GYPSUM.

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Presentation transcript:

GYPSUM

GYPSUM In nature : Gypsum Rock Pure gypsum rock : CaSO4.2H2O Impurities : MgO, Al2O3, Fe2O3, SiO2, CaCO3, MgCO3...

PRODUCTION STEPS Excavating Crushing (~25 mm diameter) Grinding Heating (calcining) Cooling and Pulverizing Marketing in Bags

CALCINATION Gypsum rock wahen heated to 100-190°C looses ¾ of its water. CaSO4.2H2O → CaSO4.½H2O + 3/2 H2O Plaster of Paris This is low burning process and named as INCOMPLETE CALCINATION. When calcination is carried out at temperatures above 190°C all water is removed. CaSO4.2H2O → CaSO4 + 2H2O gypsum anhydrite This is high-burning process & COMPLETE CALCINATION.

Both of these products form gypsum rock by recombining with water. CaSO4.½H2O + 3/2H2O → CaSO4.2H2O CaSO4 + 2H2O → CaSO4.2H2O Calcination process is carried out in two types of kilns. Kettle Kilns Rotary Kilns

KETTLE KILN MIXER FIRE BRICK ~ 2-3 m GYPSUM ROCK DISCHARGE HEAT ~ 2.5-3 cm ~ 2-3 m DISCHARGE GYPSUM ROCK MIXER

ROTARY KILN

GYPSUM PLASTERS Obtained by Incomplete Calcination (CaSO4.½H2O) Plaster of Paris : is formed by incomplete calcination at 100-190°C. No admixtures are found. Hard Wall Plaster Plaster of Paris + Admixtures (Glue, Sand...)

Obtained by Complete Calcination (CaSO4) Flooring Plaster (CaSO4 with no impurities) Hard Finish Plaster (CaSO4 + Al2(SO4)3) (CaSO4 + Na2B4O7)

PROPERTIES & USES OF GYPSUM PLASTERS Plaster of Paris Setting time ~5-20 min. Used for sculpturing, ornamental work, small repair work

PROPERTIES & USES OF GYPSUM PLASTERS Hard Wall Plaster Setting time ~1 hr Compressive strength ~7 MPa Admixtures result in increased plasticity & setting time & reduced shrinkage Can be used for plastering walls Production of prefabricated structural units Masonry bricks & blocks

PROPERTIES & USES OF GYPSUM PLASTERS Flooring, Hard Finish Plaster Setting time ~1-16 hrs Compressive strength > 7 MPa Can be used for producing prefabricated units, masonry bricks & blocks & flooring & pavement bricks & tiles.

PROPERTIES & USES OF GYPSUM PLASTERS Gypsum often serves as a fire proofing material even though its strength is destroyed by long continuous heat. It forms a powder covering the surface which acts as an effective insulator. Gypsum products tend to disintegrate when exposed to moisture. Therefore, they should not be used for exterior work & for moist interiors. (NON-HYDRAULIC)

BY-PRODUCT GYPSUM Phospogypsum – Major by-product of phosporic acid production phosphate + sulfuric acid --> fertilizer + gypsum Desulfogypsum – Obtained from the desulfurization of combustion gases in coal burning power plants (Harmful SO2 gas is turned into CaSO4.2H2O