Process Training

Calcination

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 Calcination Process

Gypsum Process Stucco

Heat

Gypsum when heated gets converted to

stucco.

This process is called calcination

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 Calcination Process

To Atmosphere
100 m3 Blended
Classifier Dust Collector
Gypsum Silo
Bag House

Blended Gypsum
BWF

HAG Hammer Mill

Hot Air Stucco I D Fan

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 Calcination Process

Dust Collector
Bag House

Bucket Elevator
250 m3
Stucco Silo

Ball mill Cooler

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 Classifier (sheet 1)

Drive

Vanes gap adjusting mechanism

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 Classifier (sheet 2)

 Purpose: To separate relatively smaller size

particles from the hammer mill discharge
such that the specific surface area of the
stucco is 300 - 350 m2 / kg (approx) at the
classifier top outlet.
 Principle: Classifier works on the principle of
centrifugal force.

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 Bag House (sheet 1)

 Bag filter: (6 zones; 75 x 6 = 450 bags); I.D.fan

capacity: 93000 m3/ Hr.
 Purpose: To separate the stucco particles from the
hot air.
 Principle: Due to negative pressure (Vacuum)
inside the bags, stucco from the (stucco + air)
mixture is separated with the help of filtering cloth.

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 Bag House (sheet 2)

(Stucco+ gas) inlet to Bag House

Bag House (Calcination) (Gas) outlet from Bag House

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 Total Bag Houses : 5 Nos.

1) for NG crusher
2) for Blended gypsum silo + board trimming dust.
3) for Calcination process (Main B.H.)

4) for Ball mill

5) for Stucco storage silo.

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 Induced Draft/ Forced Draft fans and
Air Compressors in the Calcination

 Induced Draft (I.D.) fans: 5 Nos.

1) For all 5 dust collectors we have 5 I.D. Fans
 Forced Draft (F.D.) fans: 4 Nos.
1) Dilution air fan (linked from main dust collector I.D. fan outlet)
2) Combustion air fan (linked from Rotary cooler air outlet)
3) Primary air fan (for fuel dispersion purpose)
4) Cooling air fan (for calcination burner system)
 Air Compressors: (1+1Standby): 2 Nos.
Supplies compressed air (P=5-6 kg/cm2) for both calcination +
Board plant operations.

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 Ball Mill (sheet 1)

Principle:
In the first stage, large particles are
reduced to smaller size by impact
and in the second stage the smaller
particles are further reduced by
compression & attrition brought
about by the nipping action of two
balls revolving in contact with each
Ball Mill other.

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 Functions of Ball Mill (sheet 2)

 To produce material of almost any degree of

fineness. Our plant requirement of Specific surface
area = 500 - 550 m2/Kg
 To improve wet board bonding (Due to smaller size
of the stucco).
 To increase core strength.

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 Rotary Cooler (sheet 1)

 Type of cooling: Indirect cooling.

 Cooler RPM:~ 7
 Air used for cooling: Ambient air.
 Direction of air with respect to stucco: Counter
current.
 Angle of Inclination: 10

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 Functions of Rotary cooler (sheet 2)

 Reduction of the temperature of the stucco from

1250C to 750C.
 To enable stucco to be stored in silo without
suffering secondary calcination.
 Reduces load on the Chilling plant.

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 Stucco Storage silo:

 Storage Capacity: 200 MT

 Useful Volume: 260 m3.
 To avoid jamming of the silo outlet and free flowing
of the stucco, air purgers are provided to keep the
stucco in fluidized state.

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 Additives used in Board Mfg. (Sheet 1)

 Dry additives
1) Starch: Starch plays vital role in dry bonding (not in wet
bonding) of paper and core. Starch gets gelatinised at the
temperature 700C to 800C.

2) HRA (Heat Resistant Accelerator): HRA Plays

main role in nucleation process. This gives faster setting of
the stucco (By reducing setting time). HRA is the mixture of
95% crushed NG + 5% sugar.

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 Additives used in Board Mfg. (Sheet 2)

3) Vermiculite: Vermiculate is basically used in fire line

boards because of its typical property of expansion when
exposed to fire where gypsum gets shrinked due to excessive
heat.

4) Glass Fibre: Used in fire line boards for its heat resistant
property. Also it helps to improve the strength of the board.

5) Cement: To control the pH of the slurry, cement is added.

As the PG gives lots of variation in pH. It is advisable to bring
the stucco pH = 6.5 units.

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 Additives used in Board Mfg. (Sheet 3)

 Wet Additives
1) Foam: Teepol solution [Teepol: water (3:1)] is
called as Foam.
- To increase fluidity of slurry (free flowing nature).
- To reduce board weight.
2) Silicone oil: Main function of the silicone oil is to
increase moisture resistant capacity of the board.

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 Types of Papers used in Board Mfg.
process (Sheet 1)

1) ITC paper: (200/210/220 gsm).

2) VISY paper: (150/160/170 gsm).
3) Siam craft: (170/180 gsm).
4) Devidson: (170/180 gsm).
 Types of boards w.r.t. the Paper colors
 MR boards : Green
 Fire line boards : Pink
 Regular boards : Buff

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 Functions of Paper : (Sheet 2)

 Both top and bottom papers give 90% of the total

Board Strength.
 Paper GSM (gm/ m2) also plays an important role in
board strength. More the GSM of paper more is the
strength of the board.

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 Calcination Process

 In Calcination process, hot gas is generated through complete combustion of

fuel (Furnace oil).
What do you mean by complete combustion of fuel?
 Complete combustion is the process of 100% combustion of fuel in presence of
oxygen as the excess reactant. (i.e. fuel is the limiting reactant in the reaction)
What is Calcination?
 Calcination is the process of holding a material for prolonged periods
at elevated temperatures until it decomposes, usually with the
evolution of gas (typically water and carbon dioxide).
 In Calcination process excess water & 11/2 molecule of combined water from
Gypsum (CaSO4.2H2O) is removed to get Stucco (CaSO4.1/2H2O) as the final
product. (Stucco is also called as Hemihydrate/ plaster)

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 Reactions involved in Calcination
Process

Calcination Temperature: 1670C.

CaSO4.2H20 CaSO4.½H2O + 1½ H2O Right Heating
Gypsum Stucco (Hemi hydrate)
(Mol. wt. 172 g/gmole) (Mol. wt. 145 g / gmole)

CaSO4 + 2H2O More Heating

Soluble or Insoluble
Anhydrite
(Mol. wt. 136 g/gmole)

CaSO4.2H2O Less Heating

Residual gypsum

Impurities Impurities

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 Molecular Weight Calculations:

 Calculation of Gypsum (CaSO4.2H2O) Molecular weight :

Ca= 40 gm/gmatom S = 32 gm/gmatom
O = 16 gm/gmatom H = 1.0 gm/gmatom
Therefore, Mol. Wt. of Gypsum
= {40+32+16x4+2x(1x2+16)}
= 172 gm/gmmole
 Calculation of Stucco (CaSO4.1/2H2O) molecular weight:
= {40+32+16x4+ 1/2 x(1x2+16)}
= 145 gm/gmmole
 Main Calcination Reaction:
CaSO4.2H2O heat CaSO4. ½H2O + 1½H2O
i.e. 27/172 x 100=15.69% (w/w%) water removal from the gypsum.

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 Thank you.
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