The Comprehensive Guide to Gypsum Granules Manufacturing Process in Crushing and Sand-Making Industry
The global construction boom has driven exponential demand for high-quality sand and aggregates, with gypsum granules emerging as a critical material in cement production, soil conditioning, and industrial applications. As a professional in crushing and sand-making production lines, understanding the gypsum granules manufacturing process is essential to optimize output quality and operational efficiency.
1. Raw Material Preparation
– Gypsum rock is extracted via mining or sourced as a byproduct from flue-gas desulfurization (FGD). Primary crushing reduces large blocks to ≤50mm using jaw crushers or hammer crushers.
– Moisture control (<10%) is critical to prevent clogging in downstream processes.
2. Secondary Crushing & Grinding
– Secondary cone crushers or impact crushers further reduce particles to 10–20mm.
– For fine granules (<5mm), vertical shaft impactors (VSIs) or roller mills are employed. Closed-circuit systems with vibrating screens ensure size uniformity.
3. Calcination & Drying
– Crushed gypsum is heated in rotary kilns or batch kettles at 150–180°C to remove chemically bound water (calcination), converting dihydrate (CaSO₄·2H₂O) to hemihydrate (CaSO₄·0.5H₂O).
– Flash dryers may integrate with grinding for energy efficiency.
4. Granulation & Classification
– Calcined gypsum (plaster) is mixed with water/binders in pelletizing discs or drum granulators to form 2–5mm granules.
– Air classifiers segregate oversize/fines for recycling, ensuring product consistency.
5. Packaging & Storage
– Finished granules are packed in moisture-proof bags or bulk silos. Humidity-controlled storage prevents rehydration.
1. How to minimize dust in gypsum crushing?
Use wet suppression systems or bag filters; opt for enclosed conveyors.
2. What’s the energy consumption benchmark?
~30–50 kWh/ton for crushing; calcination requires 700–900 kcal/kg gypsum.
3. Can recycled gypsum be used? Yes, post-consumer gypsum (e.g., demolition waste) requires impurity removal via screening/washing.
A 500 TPD facility deployed a three-stage crushing system (jaw + cone + VSI) with a rotary kiln calciner, achieving 98% granule yield (3–4mm). Automated screening reduced labor costs by 20%.
Mastering gypsum granule manufacturing hinges on tailored crushing circuits, precise calcination, and efficient granulation. Innovations like AI-driven size monitoring and waste heat recovery are reshaping the industry’s future competitiveness.—End—
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