Gypsum: Properties, Uses, and Industry Insights
Gypsum: Properties, Uses, and Industry Insights
Definition of Gypsum
Material of white color, fine texture and low hardness that is obtained by calcination of the
hydrated calcium sulfate or alabaster, which has the property of being a binder
that hardens quickly and is used in interior coatings.
Gypsum is crystallized calcium sulfate with two molecules of water. It is found very
abundant in nature, having been deposited by the drying of inland seas and
lagoons, in whose waters it was dissolved.
It can be compact, granular, layered, fibrous, colorless, and transparent in structure.
when it is pure, but generally clay and iron stain it yellow more or less
reddish
It is used to make partitions, vaults, coatings, continuous pavements, plasters,
frames, artificial marble, etc.
It is a soft material, and somewhat soluble in water, which is why it cannot be used outdoors.
Having a delicate surface makes it very vulnerable to bumps and scratches.
Training
Gypsum is of sedimentary origin, due to the dehydration of saline basins; by hydration.
from anhydrite; by fumarolic action of sulfurous waters on limestones or tuffs
volcanic.
Gypsum can form in different ways: by direct precipitation, by flocculation, by
crystallization in veins or by the transition of anhydrite (CaSO4·0.5H2O) to gypsum
(CaSO4·2H2O) with gain of water.
Formed in an evaporitic environment, by direct precipitation of solutions in connection with
calcareous rocks and clays in evaporitic deposits associated with ancient seas or lakes
savory.
Por hidratación directa de la anhidrita: también se puede formar en filones de yeso cuando
in volcanic areas, when through fumarolic action of sulfurous waters; the vapors of
sulfuric acid reacts with the layers of limestone in the bedrock.
Due to the action of sulfuric acid from the pyrites acting on the calcite of
marl and calcareous clays.
Physical properties
Color: Colorless or very variable: white, red, pink, black, gray, etc.
Color of the stripe: White.
Gloss: Glossy or matte.
Hardness: 2 (Soft, scratches with a fingernail), except for alabastrine varieties.
Densidad: 2'3 g/cm3 (Ligero).
Others: It has three exfoliation systems, with the basal one being very pronounced.
Structure
Laminated crystals, twins in various forms are common: arrow tips, tail
of swallow, spearheads; the apparent variety of crystal shapes can
reduce to a type, the so-called 'Trapezian' by the French mineralogist, René J. Haüy.
Types of Plaster
White plaster: the finest plaster, white in color, used for exterior rendering of
partitions and walls. The white gypsum is the one that comes from the purest alabaster. Of fine grain and
uniform, is used for plastering, stucco, and whitening.
Dead plaster: Dead plaster is a material that never hardens. It usually happens
by adding more water to the preparation than indicated.
Black gypsum: the coarser gypsum, gray in color, used for plastering of walls.
and walls. The black plaster is the one obtained with alabaster that contains a large amount of
impurities, directly calcinated, which blackens with the fumes and ashes of
fuels. It is used in works that are not to remain visible: vaults,
Partitions and Layouts.
Plaster Industry
The thickest and most abundant deposits of gypsum formed in the Triassic and Era.
Tertiary, several million years ago. These deposits constitute the largest source of
raw material for the plaster industry.
Gypsum deposit exploitations are typically carried out in open-pit mines.
open-pit, although there are also operations in underground mines. These
extractions are carried out by mining engineering professionals, who project
the exploitation fronts analyze the environmental impacts and their minimization, as well as
they carry out the restoration work of the Natural Space. Gypsum is a raw material
that due to its high solubility in the earth's crust, only in relatively rare cases is
presented in large quantities. In these operations, the objective is to achieve a
raw material with a minimum purity in gypsum of around 85% for the gypsum of
construction and a rate of about 92% for the plasters.
To achieve this result, conventional mining techniques are applied.
banking, drilling and dumping with electrical pegs and explosives. The raw material is
collected and transported by trucks to the factory for processing.
The use of gypsum as a byproduct of other processes is an advantage from
the environmental point of view because by reusing by-products and limiting the
aggression of the environment in both directions. Currently, it occurs annually
more synthetic gypsum than that extracted from natural sources.
Gypsum Manufacturing
Primary crushing
The crushing of the raw material consists of reducing the size of the mineral according to
it comes from the quarry, from 1 m3, up to a size between 0-40 mm. For
To achieve this reduction, jaw crushers or mills are used.
conical, which reduce the size of the mineral through impacts.
Jaw Crusher: A jaw crusher is one of the main types
of primary crushers. They are designed from the rectangular or square opening of the
Feeding. Primary jaw crushers usually have an opening
square, while the secondary ones are rectangular in design. They reduce the rocks.
large ones breaking them by compression. A fixed jaw, mounted in an alignment in
"V" is the immovable surface that breaks, while the movable jaw exerts the force.
on the rock forcing it against the immobile plate. The space at the bottom of the plates that
the jaws form a 'V' shape is the gap corresponding to the size of the product
crushed. The rock remains in the jaws until it is small enough to
pass through the hole at the back of the jaws.
Cone Crushers: A cone gyratory crusher is another type of crusher.
employees in the primary grinding of gypsum. They are designed either from the cavity of
step and diameter of the movable part or from the size of the receiving opening of
sample. They can be used for primary or secondary crushing. The crushing action
it is caused by the closure of the gap between the line of the mounted moving part on the spindle
vertical center and the fixed concave lines of the main frame of the crusher. The hollow is
open and closed by an eccentric located at the bottom of the spindle.
Once the primary crushing operation is completed, the ore is transported by means of
from belt conveyors, bucket elevators, etc. to the silos/stock yard and
homogenization.
Secondary crushing
With this second milling, the particle size is reduced to have a size
suitable for the feeding of some furnaces or for the final use to which it is intended
manufactured plaster.
For that second reduction, roller mills are used. The material is forced to pass through.
between a plate and a roller or between two rollers (rough or smooth) that rotate, reducing the
particle size.
Calcination
It is the process through which dehydration reactions and changes are carried out.
phase to obtain semi-hydrate, anhydrite, etc. According to the type of phases desired.
different types of ovens will be used as listed below to
each type of final product needed.
Rotary Kiln: The rotary kiln is particularly suited for the calcination of the
granulated aljez stone (0-25 mm). This, without pre-drying, is continuously fed to
counterflow oven with hot gases via a belt feeder
weight. Hot gases are produced in a brick combustion chamber. The
the exterior of the oven is not made of brick but consists of thick steel plates that
they ensure a uniform distribution of particles throughout the cross-section
from the oven. A high thermal efficiency is achieved due to the direct transfer of the
heat from hot gases to solid.
The production of these furnaces can reach 600 tons per day. They are used both for the
production of beta semihydrate (calcination temperature between 120 and 180ºC) as of
anhydrite (at temperatures between 300 and 800ºC). Its subsequent mutual mixing, in the
appropriate proportions to achieve the characteristics you want to give to the product
final allows obtaining the so-called multiphase plasters.
Furnace and other indirect fire ovens: The furnace is a calcination unit in
where the gypsum is heated indirectly through tubes or through a double
external chamber through which hot combustion gases circulate: these are furnaces
in which the combustion gases do not come into direct contact with the stone of
gypsum. The material placed inside to be calcined is usually agitated.
mechanically to improve energy transfer and product homogeneity.
Furnaces are usually discontinuous in which the material to be calcined is loaded into the furnace,
it is calcined and finally discharged, although there are also furnaces with loading and unloading.
of material continues. The controllability of the temperatures to which it is subjected
the product is larger and with it the homogeneity of the obtained product. However, the
thermal efficiency is lower than in direct fire rotary kilns. They usually
to be used for the production of beta semi-hydrate that will later be used in
the production of plaster.
Flash Oven: In this type of oven, hot gases at 650ºC and high speed are
are put in contact in a chamber with the material that is finely ground. The material
is dragged by the gases and taken to cyclones where the product is separated. The process
Dehydration occurs in just a few seconds (between 1.5 and 2 s), resulting in a
product at an average temperature of around 160ºC. There are calciners where the
initial chamber for contact with combustion gases - the product is a mill with the aim of
reduce particle size further
The obtained product usually has a high content of anhydrite III, which means that
it is very reactive and capable of hardening in just a few minutes when hydrated.
It is used in the manufacture of prefabricated products such as plasterboard (drywall) to
increase the production speed.
The products obtained in the previous stage are subjected to refining or grinding.
to obtain suitable particle sizes according to the final product to be achieved.
To carry out this operation, the following elements are used based on the
desired granulometry:
Fine-tuning
Plaster for making plasterboard (PLADUR): The flash furnace often also performs the
joint grinding leaving a product below 300 microns, aided by means of
of cyclones and filters for the capture of this size.
Mixed
This operation consists of the gravimetric dosing of the major components.
(SH, ANH) and the minor components (additives: retarders, retainers, etc.) towards
the mixers. Depending on the design required for the final product, different ones are made
formulations that allow us to make "custom plasters".
These mixers can be of different types depending on the precision to be achieved and
production can be continuous or discontinuous. Normally there tends to be better
control in discontinuous systems and having an automated control system.
Packaging - Loading
Once the products have been mixed, they are sent to silos for further processing.
packaging and palletizing, or their bulk distribution.
Uses
Its applications are multiple: in masonry (preparation of simple mortars for the
construction of partitions and vaults for the formation of ceilings, coatings and finishes,
engraved, stuccos, etc.) in the manufacturing of tongue-and-groove boards for ceilings
false ceilings, coffered ceilings, floors, floral motifs and decorative elements.
Plaster in Interiors
Plaster in Interiors is commonly used as a smooth base for decoration.
posterior.
Its warm and soft tones, with the matte appearance of the walls in a fresh coat, create atmospheres.
welcoming and natural.
Its use is limited to walls, ceilings, and vertical planes such as columns and supports.
structural.
It should not be used in areas of the house subjected to a high degree of humidity.
There are different types of plaster for various uses indoors: for first coats,
to apply as a single coat and to make repairs.
The plaster has a delicate surface that limits its use on horizontal planes, although
shelves made of cured boards or reclaimed wood can be treated with a light layer of
stucco to achieve a rustic whited appearance.
The textured plaster has a relief finish that is used to hide defects.
lower than the surface. If one wants to eliminate them, it is a difficult task because it is necessary to
cut them or cover them with a very thin layer of plaster, applying glue first so that the
the plaster adheres well to the textured surface.
Plaster
Paste composed of lime or gypsum and marble powder, mixed with water blended with glue.
that is used as a coating for exterior or interior walls and which can
it can also be applied as imitation marble.
Gypsum Board
The drywall is made with stucco or quick-setting gypsum, mixed to consistency
fluid and pouring it into molds. They are reinforced with straw, hemp, burlap,
wires, etc. and grooves and tongues are left to be able to form partitions.
It is mainly used for making false ceilings and as partition elements.
interiors.
Thermal gypsum boards include expanded polystyrene reinforcement and are used
as insulators.
Some incorporate a film that resists water vapor, making them suitable for
bathrooms, kitchens, and other premises where there is ambient humidity.
they are associated with units ranging from the Jurassic to the Cretaceous. The
manifestations of evaporites present in the Tertiary formations, especially of
Falcón State consists of very small layers of secondary origin and without significance.
economic.
The evaporitic belts are:
Gypsum Belt of Táchira State: in the areas of El Alto and Paramito, region of Pregonero,
a sequence of interstratified Gypsum with sandstones and shales from the Formation is located
Río Negro. The layer is about three meters thick and is not uniform throughout.
extension as it lenticularizes in several places. The same layer outcrops in Tenegá and
It seems to continue throughout the entire formation, over a distance of 6 to 8 km.
Gypsum Belt of Yaracuy State: gypsum deposits extend from Corocote
up to Urachiche intermittently. The most important deposits surface in San
Pablo, Campo Elías and Camunare, where they have been intermittently exploited,
being affected by a series of failures that are located throughout the area
southwestern part of the Yaracuy State, and associated with the great system of the Boconó Fault.
The deposits are part of the Nirgua Formation, essentially made up of schists.
Graphitic, quartz-mica schists and massive limestones. Gypsum has been located.
intercalated with schists and schistose limestones. Dolomites were not located in the
studied sequences.
Gypsum and anhydrite belt of the Guárico State: the deposits are located in the San area
Francisco de Macaira, constituting high-quality evaporite masses, near one
of the main landslides in the area. Geologically, they are characterized by their
defined stratigraphic position, its pronounced lenticularity, stratification, layering
marked, strong dips apparently towards the north, and intense deformation of the
layers with isoclinal folds and small faults. So far they have been
located and partially exploited evaporite deposits in Pintera 1, Pintera 2 and
gypsum mine. The ore is characterized by its sugary appearance, fine grain, luster
perlino, and a white to grayish-white color due to the presence of organic material.
The deposits consist of solid and compact layers with irregular fractures.
Gypsum Belt of Sucre State: the deposits are located along the southeastern extreme.
from the Paria Peninsula, between the Cumaca cove (west) where they disappear
lenticularity and Macuro (east) where they go into the sea. They have a length of 17 km,
of which 7 is covered by alluvium in the plains of Carenero, Patao, Uquirito,
Güinimita, Yacuas and Morrocoy.
The layer is cut by several transverse faults, with an average strike of N 15-20 O,
which are part of a regional system. The gypsum deposit is located in
the upper part of the Patao member, the underlying horizons to the Gypsum form a
thick layer of dolomitic limestones, which thin out towards the east. Among the
In the coves of Patao and Uquirito, the interval of compact limestones transitions to schists very
limestones with only thin lenses of limestone. Above the gypsum layers are located
graphitic schists, micaceous limestones.
The thickness of the Gypsum layer increases from west to east, according to the following
Figures: Puerto de Hierro 23 m; Patao 38 m; Uriquito 55 m and Morrocoy 70 m. In Macuro,
where there is a lot of outdoor activity, a discontinuous section of is exploited
Import and Export
The demand for gypsum is closely related to the construction industry.
whose demand for prefabricated materials, plaster for coatings, and cement is the main factor that
affects gypsum consumption. According to the United States Geological Survey (USGS) the
world production of gypsum from natural sources reached 106 Mt in the year
2005 and has been above 100 Mt in recent years, although the statistics
from the British Geological Survey (BGS) only account for 96.8 Mt in 2003. There are 89
producer countries, but only among eight of them they account for almost 70% of the production.
This production must be supplemented by another 110 Mt of synthetic gypsum produced by processes.
of desulfurization of the emission gases from thermal plants and other processes
industries such as the manufacture of phosphate fertilizers or the production of dioxide
titanium.
The European Union represented about 22% of global production, with Spain
the main producer of the area. The European market is clearly dominated by three
multinationals: British Plaster Board Gypsum Industries (BPB) from the United Kingdom that
represents 45% of the market, Platres Lafargue from France with a share of 35% and
Knauf from Germany with a 20% market share. With a revenue of over 3
billions of euros, the European gypsum and anhydrite industry operates with about 220
factories and generates about 400,000 direct and indirect jobs.
Importing Countries
Natural gypsum: the main importing countries of natural gypsum are the United States.
(7,000,000 t/year), Japan (3,800,000 t/year) and Belgium (500,000 t/year) and with 350,000 t/year
each one is followed by Switzerland, the United Kingdom, and Germany (Federal Republic).
Exporting Countries
Natural Gypsum: the main exporting countries are Thailand 15,000,000 tons/year, Canada
5,000,000 tons/year, Spain 2,200,000 tons/year and Mexico 2,200,000 tons/year.
Calcined Gypsum: the main exporting countries of calcined gypsum are France.
(283,000 tons/year), Belgium (130,000 tons/year), Spain (130,000 tons/year), Austria (110,000 tons/year)
United States (100,000 t/year), Thailand (45,000 t/year), and United Kingdom (12,900 t/year).
World Consumption
Región | (%) |
Norte América | 29,99 |
Asia | 26,68 |
Europe | 21.16 |
Eastern Europe | 3.40 |
Middle East | 10.01 |
South and Central America | 3.51 |
África | 3,12 |
Oceanía | 2,09 |
Total | 100,00 |
As for developed countries, the calcined gypsum industry and its derivatives
they absorb most of the plaster produced. Therefore, as an example, it is shown
the consumption in the United States and in Germany in the years 1996 and 1995 respectively.
In the United States, 74% of all gypsum is consumed in the manufacturing of stucco and
prefabricated products, including wall coverings as shown in the
graph.
In Germany, stucco for construction accounts for about 40% of the total gypsum.
the gypsum board (stucco) sector is more important in Germany, compared to
United States, due to different construction practices. In both countries, the
Cement manufacturing consumes about 18% of the total gypsum demanded.
CONCLUSION