Gypsum processing and the machine
Gypsum is a particularly useful processed material
. Its main application is as a building material, mostly produced as so-called plaster of Paris for plastering walls and making decorative features in buildings. However gypsum also has a diversity of other uses including making writing chalk, soil conditioning for agriculture, making moulds for pottery, as an additive in the manufacture of Ordinary Portland Cement (OPC), in surgical splints, in increasing the hardness of water, as an additive in certain foods such as tofu and in some types of medicines and pharmaceuticals.
Gypsum processing plants vary widely in scale and level of technology. They range from plants producing one or two tonnes per day using low-cost manual technologies, to plants of a thousand tonnes per day that are highly mechanized and capable of producing different types and grades of gypsum plaster or plaster boards.
There are five basic stages in gypsum processing:
Excavation is sometimes carried out by digging out an area of ground where the gypsum is located using open-cast techniques. To reach deeper deposits drift or shaft mines may be needed.
Crushing the gypsum rock is advisable before processing further, especially if subsequent heating is to be done in a pan rather than a shaft kiln. Crushing will ensure a product which is more uniform and requires less energy to heat. Crushing can be done manually with a hammer or hand-held roller, but mechanical crushing is faster and less laborious. Most clay-crushing equipment, such as that used for brick-making and pottery, would be suitable. Crushing should reduce the gypsum to grains of less than a few millimetres across. Gypsum sand does not need crushing.
Screening with a sieve (manual or motor-driven) will remove large grains which have not been crushed properly and which may contain impurities.
Grinding, for example in a ball, rod, or hammer mill, is necessary if the gypsum is to be used for high quality plasterwork or for moulding, medical, or industrial applications. Unlike with other cements, such as lime and Ordinary Portland Cement, special mills for mineral grinding may not be required and the relatively soft gypsum could be pulverised in agricultural mills, which are generally widely available.
Gypsum processing and the machine
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