction.
A more complete list of products appears in Appendix B.
Companies
The 40 companies populating the industry are of two distinct
types:
(1) Companies operating calcining-fabricating
installations
(2) Companies conducting only mining and grinding
operations
The 13 companies comprising the first group, with two excep-
tions (Kaiser Gypsum Company and California Gypsum Company),
also mine a major fraction of their crude gypsum supply.
Collectively, they operate 77 calcining-fabricating plants
and 41 mines. Of these, 36 are integrated mine-plus-plant
facilities. Nine of the companies are multi-industry
organizations with operations in at least one other industry
producing end-products for use by the construction industries.
The second group includes 29 companies who sell sized, ground,
or crushed gypsum rock to the companies of the first group,
to the open market for agricultural use, and to the cement
industry. With exceptions, notably Universal Atlas Portland
Cement Company and Southwestern Portland Cement Company,
these companies are all smaller than those of the first type.
Their combined operations produce less than one-quarter of
the total gypsum mined.
Five companies produced about 85 percent of the total calcined
gypsum in 1972:
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United States Gypsum Company
National Gypsum Company
Georgia-Pacific Corporation
The Flintkote Company
Kaiser Gypsum Company, Inc.
Slightly more than three-quarters of the crude gypsum pro-
duced was mined by five companies in 1972:
United States Gypsum Company
National Gypsum Company
Georgia-Pacific Corporation
The Flintkote Company
The Celotex Company
Appendix C contains a complete list of producing companies.
Environmental Impact
Fugitive emissions of particulate gypsum or calcium sulfate
from crushing and grinding equipment, calciners, and dryers
are inherent in the industry. No serious problems have
resulted when dust control equipment is adequate. No quan-
tifying information is available. Gypsum dust is non-toxic.
In addition to the temporary overburden piles generated in
strip mining, mentioned above, calcining plants may have
occasional, inadvertent solid wastes of "overburned"
material resulting from faulty operation. Disposal of this
material, anhydrite, is by landfill methods or by beneficial
use in grading low-lying plant areas. The material is
entirely nontoxic.
Because process heat is supplied by fuel combustion, sulfur oxides,
nitrogen oxides, particulates, and hydrocarbons may be present in
combustion gases, depending on the fuel burned and on the combustion
efficiency.
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Bibliography
Gypsum: Housing Starts Drop May Lower Demand. Rock
Products. 77.: 50-51, December 1974.
Havard, J. P. Gypsum. In: Industrial Minerals and Rocks,
3rd Edition, Lovejoy, J. M. (ed.). New York, Am. Soc. of
Min. Met. & Petr. Eng., I960. p. 471-476.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1972, Schreck,
A. E. (ed.). Washington, U. S. Dept. of the Interior, 1974.
1:597-604.
Reed, A. H. Gypsum, Quarterly. In: Mineral Industry
Surveys. Washington, U. S. Dept. of the Interior, July 23,
1974. 7 p-
Schroeder, J. H. Gypsum. In: Mineral Pacts and Problems.
Washington, U. S. Dept. of the Interior, 1970. p. 1039-1048.
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INDUSTRY ANALYSIS
Mining of domestic sources of gypsum dates to 1792; the use
of gypsum-derived plasters, to 1835; and commercial produc-
tion of gypsum wallboard, to the first decades of the present
century. The present-day technology relating to all three of
these phases is in general use, with minor variations, by all
companies operating within this highly competitive industry.
Data derived from the sources listed in the Bibliographies
of the Process Descriptions are generally valid for all
installations.
Availability of quantitative information on emissions has in
most cases been inadequate to completely define the physical
characteristics and quantities of process wastes, or even
the factual existence of an emission. In these cases the
possible occurrence of an emission and its probable magnitude
have been estimated from what is commonly known about similar
or identical types of equipment operating on material having
closely related properties.
The chemical tree of Figure 1 attempts to give diagrammati-
cally a qualitative overview of the entire industry from a
raw material-product standpoint. A fairly wide diversity
of end uses requires a disproportionately small fraction
(2 percent) of total product tonnage represented by dead-
burned gypsum.
The process flowsheet of Figure 2 shows process blocks repre-
senting the two most frequently used, alternative calcining
methods in batchwise operated pot kilns and continuous rotary
kilns. The infrequently used method of calcining the gypsum
in hammermills is not shown.
The single raw material shown on the flow diagram and labeled
"gypsum deposit," includes deposits of gypsite and selenite
as well as bedded gypsum, the most important and desirable
source.
A number has been assigned to each of the process blocks,
uniquely identifying the process with an appropriate title
and with a process description. Flag symbols at the upper
right-hand corner of the process block are used to indicate
the nature of the waste streams, if any, discharged from the
process - a circle for atmospheric emissions, a triangle for
liquid wastes, and a rhombus for solid wastes. The flags do
not differentiate between inadvertent (fugitive) and designed
wastes.
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Raw Materials
Industry
End-Products:
Gypsum ^~
Gypsite — *-
Selenite -»•—
Hiinrfllrined J ^.
Gypsum J
^ (Calcined) ^
"~ I Gypsum J
_^n_' Anvinil tiipnl '_
<• Gypsum '
Prefabricated
•fc board
products
^ t Wall >
^ (plasters)
plaster )
(of par Is/
to ( "Soluble )
lanhydrlte'T"
^ (Dead-burned)
( gypsum /
•^ III «~J „! __4. II
->~ Wall board
-^-Chipboard sandwiches
_^__ n,-,^!.- 1-,4-h
-^— Formboard
-^—Exterior sheathing
->-Roof decking
-*•— Pottery molds
-**- Ceramic molds
-**- Surgical casts
->— Specialty products
-^-Dessicants
~^~ Floor plasters
^ Hard plasters
L^- DessicanLs
~*~~ Hard plasters
->— Keene ' s cement
->- Paper fillers
FIGURE I. GYPSUM AND WALLBOARD PRODUCT TREE
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Heat
Alum Sol 'n-
Heat _
Calcination/
Pulverizing 9
9
5
*^
•>-
raCKag ing
6
Additives •*— n
Rl pnrii nn
AriHitivfr" . .
Heat _
t "
Fabrication
Plant 8
? "^
_^J
M
9
9
^ | Cement
t Retarder
FIGURE 2. GYPSUM PRODUCTS FROM GYPSUM ROCK
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GYPSUM AND WALLBOARD INDUSTRY PROCESS NO. 1
MINING
1. Function
The process recovers gypsum rock (CaSO»'2H20) in a trans-
portable size of up to 15-cm diameter lumps from bedded
gypsum deposits. Both open-pit and underground mining
methods are used, depending upon the depth and thickness
of the deposit and character of the overburden. Open-pit
mines predominate.
The process may include the steps of coarse crushing and
size separation.
In open-pit operations, scrapers, draglines, front-end
loaders, trucks, conveyor belts, and other types of
earth-moving equipment are used to strip the overburden,
with the addition of blasting equipment to recover the
gypsum. With underground operations, equipment types are
similar to those used in underground bituminous coal
mines. Gyratory crushers are usual for size reduction.
2. Input Materials
Massive gypsum rock of the deposit constitutes the input
material. It usually contains particles of sand, clay,
shale, or limestone. These inclusions are limited to a
low percentage in commercially valuable deposits, since
any extensive beneficiation is economically unfeasible.
In a small number of instances, the deposit is gypsite
(gypsum or selenite crystals intermingled with clay).
These deposits, when of commercial value, are usually
worked by open-pit methods.
The estimated quantity of massive rock mined per metric
ton of gypsum present in wallboard product is between 1.1
and 1.2 metric tons.
Some "gypsum" deposits are, in fact, anhydrite (CaSOu).
In these cases the material may still be crushed to small
lumps (approximately 2 cm diameter) in Process 2 and sold
to the cement industry for use as Portland cement retard-
er or may be forwarded to Process 9 eventually to become
"Keene's cement"-type end products. In these cases the
quantity mined is slightly greater than 1 metric ton per
metric ton of respective end product.
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3. Operating Parameters
•Approximately three-quarters of active mines are open
pit.
•Seams 1 m thick are considered valuable if horizontal
extent is sufficient O300 hectares) and if depth is
reasonable (^50 m with rock overburden, or <5 m for
unconsolidated overburden). Most deposits are much
thicker (5 to 30 meters).
•Operations employing beneficiation (heavy-media) are
rare .
•Pines from primary crushing are usually sold to the
Portland cement industry.
4. Utilities
Energy is usually supplied from fuel oil or gasoline for
open-pit operations and may be either electrical or oil-
supplied for shaft mines. The energy consumption per
metric ton of gypsum present in wallboard is grossly
estimated to be:
•Between 2 and 10 kWh, or,
•Between 1 and 5 kg fuel oil.
5. Waste Streams
Atmospheric emissions of particulate gypsum and clay are
surmised. No quantitative information is available.
The quantity of particulates is estimated to be less than
5 kg per metric ton of gypsum present in wallboard.
Excluding stripped overburden, solid wastes of clay,
shale, limestone fragments, and low-grade gypsum are
estimated to amount to between 0.05 and 0.15 metric ton
per metric ton of gypsum present in wallboard. Disposal
is by local landfill.
In open-pit operations, UD to approximately 2 metric tons
of overburden (about 1 metric ton is usual) may be
stripped per metric ton of gypsum present in wallboard.
Disposal of these solids is also by local landfill.
6. EPA Source Classification Code
None established
10
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7. References
Cement, Lime and Plaster. In: Rogers' Industrial
Chemistry, Purnas, C. C. (ed.). New York, Van Nostrand
and Co., 1942.. p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition,
Standen, A. (ed.). New York, Interscience Publishers,
1964. 4_:20-23.
Havard, J. P. Gypsum. In: Industrial Minerals and
Rocks, 3rd Edition, Gillson, J. L. (ed.). New York,
Am. Soc. of Min. Met. & Petr. Eng., I960. p. 471-476.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1971,
Schreck, A. E. (ed.). Washington, U. S. Dept. of the
Interior, 1973. £=569-576.
Riegel, E. R. Portland Cement, Lime and Gypsum Plaster.
In: Industrial Chemistry, 5th Edition. New York,
Reinhold Publishing Corp., p. 173-175.
Schroeder, H. J. Gypsum. In: Mineral Pacts and
Problems. Washington, U. S. Dept. of the Interior,
1970. p. 1039-1048.
Taggart, A. P. Gypsum. In: Handbook of Mineral
Dressing. New York, John Wiley & Sons, Inc., 1945.
p. 3-40 to 3-42.
11
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GYPSUM AND WALLBOARD INDUSTRY PROCESS NO. 2
CRUSHING/GRINDING
1. Function
The process reduces the size of mined gypsum (CaSO,, • 2H20)
rock from approximately 15 cm maximum diameter lumps to
a range required by the type of calcining equipment used.
The steps of screening and drying are usually included
in the process.
Equipment may consist of:
•Grizzlies for rough sizing.
•Primary crushing equipment. This may be a gyratory
crusher, single-roll crusher, or hammer mill.
•Vibrating screens for size classification.
•Secondary crusher, usually of the roll type.
•Grinding equipment. This may be roller mills or
Raymond mills. Either type may be equipped to air-dry
the product.
•Rotary dryers may be used to dry the crushed product.
Pine-grinding equipment is omitted if the operation
uses rotary kilns for calcining in Process 3.
The product of the process may be forwarded in any of
five directions:
•Directly to sales as an end product (agricultural
gypsum, or "land plaster").
•Directly to sales to the cement industry for use as a
retarder in Portland cement.
•To Process 3, for calcination in pot kilns.
•To Process 4, for calcination in rotary kilns.
•To Process 9, for calcination in vertical, stack kilns.
(The quantity for this use is considerably less than for
the first-named four.)
2. Input Materials
Mined gypsum rock, ranging in size from fines to lumps
approximately 15 cm maximum diameter, is the input
material. Its estimated requirement is 1.03 to 1.07
metric tons per metric ton of gypsum in wallboard.
12
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3. Operating Parameters
•Product fineness is 95% minus 100 mesh for both feed to
pot kilns and for direct sale as agricultural gypsum.
•Particle size of product varies between 0.3 and 1.5 cm
for feed to rotary kilns.
•Particle size varies between 0.6 and 1.5 cm for direct
sale as retarder in Portland cement.
•Lump size for feed to vertical kilns (Process 9) is
typically 4 to 5 cm diameter.
•A typical integrated crushing, grinding, and screening
operation has a daily throughput of 500 to 800 metric
tons of gypsum.
4. Utilities
Consumption of electrical energy per metric ton of
gypsum in wallboard:
•Between 0.8 and 1.5 kWh for crushing to 1-cm lumps.
•Between 10 and 15 kWh for crushing and grinding to 95%
minus 100 mesh.
•In operations where a rotary dryer is used for removing
free water, the electrical energy consumption will be
increased by 3 to 5 kWh.
Fuel consumption for removing free water (estimated at
5% of gypsum weight) is estimated between 50x103 and
100x103 kcal per metric ton of gypsum in wallboard.
5. Waste Streams
Fugitive emissions of gypsum dust to the atmosphere re-
sult from all types of crushing and grinding equipment,
as well as from the rotary dryer. No quantitative in-
formation is available. The total amount of particulates
is estimated to be less than 5 kg of minus 100-mesh
gypsum per metric ton of gypsum in wallboard, with dust
collection equipment operative.
Solid wastes are discharged from grizzlies and vibrating
screens. These consist of sand, clay, limestone, and
gypsum particles. Their total weight is estimated be-
tween 30 and 50 kg per metric ton of gypsum in wallboard.
Fuel combustion may result in emissions of sulfur oxides,
nitrogen oxides, particulates and hydrocarbons, depending
on fuel burned and combustion efficiency.
6. EPA Source Classification Code
3-05-015-01 Raw Material Dryer
3-05-015-02 Primary Grinder
13
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References
Cement, Lime and Plaster. In: Rogers' Industrial
Chemistry. Furnas, C. C. (ed»). New York, Van Nostrand
& Co., 1942. p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition,
Standen, A. (ed.). New York, Interscience Publishers,
1964. 4_:20-23.
Havighorst, C. R. A Quick Look at Gypsum Manufacture.
Chem. Eng. ;72:52-54, January 4, 1965.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1971,
Schreck, A. E. (ed.). Washington, U. S. Dept. of the
Interior, 1973. I_:569-576.
Riegel, E. R. Portland Cement, Lime and Gypsum Plaster.
In: Industrial Chemistry, 5th Edition. New York,
Reinhold Publishing Corp., p. 173-175.
Schroeder, H. J. Gypsum. In: Mineral Pacts and
Problems. Washington, U. S. Dept. of the Interior, 1970.
p. 1039-1048.
Shreve, R. N. Gypsum. In: Chemical Process Industries,
3rd Edition. New York, McGraw-Hill, Inc., 1966. p. 180-
182.
Taggart, A. F. Gypsum. In: Handbook of Mineral Dress-
ing. New York, John Wiley & Sons, Inc., 1945. p. 3-40
to 3-42.
14
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GYPSUM AND WALLBOARD INDUSTRY' PROCESS NO. 3
POT CALCINATION
1. Function
The process removes combined water from ground gypsum
rock (CaSOi,'2H20) by calcination in a kiln of specialized
design (gypsum pot-kiln).
The kiln feed is received from Process 2. Almost all of
the product tonnage is calcium sulfate hemihydrate
(CaSOn "|H20). It is forwarded to Process 5 for pulveriza-
tion. In a small fraction of the cases, the product is
"second-settle" stucco, or anhydrite (CaSOi,) and may have
end uses similar to those of the Keene's cement end
product of Process 9.
The step of mixing calcium chloride liquor (CaCl2) is
included in the process. The mixing is conducted in the
batch kiln-feed stream. A subsequent step of cooling, or
"soaking," is also included.
Essential equipment consists of an externally fired, up-
right, cylindrical pot or kettle of steel or cast iron,
provided internally with rotating horizontal stirrer arms.
Cooling pits are rectangular steel boxes.
2. Input Materials
The process is fed ground gypsum rock from Process 2,
having a particle size of approximately 95$ minus 100
mesh. Between 1 and 1.03 metric tons are required per
metric ton of gypsum present in the wallboard product.
Approximately 1 to 2 kg CaCl2 per metric ton of gypsum
present in wallboard product is added to the charge.
This is probably added as a 35% solution. Its function
is to hasten rehydration to the hemihydrate of any an-
hydrite formed. The addition of CaCl2 is omitted when
"soluble" anhydrite is the intentional product.
3. Operating Parameters
Both CaSOu'-lHaO (plaster of paris or "first-settle"
stucco) and anhydrous CaSOu (anhydrite or "second-settle"
stucco) are produced in the identical pot-kilns (in
different batches) of the following description:
15
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•Kiln sizes range from 3 m diameter by 3 m deep to
5 m diameter by 6 m deep.
•Weight of charge ranges from 10 to 30 metric tons of
ground gypsum rock.
^Kilns are operated batchwise at substantially atmos-
pheric pressure.
•Stirrer revolves at approximately 20 rpm.
In producing CaSOn'fHaO, the controlled parameters are
temperature and residence time:
•Empty kiln preheated to about 100°C.
•Batch charge remains at 120° to 130°C for period of 1
to 2 hours.
•Kiln is discharged at temperature of approximately l60°C.
In the small number of cases where anhydrous CaSOtt is
produced, the charge is allowed to undergo the same se-
quence as described above and then allowed to remain in
the kiln during a constant-temperature period at about
190°C. This requires an additional 30 to 60 minutes.
The kiln is discharged at a temperature of approximately
220°C.
Exact temperatures and residence times required are a
function of the particular kiln.
4. Utilities
Quantities are expressed per metric ton of gypsum present
in wallboard product.
•Heat, as either coal, natural gas, or fuel oil -
between 2.5xl05 and 3-5xl05 kcal.
•Electrical energy - between 2 and 5 kWh.
5. Waste Streams
During charging and discharging operations of the kiln,
fugitive emissions of particulate CaS04-2H20, CaSCU'^H20,
or CaS04 to the atmosphere are surmised. No information
is available on either absolute quantity or particle
size. Estimated quantity is less than 3 kg per metric
ton of gypsum present in wallboard product, with dust
control equipment operating, and approximately 20 kg per
metric ton of gypsum in wallboard product without dust
control equipment.
Fuel combustion may result in emissions of sulfur oxides,
nitrogen oxides, particulates and hydrocarbons, depending
on fuel burned and combustion efficiency.
6. EPA Source Classification Code
3-05-015-03 Calciner
16
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References
Cement, Lime and Plaster. In: Rogers' Industrial
Chemistry, Furnas, C. C. (ed.). New York, Van Nostrand
& Co., 1942. p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition,
Standen. A. (ed.). New York, Interscience Publishers,
1964. 4_:20-23.
Havighorst, C. R. A Quick Look at Gypsum Manufacture.
Chem. Eng. 72.:52-54, January 4, 1965.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1971,
Schreck, A. E. (ed.). Washington, U. S. Dept. of the
Interior, 1973- I.: 569-576.
Riegel, E. R. Portland Cement, Lime and Gypsum Plaster.
In: Industrial Chemistry, 5th Edition. New York,
Reinhold Publishing Corp., p. 173-175.
Schroeder, H. J. Gypsum. In: Mineral Facts and
Problems. Washington, U. S. Dept. of the Interior, 1970.
p. 1039-1048.
Shreve, R. N. Gypsum. In: Chemical Process Industries,
3rd Edition. New York, McGraw-Hill, Inc., 1966.
p. 180-182.
Taggart, A. F. Gypsum. In: Handbook of Mineral Dress-
ing. New York, John Wiley & Sons, Inc., 1945. p. 3-40
to 3-42.
17
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GYPSUM AND WALLBOARD INDUSTRY PROCESS NO.
ROTARY CALCINATION*
1. Function
The process removes combined water from lump gypsum
(CaSOu «2H20) rock received from Process 2. The product
is forwarded to Process 6 for size reduction. In addi-
tion to calcination, two steps are included:
•Addition of CaCl2 to the kiln feed and mixing.
•Cooling, or "soaking," the calcined product in silos.
Essential equipment consists of a continuously operating
rotary kiln and at least several "aging" silos, provided
with means of ventilation.
2. Input Materials
Crushed gypsum rock, between 0.3 and 1.5 cm in diameter,
is fed continuously to the kiln. Between 1.0 and 1.03
metric tons (estimated) of kiln feed are required per
metric ton of gypsum present in wallboard product.
Approximately 1 to 2 kg of CaCl2 are added to the kiln
feed for "pre-aging" the product.
3. Operating Parameters
Kilns are direct fired. The charge attains a tempera-
ture of between 175° and 200°C. "Aging" the product in
the "aging" silos is a necessary step to allow the de-
hydration to complete itself in the "underburned" por-
tions of the charge and to allow rehydration of any
anhydrous calcium sulfate to occur.
Kilns are in the same size range as cement kilns —
approximately 3.5 m diameter by 100 to 125 m in length.
4. Utilities
Quantities are expressed per metric ton of gypsum present
in wallboard product:
*This process is an alternate to Process 3, Pot Calcination.
The latter is used in the majority of the operations process-
ing gypsum. The use of rotary kilns for calcining is declining,
18
-------
•Heat, supplied by coal, natural gas, or fuel oil -
between 3x105 and 3.5xl05 kcal (estimated).
•Electrical energy - 3 to 6 kWh (estimated).
5. Waste Streams
Calcination in rotary kilns results in a greater amount
of fugitive particulate emissions to the atmosphere than
does pot calcination.
With dust control equipment operative on the kiln ex-
haust, estimated total weight of particulates emitted to
the atmosphere is estimated to be less than 5 kg of
anhydrite per metric ton of gypsum in wallboard
product.
Fuel combustion may result in emissions of sulfur oxides,
nitrogen oxides, particulates and hydrocarbons, depending
on fuel burned and combustion efficiency.
6. EPA Source Classification Code
3-05-015-03 Calciner
7. References
Cement, Lime and Plaster. In: Rogers' Industrial
Chemistry. Purnas, C. C. (ed.). New York, Van Nostrand
& Co., 1942. p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition,
Standen, A. (ed.). New York, Interscience Publishers,
1964. 4k20-23.
Havighorst, C. R. A Quick Look at Gypsum Manufacture.
Chem. Eng. 72.: 52-54, January 4, 1965.
Riegel, E. R. Portland Cement, Lime and Gypsum Plaster.
In: Industrial Chemistry, 5th Edition. New York,
Reinhold Publishing Corp., p. 173-175.
Schroeder, H. J. Gypsum. In: Mineral Pacts and
Problems. Washington, U. S. Dept. of the Interior, 1970.
p. 1039-1048.
Shreve, R. N. Gypsum. In: Chemical Process Industries,
3rd Edition. New York, McGraw-Hill, Inc., 1966. p. 180-
182.
Taggart, A. P. Gypsum. In: Handbook of Mineral
Dressing. New York, John Wiley & Sons, Inc., 1945.
p. 3-40 to 3-42.
19
-------
GYPSUM AND WALLBOARD INDUSTRY PROCESS NO. 5
PULVERIZING
1. Function
The process further reduces the particle size of the
calcined gypsum received from either Process 3 or
Process 4. The product, if "first-settle" stucco or
calcium sulfate hemihydrate (CaSO.* -%H20) , is forwarded
as follows in order of increasing tonnage:
Directly to sales, as plaster of paris.
To Process 7 for blending to wall plasters.
To Process 8 for fabrication into wallboard products.
In a small fraction of instances, the calcined gypsum is
"second-settle" stucco or soluble anhydrite (CaSCU) and
is sold as the end product.
Air separation and screening are usually steps in the
process.
If the feed material is received from Process 4, equip-
ment may consist of Raymond mills or rod mills in combina-
tion with ball mills, plus shaking screens and cyclone
separators. If fed from Process 3, equipment usually
consists of ball mills and cyclone separators.
2. Input Materials
The calcined gypsum (both CaSOu--|H20 and CaS04) fed to
the process has a particle size approximating 90 to 95%
minus 100 mesh, if received from Process 3, or 1- to 2-cm
diameter lumps plus fines, if received from Process 4.
Approximately 0.85 metric ton of "first-settle" stucco
is required per metric ton of gypsum present in wall-
board. Approximately 1 metric ton of "second-settle"
stucco is needed per metric ton of soluble anhydrite end
product.
3. Operating Parameters
The process is conducted at above-ambient temperatures
(40°-60°C) and at essentially atmospheric pressure.
The product discharged by the process is 100% minus 100
mesh and may be as fine as 60% minus 200 mesh.
20
-------
4. Utilities
Electrical energy consumption is estimated to be between
10 and 20 kWh per metric ton of gypsum in wallboard
product.
5. Waste Streams
Fugitive atmospheric emissions of particulates, consist-
ing of calcined gypsum dust, are surmised during periods
of equipment malfunctioning and from imperfect duct-to-
equipment seals. The total quantity of material escaping
is estimated to be less than 0.5 kg per metric ton of
gypsum contained in wallboard product.
Normally, atmospheric emissions are not a problem, since
grinding and size-separation equipment are closed-
circuited and sealed from the atmosphere, except for the
bleed stream which is passed through a bag filter prior
to venting.
6. EPA Source Classification Code
None established
7. References
Cement, Lime and Plaster. In: Rogers' Industrial
Chemistry, Purnas, C. C. (ed.). New York, Van Nostrand
& Co., 1942. p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition,
Standen, A. (ed.). New York, Interscience Publishers,
1964. 4.:20-23.
Havighorst, C. R. A Quick Look at Gypsum Manufacture.
Chem. Eng. 72.:52-54, January 4, 1965.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1971,
Schreck, A. E. (ed.). Washington, U. S. Dept. of the
Interior, 1973. ^:569-576.
Riegel, E. R. Portland Cement, Lime and Gypsum Plaster.
In: Industrial Chemistry, 5th Edition. New York,
Reinhold Publishing Corp., p. 173-175.
Shreve, R. N. Gypsum. In: Chemical Process Industries,
3rd Edition. New York, McGraw-Hill, Inc., 1966. p. 180-
182.
21
-------
Taggart, A. F. Gypsum. In: Handbook of Mineral
Dressing. New York, John Wiley & Sons, Inc.,
p. 3-^0 to 3-^2.
22
-------
GYPSUM AND WALLBOARD INDUSTRY PROCESS NO. 6
PACKAGING
1. Function
Pulverized calcined gypsum (plaster of paris in almost
all instances), received from Process 5 in bulk, is
packaged in bags or in bulk in rail cars. The bagged
product is one of the six major end products of the
industry.
Automatic weighing-bagging machines, retractable belt-
or roller-conveyors, and fork trucks are used.
2. Input Material
An estimated 98 to 99% of the tonnage of input material
is plaster of paris (CaSCU '|H20). The remainder of the
tonnage is "soluble anhydrite," a form of anhydrous CaSO*.
The particle size of both materials is 100% minus 100 mesh
and 60% minus 200 mesh.
One metric ton of input material is required per metric
ton of end product.
3. Operating Parameters
The material is usually warm (40° to 50°C) during the
packaging process.
The usual bag used is paper or multi-walled paper with
plastic interliner and contains 45.3 kg of product,
either plaster of paris or "soluble anhydrite."
Bulk shipments in rail cars are also made.
Unadulterated plaster of paris is usually produced in
operations also producing wall plasters and wallboard.
The tonnage produced is usually considerably less than
that of mixed wall plaster. A typical operation produc-
ing all three products produces 50 metric tons per day
of plaster of paris.
4. Utilities
Electrical energy consumption is 0.5 to 2.0 kWh per
metric ton of product.
23
-------
Waste Streams
Fugitive atmospheric emissions (surmised) of fine
particulate CaSC^-i-HaO result from "puffing" at the
filling valve of the bag. Atmospheric emissions are
estimated to be less than 0.2 kg per metric ton of
product.
EPA Source Classification Code
3-05-015-04 Conveying
7. References
Cement, Lime and Plaster. In: Rogers' Industrial
Chemistry, Furnas, C. C. (ed.). New York, Van Nostrand
& Co., 1942. p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition,
Standen, A. (ed.). New York, Interscience Publishers,
1964. 4:20-23.
24
-------
GYPSUM AND WALLBOARD INDUSTRY PROCESS NO. 7
BLENDING
1. Function
The process blends relatively small quantities of addi-
tives into plaster of paris ("first-settle" stucco or
CaSOu'|H20) received from Process 6. The product is
wall plaster and is sold as one of the major end products
of the industry.
The step of packaging is included in the process.
Equipment consists of several continuous-flow mixing
devices, such as the Broughton mixer, airveyor systems,
continuous-flow weighing devices, bagging equipment, and
bag conveyors.
2. Input Materials
The major input material is "first-settle" stucco or
plaster of paris. Between 0.9 and 0.99 metric ton is
required per metric ton of bagged plaster, depending on
the particular formulation.
Additives to the plaster of paris,to impart specific
properties, include the substances listed below.
Quantities are expressed as kilograms per metric ton of
bagged wall plaster.
Retarder (glue, tankage, starch, etc.) 2-8
Accelerator (usually alum; sometimes
omitted) 1-3
Animal hair, chopped glass fiber, or
wood fiber 1-5
Sand or perlite (for "ready-mix"
plasters) 10 - 100
3. Operating Parameters
The operation is conducted at atmospheric pressure arid,
usually, the plaster of paris is still warm (40° to 50°C)
from the calcining process.
Wall plaster is usually one of the products of an in-
tegrated operation also producing wallboard and unadul-
terated plaster of paris. One typical integrated plant
produces about 100 metric tons per day of wall plasters.
25
-------
4. Utilities
Electrical power consumption, including that for the
packaging step, is estimated between 5 and 10 kWh per
metric ton of product.
5. Waste Streams
Fugitive atmospheric emissions (surmised) of fine par-
ticulate CaSOu-^E20S originate at the bagging machine
filling spout and at loading hatches of railroad cars
during bulk-loading periods. The total quantity is
estimated to be less than 1 kg per metric ton of product.
No factual information is available.
6. EPA Source Classification Code
3-05-015-04 Conveying
7. References
Cement, Lime and Plaster. In: Rogers' Industrial
Chemistry, Furnas, C. C. (ed.). New York, Van Nostrand
& Co., 1942. p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition,
Standen, A. (ed.). New York, Interscience Publishers,
1964. 4_:20-23.
Havard, J. F. Gypsum. In: Industrial Minerals and
Rocks, 3rd Edition, Gillson, J. L. (ed.). New York,
Am. Soc. of Min. Met. & Petr. Eng., I960. p. 471-476.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1971,
Schreck, A. E. (ed.). Washington, U. S. Dept. of the
Interior, 1973. 1:569-576.
Riegel, E. R. Portland Cement, Lime and Gypsum Plaster.
In: Industrial Chemistry, 5th Edition. New York,
Reinhold Publishing Corp., p. 173-175.
26
-------
GYPSUM AND WALLBOARD INDUSTRY PROCESS NO. -8
FABRICATION PLANT
1. Function
The process fabricates wallboard-type products from pul-
verized, calcined gypsum ("first-settle" stucco,
CaSOi»--2H20) received from Process 6, with additions of
various other materials. The products, chiefly gypsum
board, rock lath, and laminated panels, constitute the
major end products of the industry.
The principal process steps are:
•Blending
•Board fabrication
•Drying
•Packaging
Major equipment usually consists of:
•Pulping tanks
•Wet mixers and proportioning equipment
•Forming rolls
•"Setting-up" conveyor belt
•Tunnel dryer
j
2. Input Materials
The principal input material, "first-settle" stucco, is
required in the ratio of approximately 0.85 metric ton per
metric ton of gypsum in the fabricated product. This
corresponds to a ratio of between 0.5 and 0.8 (estimated)
metric ton of "first-settle" stucco per metric ton of
finished fabricated product, depending on the specific
type of the latter.
Materials mixed with the stucco are listed below. The
approximate quantity of each is given per metric ton of
finished product.
Process water, to slurry the stucco 0.6 m3
Lignin 1 kg
Raw gypsum (accelerator) 5 kg (est.)
Starch 5 kg
Fiber glass 2 kg
Paper pulp 4-8 kg
Soap (to produce foam) 1 kg
Sawdust (may replace paper pulp) 4-8 kg
Potassium sulfate 0.5 kg
Perlite 4-6 kg
27
-------
Other materials used in board fabrication may be paper,
chip-board, wood veneer or aluminum foil, depending on
the specific type of board produced.
3• Operating Parameters
The process is conducted at essentially atmospheric pressure.
Temperatures at selected points in the process are:
•Slurry in mixer: 40-50°C (estimated)
•Air at feed end of dryer: 150-l60°C
•Air at discharge end of dryer: 120°C
Residence times:
•Slurry in mixer: 2-40 seconds
•"Green" board on conveyor: 4-7 minutes
The daily capacity of a typical three-product operation is:
•45 metric tons of plaster-of-paris
•90 metric tons of wall plaster
•56,000 square meters of 1.27-centimeter thick wallboard,
equivalent to approximately 550 metric tons of wallboard.
The plant mentioned has a wallboard production line (setting
conveyor plus dryer) approximately 420 meters long.
4. Utilities
Estimated total electrical energy consumption is between
10 and 20 kWh per metric ton of average product.
Heat, supplied as steam at 18 kilograms per square centimeter
gage pressure, is required at an approximate ratio of
300 x 103 kcal per metric ton of average product.
5. Waste Streams
Fugitive atmospheric emissions of particulate CaSOu«2H20
are surmised to originate at feed ports of mixers. No
factual information is available. Their quantity is
estimated to be less than 0.5 kilogram per metric ton of
average product.
6. EPA Source Classification Code
3-05-015-04 Conveying
28
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References
Cement, Lime and Plaster. In: Rogers' Industrial Chemistry,
Purnas, C. C. (ed.). New York, Van Nostrand & Co., 1942.
p. 872-877.
Hammond, W. A. Calcium Compounds, In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition. Standen,
A. (ed.). New York, Interscience Publishers, 1964.
4_:20-23.
Havard, J. P. Gypsum. In: Industrial Minerals and Rocks,
3rd Edition. Gillson, J. L. (ed.). New York, Am. Soc.
of Mln. Met. & Petr. Eng., I960. p. 471-476.
Havighorst, C. R. A Quick Look at Gypsum Manufacture.
Chem. Eng. (N.Y.). 7j2:52-54, January 4, 1965.
Niles, B. W. Gypsum Board. In: Kirk-Othmer Encyclopedia
of Technology, 2nd Edition. Standen, A. (ed.). New York,
Interscience Publishers, 1970. 21:621-625.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1971,
Shreck, A. E. (ed.). Washington, U.S. Dept. of the
Interior, 1973. I_:569-576.
Riegel, E. R. Portland Cement, Lime and Gypsum Plaster.
In: Industrial Chemistry, 5th Edition. New York, Reinhold
Publishing Corp., p. 173-175.
29
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GYPSUM AND WALLBOARD INDUSTRIES PROCESS NO. 9
CALCINATlON/PULVERIZING
1. Function
The process produces finely ground (<100 mesh) dead-burned
gypsum, or anhydrite (CaSCU) from 5-cm diameter lumps
of gypsum received from Process 2. The pulverized product
of the process is an end product of the industry.
The principal process steps, in sequence, are, in general:
•Calcination
•Cooling
•Pulverizing
In special cases, where the product is Keene's cement, the
sequential process steps are:
•Calcination
•Cooling
•Soaking in alum solution
•Recalcination
•Cooling
•Pulverizing
Major equipment consists of:
•Stack kilns or beehive ovens
•Soaking tanks (used only if product is Keene's cement)
•Raymond mill, or rod-ball mill
2. Input Materials
Lumps of gypsum rock, inferred to be about 5 cm diameter,
are fed to the process. The quantity is estimated to be
approximately 1.3 metric ton per metric ton of dead-burned
gypsum produced.
3. Operating Parameters
The process is conducted at atmospheric pressure and at
temperatures in the range of 600° to 700°C. Calcination
time is about four hours.
No information is available pertaining to the physical size
of kilns, or on the parameters relating to the soaking in
alum solution in the case of production of Keene's cement.
30
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This process is used in the production of products which
account for less than 2% of the total consumption of all
crude gypsum. The principal products in this category are:
•Specialty plasters (including Keene's cement)
•Paint pigments
•Paper filler
Utilities
Heat, usually supplied by coal, is required in the calcina-
tion step. The quantity is estimated between 3 x 105 and
5 x 105 kcal per metric ton of dead-burned gypsum.
Total electric energy consumption is estimated between
1 and 3 kWh per metric ton of dead-burned gypsum.
Waste Streams
Fugitive atmospheric emissions of particulate anhydrite
are surmised to originate at the stack-kiln exhaust. No
quantitative information is available. The total quantity
of solids emitted is estimated to be less than 5 kg of
anhydrite per metric ton of dead-burned gypsum produced,
with dust abatement equipment operative.
Fuel combustion may result in emissions of sulfur oxides,
nitrogen oxides, particulates and hydrocarbons, depending
on fuel burned and combustion efficiency.
EPA Source Classification Code
3-05-015-03 Calciner
References
Cement, Lime and Plaster. In: Rogers' Industrial Chemistry,
Furnas, C. C. (ed.). New York, Van Nostrand & Co., 1942.
p. 872-877.
Hammond, W. A. Calcium Compounds. In: Kirk-Othmer
Encyclopedia of Chemical Technology, 2nd Edition. Standen,
A. (ed.). New York, Interscience Publishers, 1964.
4_:20-23.
Havard, J. F. Gypsum. In: Industrial Minerals and Rocks,
3rd Edition. Gillson, J. L. (ed.). New York, Am. Soc.
of Min. Met. & Petr.. Eng., I960. p. 471-476.
Reed, A. H. Gypsum. In: Minerals Yearbook, 1971, Shreck,
A. E. (ed.). Washington, U.S. Dept. of the Interior, 1973.
1:569-576.
Schroeder, H. J. Gypsum. In: Mineral Facts and Problems.
Washington, U.S. Dept. of the Interior, 1970. p. 1039-1048.
31
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Table A-l. LIST OF RAW MATERIALS
1. Gypsum (CaSOu»2H20)
•Bedded gypsum rock (most important source)
•General composition range:
CaS04-2H20 85 to 95%
occasionally to 99%
Impurities are: clay
shale
limestone
anhydrite
silica
2. Gypsite (gypsum intermingled with clay)
•Usually secondary, surface deposits (less important source)
•General composition range:
CaSO^»2H20 70 to 8*5%
Clay 10 to 20%
Other impurities are as for gypsum
3. Selenite (large gypsum crystals in clay gahgue)
•Usually secondary, surface deposits (minor source)
•General composition similar to that of gypsite.
4. Anhydrite (CaSOu)
•Usually mined only for use as cement retarder.
•General composition range:
CaSOu 85 to 95%
Identity of impurities same as for bedded gypsum.
32
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APPENDIX B
PRODUCTS
33
-------
Table 3-1. LIST OF PRODUCTS
Prefabricated gypsum-core board products:
Paper-covered wallboard
Chipboard-covered wallpanels
Paper-covered "rock"-lath
Exterior sheathing
Pormboard (for poured industrial roofs)
Wall plasters
Plaster of paris
"Soluble anhydrite"
Dead-burned gypsum
Agricultural gypsum (land plaster)
Portland cement retarder
34
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APPENDIX C
COMPANIES AND PRODUCTS
35
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Table C-l. GYPSUM MINES AND CALCINING PLANTS IN THE UNITED STATES IN 19731
Company
Location of Operation
County & State
Type of Operation
CJ
01
Agro Minerals, Inc.
Box 279
Droville, WA 98855
American Gypsum Company
Box 6345
Albuquerque, NM 87107
California Gypsum Company
37851 Cherry St.
Newark, CA 95460
Duke City Gravel Products
2421 Iris Road, NW
Albuquerque, NM 87104
The Celotex Corporation
1500 N. Dale Mabry
Tampa, PL 33607
Consumers Co-op Association
502 Pioneer Rd.
Weiser, ID 83672
Cox Enterprises, Inc.
50 E. Main N.
Manti, UT 84642
Dulin Bauxite Company, Inc.
835 Valley
Hot Springs, AR 71901
Fannin-Superior Gypsum
Company
Route 1, Box 7, Hwy. 46
Wasco, CA 93280
Okanogan, Washington
Bernalillo, New Mexico
Almeda, California
Sandoval, New Mexico
Webster, Iowa
Bergen, New Jersey
Ottawa, Ohio
Fisher, Texas
Park, Wyoming
Washington, Wyoming
Sanpete, Utah
Pike, Arkansas
Kern, California
Mine Only
Plant Only
Plant Only
Mine Only
Mine & Plant
Plant Only
Mine2 & Plant
Mine & Plant
Mine & Plant
Mine Only
Mine Only
Mine Only
Mine Only
-------
Table C-l (Continued) GYPSUM MINES AND CALCINING PLANTS IN THE UNITED STATES IN 1973l
co
Company
'Location of Operation
County & Sta_t_e
The Plintkote Company
480 Central Avenue
E. Rutherford, NJ 07073
Predericksburg Gypsum Company
Mason Route
Predericksburg, TX 78624
Georgia-Pacific Corporation
900 S.W. Fifth Avenue
Portland, OR 97204
Grand Rapids Gypsum Company
201 Monroe Avenue, NW
Grand Rapids, MI 49502
Harrison Gypsum Company, Inc
Box 176
Lindsay, OK 73052
H. M. Holloway, Inc.
714 Sixth Street
Wasco, CA 93280
Alameda, California
Fremont, Colorado
Chatham, Georgia
Clark, Nevada
Camden, New Jersey
Nolan, Texas
Gillespie, Texas
New Castle, Delaware
Glynn, Georgia
Webster, 'Iowa
Marshall, Kansas
Kent, Michigan
Erie, New York
Westchester, New York
Hardeman, Texas
Sevier, Utah
Big Horn, Wyoming
Kent, Michigan
Caddo, Oklahoma
Kern, California
Type of Operation
rn
Plant Only
Mine & Plant
Plant Only
Mine & Plant
Plant Only
Mine & Plant
Mine Only
Plant
Plant
Mine
Mine
Mine2
Mine2
Plant
Mine
Mine
Mine
Only
Only
& Plant
& Plant
& Plant
& Plant
Only
& Plant
& Plant
& Plant
Mine2& Plant
Mine Only
Mine Only
-------
Table C-l (Continued). GYPSUM MINES AND CALCINING PLANTS IN THE UNITED STATES IN 19731
Company
Location of Operation
County 8c State
Type of Operation
00
Johns-Manville Corporation
Kaiser Gypsum Company, Inc.
300 Lakeside Drive
Oakland, CA 94604
Michigan Gypsum Company
2840 Bay Road
Saginaw, MI 48601
E. W. Munroe
101 E. Vine Drive
Fort Collins, CO 80521
National Gypsum Company
325 Delaware Avenue
Buffalo, NY 14202
Clark, Nevada
Contra Costa, California
Los Angeles, California
Duval, Florida
Burlington, New Jersey
King, Washington
losco, Michigan
Larimer, Colorado
Maricopa, Arizona
Final, Arizona
Contra Costa, California
Los Angeles, California
New Haven, Connecticut
Hillsborough, Florida
Chatham, Georgia
Lake, Illinois
Martin, Indiana
Webster, Iowa
Barber, Kansas
Jefferson, Louisiana
Baltimore, Maryland
losco, Michigan
Rockingham, New Hampshire
Burlington, New Jersey
Bronx, New York
Erie, New York
Lorain, Ohio
Fisher, Texas
Mine & Plant
Plant Only
Plant Only
Plant Only
Plant Only
Plant Only
Mine Only
Mine Only
Plant Only
Mine Only
Plant Only
Plant Only
Plant Only
Plant Only
Plant Only
Plant Only
Mine2& Plant
Mine & Plant
Mine & Plant
Plant Only
Plant Only
Mine & Plant
Plant Only
Plant Only
Plant Only
Mine2 & Plant
Plant Only
Mine & Plant
-------
Table C-l (Continued). GYPSUM MINES AND CALCINING PLANTS IN THE UNITED STATES IN 1973
Company
Location of Operation
County & State
Type of Operation
co
Final Mammoth Gypsum Company
2020 S. 9th Street
Coolidge, AZ 85228
Quad-Honstein Joint Venture
5770 Mclntyre St.
Golden, CO 80401
Raymond Schweitzer Gypsum
Route 2
Okarche, OK 73762
Republic Gypsum Company
1100 Mercantile Bank Bldg.
Dallas, TX 75201
South Dakota Cement
Commission
Drawer 351
Rapid City, SC 57701
Southwestern Portland
Cement Company
Box 392
El Paso, TX 799^3
Superior Companies
Box 6497
Phoenix, AZ 85005
Temblor Gypsum Company
Carrisa Plains Star Rt.
Box 80
St. Margarita, CA 93^53
Final, Arizona
Larimer, Colorado
Canadian, Oklahoma
Santa Pe, New Mexico
Jackson, -Oklahoma
Meade, South Dakota
Hudspeth, Texas
Final, Arizona
Yavapai, Arizona
Kern, California
Mine Only
Mine Only
Mine Only
Mine & Plant
Mine & Plant
Mine Only
Mine Only
Mine Only
Mine Only
Mine Only
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Table C-l (Continued). GYPSUM MINES AND CALCINING PLANTS IN THE UNITED STATES IN 19731
Company
Lo c a 11o n o f Operaticn
County & State
Temple Industries, Inc.
Box 368
Diboll, TX
Temple Gypsum Company,
Subsidiary
West Memphis, AK
Texas Gypsum Company, Inc.,
Subsidiary
Box 768
Irving, TX 75060
United States Gypsum Company
101 South Wacker Drive
Chicago, IL 60606
CD
Critenden> Arkansas
Comanche, Ohlahoma
Dallas, Texas
Imperial, California
Duval, Florida
Lake, Indiana
Martin, Indiana
Des Moines, Iowa
Webster, Iowa
Orleans, Louisiana
Baltimore, Maryland
Suffolk, Massachusetts
losco, Michigan
Wayne, Michigan
Fergus, Montana
Pershing, Nevada
Washoe, Nevada
Genesee, New York
Richmond, New York
Rockland, New York
Ottawa, Ohio
Elaine, Oklahoma
Philadelphia, Pennsylvania
Harris, Texas
Nolan, Texas
Sevier, Utah
Chesapeake, Virginia
Washington, Virginia
Type of Operation
Plant Only
Mine Only
Plant Only
Mine & Plant
Plant Only
Plant Only
Mine2 & Plant
Mine & Plant
Mine & Plant
Plant Only
Plant Only
Plant Only
Mine Only
Plant Only
Mine2 & Plant
Mine Only
Plant Only
Mine2 & Plant
Plant Only
Plant Only
Mine2 & Plant
Mine & Plant
Plant Only
Plant Only
Mine 8= Plant
Mine & Plant
Plant Only
Mine2 & Plant
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Table C-l (Continued). GYPSUM MINES AND CALCINING PLANTS IN THE UNITED STATES IN 1973
wompany
United States Steel
Corporation
Universal Atlas Portland
Cement Division
600 Grant Street
Pittsburgh, PA 15230
U.S. Soil Conditioning
Company
Box 346
Salida, CO 81201
Victor Material Company
Box 1024
Victorville, CA 92392
Walton Gypsum Company
Route 1
Homestead, OK 73745
Weyerhaeuser Company
Route 4, Box 78
Nashville, AR 71852
White Mesa Gypsum Company
124 Jackson NE
Albuquerque, NM 78108
Art Wilson Company
Box 1160
Carson City, NV 89701
E. J. Wilson & Sons
Dubois, ID 83423
Location of "Operation
County _& State
Type of Operation
Elaine, Oklahoma
Fremont, Colorado
San Bernardino, California
Elaine, Oklahoma
Howard, Arkansas
Sandoval, New Mexico
Lyon, Nevada
Lemhi, Idaho
Mine Only
Mine Only
Mine Only
Mine Only
Mine & Plant
Mine Only
Mine Only
Mine Only
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Table C-l (Continued). GYPSUM MINES AND CALCINING PLANTS IN THE UNITED STATES IN 1973l
Location of Operation m „ n , .
County & State Type of Operation
Winn Rock, Inc. Winn, Louisiana Plant Only
Box 790
Winnfield, LA 71483
Wyoming Construction Albany, Wyoming Mine Only
Company
Box 907
Laramie, WY 82070
— - —
Companies Producing Gypsum or Gypsum Products During 1973
Company operations listed below comprising a mine only, may produce one or more
of the following forms of uncalcined gypsum:
Lump gypsum rock (intermediate product) for use by other operations within
the industry.
. Gravel-size gypsum rock for use as Portland cement retarder.
Pulverized gypsum for agricultural use (land plaster).
Operations comprising only a plant produce:
Fabricated products (wallboard, rock lath, or formboard),
Wall plaster,
Plaster of paris, and in addition, may produce small quantities of "soluble
anhydrite", or dead-burned gypsum.
Operations comprising both a mine and a plant always produce lump gypsum rock
(intermediate product) and fabricated products, almost always produce wall plaster
and plaster of paris, and may produce any of the other products mentioned above.
Indicates underground mine; otherwise open-pit operation.
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TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
REPORT NO.
EPA-600/2-77-023q
2.
. TITLE AND SUBTITLE
Industrial Process Profiles for Environmental Use:
Chapter IT- The Gypsum and Wallboard Industry
3. RECIPIENT'S ACCESSION-NO.
5. REPORT DATE
February 1977
6. PERFORMING ORGANIZATION CODE
. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO
P.E.Muehlberg and B.P.Shepherd (Dow Chemical)
Terry Parsons. Editor
. PERFORMING ORGANIZATION NAME AND ADDRESS
Radian Corporation
8500 Shoal Creek Boulevard, P.O. Box 99U8
Austin, Texas 78766
10. PROGRAM ELEMENT NO.
1AB015
11. CONTRACT/GRANT NO.
68-02-1319/Task
12. SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. ENVIRONMENTAL PROTECTION AGENCY
Cincinnati» Ohio 1+S268
13. TYPE OF REPORT AND PERIOD COVERED
Initial: 8/75-11/76
14. SPONSORING AGENCY CODE
EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
The catalog of Industrial Process Profiles for Environmental Use was developed as an
aid in defining the environmental impacts of industrial activity in the United States.
Entries for each industry are in consistent format and form separate chapters of the
study. The gypsum and wallboard industry comprises operations which mine gypsum
deposits and process the mined gypsum rock into crushed or pulverized uncalcined
gypsum, pulverized calcined gypsum and a diversity of prefabricated gypsum-core
board products. One chemical tree, one process flow sheet and nine process descrip-
tions have been prepared to characterize the industry. Within each process descrip-
tion available data have been presented on input materials, operating parameters,
utility requirements and waste streams. Data related to the subject matter, including
company, product and raw material data, are included as appendices.
!7. KEY WORDS AND DOCUMENT ANALYSIS j
a. DESCRIPTORS
Pollution
Industrial Processes
Chemical Engineering
Gypsum
Wallboard
18. DISTRIBUTION STATEMENT
Release to Public
b.lDENTIFIERS/OPEN ENDED TERMS
Process Assessment
Environmental Impact
19. SECURITY CLASS (This Report)
Unclassified
20. SECURITY CLASS (Tills page)
Unclassified
c. COSATI Field/Group
13B
13H
07A
08G
11L, 13C
21. NO. Ot PAGES
49
22. PRICE
EPA Form 2220-1 (9-73)
43
fcUSGPO: 1978 — 757-086/0807
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