Complete Turnkey Gypsum Powder Plants – High Purity, Low Energy, Stable Quality Specialized gypsum powder production lines from 30,000 to 300,000 TPY. Our integrated systems cover the entire process from raw gypsum crushing, grinding, calcination, to cooling and packing. With fluidized bed calciner or rotary kiln technology, we guarantee consistent semi-hydrate gypsum powder (β-hemihydrate) with purity >90%, initial setting time 6-15 minutes, and 2-hour flexural strength ≥2.5 MPa. Whether processing natural gypsum, FGD gypsum, or phosphogypsum, we provide full EPC services — trusted by plasterboard, construction plaster, and cement retarder manufacturers in over 30 countries.
Our gypsum powder production line is a complete, integrated facility engineered to produce high-quality β-hemihydrate gypsum powder from natural and synthetic gypsum sources. We deliver the entire plant as a single-source EPC project.
System Scope of Supply
Core Process Equipment:
· Raw gypsum receiving hopper with grid and belt conveyor
· Jaw crusher + hammer crusher (two-stage crushing to ≤25 mm)
· Gypsum grinding mill (ball mill or vertical roller mill) for powder preparation
· Fluidized bed calciner OR rotary kiln calcination system (gas, oil, or coal fuel)
· Hot gas generator (if no waste heat available)
· Product cooling system (fluidized bed cooler or rotary cooler)
· Ball mill or impact mill for post-calcination grinding and refinement
· Product storage silos (bolted steel or concrete)
· Automatic weighing and bag packing system (25/40/50 kg bags) + bulk loading
· Integrated baghouse dust collectors for entire plant (emission <10 mg/Nm³)
· Full PLC/DCS central control system with online temperature, pressure, and phase composition monitoring
Gypsum Raw Material Types:
· Natural gypsum (CaSO₄·2H₂O, purity 80-95%)
· Flue gas desulfurization (FGD) gypsum (synthetic, moisture 10-15%)
· Phosphogypsum (requires washing/neutralization pre-treatment)
· Citrogypsum, borogypsum, fluorogypsum (chemical by-product gypsum)
· Recycled gypsum from plasterboard waste
Finished Product Specifications We Guarantee:
· Product: β-hemihydrate gypsum (CaSO₄·½H₂O) content >90%
· Initial setting time: 6-15 minutes (adjustable via retarder/accelerator dosing)
· Final setting time: ≤30 minutes
· 2-hour flexural strength: ≥2.5 MPa (building gypsum grade)
· 2-hour compressive strength: ≥4.0 MPa
· Specific surface area: 350-500 m²/kg (Blaine)
· Applications: Plasterboard, gypsum blocks, construction/bonding plaster, gypsum mortar, cement retarder, dental plaster
From Raw Gypsum to Premium Building Plaster: How Your Plant Works
Raw Gypsum Crushing & Storage – Raw gypsum ore (≤600 mm) is crushed in a jaw crusher to <100 mm, then a hammer crusher reduces it to ≤25 mm. The granules are stored in a buffer silo or covered stockpile. For wet FGD gypsum, a pre-drying step reduces moisture from 10-15% to <5% before grinding.
Grinding to Calcination Feed – The crushed gypsum is fed into a ball mill or vertical roller mill, ground to a fine powder (80-200 mesh, depending on calciner design). This increases surface area for uniform heat transfer during calcination.
Precise Calcination in Fluidized Bed – The gypsum powder is fed into the fluidized bed calciner, where it is fluidized by hot gas (140-165°C) and heated evenly. The residence time (typically 5-15 minutes) and temperature are precisely controlled to convert CaSO₄·2H₂O to CaSO₄·½H₂O, removing 75% of the chemically bound water. The calciner's multi-zone temperature sensors and automatic draft control ensure >90% hemihydrate conversion.
Product Cooling & Aging – The hot stucco (semi-hydrate) is immediately cooled in a fluidized bed cooler to <80°C to prevent re-hydration and stabilize the phase composition. An aging silo (optional) allows homogeneous moisture and phase distribution over 24-48 hours, further improving consistency.
Post-Grinding & Packing – The cooled gypsum powder passes through a ball mill or impact mill for final refinement to target Blaine (350-500 m²/kg). It is then stored in product silos, ready for packing in 25-50 kg bags or bulk loading into trucks. A PLC/DCS system controls and monitors the entire line.
Standard Gypsum Powder Production Line Configurations (Fluidized Bed Calciner)
| Plant Capacity (TPY) | Main Calciner Model | Calciner Heat Input (kW) | Gypsum Mill Model | Product Blaine (m²/kg) | Site Area (m², approx.) |
|---|---|---|---|---|---|
| 30,000 | GJ-3F | ~1,500 | Φ1.8×7m | 350-450 | 5,000-8,000 |
| 60,000 | GJ-5F | ~2,800 | Φ2.2×7m | 350-500 | 8,000-12,000 |
| 100,000 | GJ-10F | ~5,000 | Φ2.4×8m | 350-500 | 12,000-20,000 |
| 200,000 | GJ-20F | ~9,000 | Φ3.2×9m | 350-500 | 20,000-35,000 |
| 300,000 | 2×GJ-15F or GJ-30F | ~15,000 | 2×Φ2.4m or VRM | 350-500 | 35,000+ |
*Rotary kiln calcination is also available for capacities >100,000 TPY or for multi-phase gypsum products (including alpha-hemihydrate). Fluidized bed is recommended for β-hemihydrate due to superior phase control and lower fuel consumption.*
Key Performance Guarantees
| Parameter | Guaranteed Value |
|---|---|
| β-hemihydrate (CaSO₄·½H₂O) content | >90% |
| Initial setting time | 6-15 minutes (adjustable) |
| Final setting time | ≤30 minutes |
| 2-hour flexural strength | ≥2.5 MPa |
| Fuel consumption (std coal/t product) | ≤40 kgce/t |
| Dust emission | <10 mg/Nm³ |
| Plant availability | >85% (annual) |
EPC Project Scope Options:
· Full EPC (Turnkey): Complete plant from raw gypsum receiving to bagged/bulk powder dispatch, including civil, steel structure, calciner, grinding, cooling, electrical, automation, and operator training.
· EP (Engineering & Equipment Supply): Design plus supply of all core equipment. Civil works and local erection by others, with our supervision.
· Core Calcination & Grinding System: Supply of fluidized bed calciner, gypsum mill, cooler, and dust collection system only.
Tell us your raw gypsum type, target annual output, and required product application (plasterboard, mortar, cement retarder, etc.). We will prepare a complete gypsum powder production line proposal with process flow diagram, equipment list, and firm EPC price.
Proven Performance: Global Gypsum Powder Plant Projects
Case 1: 100,000 TPY Building Gypsum Powder Plant, Middle East
· Scope: Full EPC (Natural gypsum receiving to bagged powder)
· Configuration: Φ2.4×8m ball mill + GJ-10F fluidized bed calciner + post-grinding mill
· Raw material: Natural gypsum, CaSO₄·2H₂O 92% purity
· Product: Building plaster, β-hemihydrate 93%, initial setting 10 min, 2h flexural strength 2.8 MPa
· Result: Fuel consumption 36 kgce/t. Commissioned in 10 months. Product sold at a premium to local plasterboard plants for consistent quality.
Case 2: 200,000 TPY FGD Gypsum Processing Line, East Asia
· Scope: Full EPC with pre-drying and cooling
· Configuration: Pre-dryer + Φ3.2×9m ball mill + GJ-20F fluidized bed calciner + post-cooler + aging silos
· Raw material: FGD gypsum from a 2×600 MW power plant
· Product: Plasterboard-grade stucco, β-hemihydrate 91%, consistent setting at 8 ±1 minutes
· Result: Successfully converted a power plant waste stream into a profitable product. 160,000 TPY plasterboard plant uses this powder directly. Saved the power plant €3 million/year in gypsum disposal costs.
Case 3: Phosphogypsum Upgrading Project, Africa
· Scope: EPC with washing + neutralization + calcination
· Raw material: Phosphogypsum with 1.2% P₂O₅ impurity
· Pre-treatment: Two-stage washing + lime neutralization circuit, reducing P₂O₅ to <0.1%
· Result: Treated phosphogypsum calcined successfully into building plaster meeting local standard. The plant turned a waste liability into a construction material supply.
EPC Delivery & Gypsum Quality Assurance
· Single-Source EPC Responsibility: We are the sole engineering, procurement, and construction partner for your gypsum powder plant. No split responsibility between crusher, mill, calciner, and packing system suppliers.
· Gypsum Analysis & Pilot Calcination: Before design, we run a complete thermal analysis (TGA/DSC) on your gypsum sample to determine the optimal calcination temperature. A pilot calcination test produces a 5 kg sample for your quality verification. We provide a guaranteed phase composition and strength report.
· Performance Test & Handover: A 72-hour continuous performance test is conducted to verify output, β-hemihydrate purity, setting time, and fuel consumption. The plant is handed over only after meeting all contractual performance guarantees.
· After-Sales & Spare Parts: 12-month defect liability period. Spare parts for crusher, mill, calciner, and packing machine are stocked regionally. Training for 3 operators and 1 lab technician is included.
Ready to Build Your State-of-the-Art Gypsum Powder Plant?
Send an inquiry. You will receive:
A complete gypsum powder production line proposal tailored to your raw material, capacity, and product application.
A process flow diagram, equipment list, and firm EPC price.
A detailed project schedule from design to commissioning.
Optional: Free gypsum sample calcination test with full phase composition and strength analysis report.
Your raw material details and business plan are strictly confidential.
Kolev Equipment Technology Co., Ltd. is a large-scale private technology enterprise specializing in the research, development, production, and sales of mining and metal ore processing equipment. With over 20 years of experience in ultra-fine grinding, industrial drying, and crushing sand making industries, we provide intelligent solutions and mature supporting products worldwide.
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