GYPSUM PRODUCTION PROCESS
Gypsum production plant is a calcination unit for production of powdered gypsum (calcined).
Gypsum which is coming from pit is brought to the appropriate size with gypsum jaw crusher. The hammer crusher then moves to the kiln feed size. As a result of crushing process, the gypsum size is 0-10 mm and the crushed material is pulled into the feed silo with elevator. The steam formed in the kiln is isolated by the pipe system. The gypsum which is calcined as a result of the calcination process is taken to the intermediate bunker.
After waiting and cooling, the calcined gypsum is sent to the grinding mill. The calcined gypsum material which reaches the desired size during the grinding is separated and transferred the packaging stock silos.
The gypsum in the packaging stock silos is packaged and shipped or guided to the mixers because of some chemical products are added to make special products such as construction plaster, satin gypsum, mold gypsum by the addition of chemicals and they are shipped to the market.
Chemical Process Plants allows adapting to changing operating conditions and consequently provide for stable and reliable production of gypsum.
Raw Material Crushing and Screening
Gypsum furnace coming from the quarries (max. 60 cm) to the factory stone stock area is the system which is broken up to the maximum size of 0-10 mm. The main machines forming this system are primary crusher, secondary crusher, vibrating screen and transmission lines. This system allows the gypsum to be adjusted to the range of grain required for the calcination.
Calcined Rotary, Vertical Kiln
Our kiln designs are designed according to the chemical analysis of gypsum, capacity values and fuel type. The data is carefully examined by our project department and calorization furnaces with appropriate diameter, height and interior design are performed by considering the minimum fuel consumption. In our bakery systems, the tonnage information of the gypsum entering in the kiln systems, the temperature values at certain points of the system, the control of the pressure values in the furnace cycle and the furnace, and the production of high quality foundation plaster in UNICHEM Gypsum Technology are provided. The furnace units, which are the heart of Gypsum Plants, eliminate human error with PLC automation control.
Grinding and Seperation
In these systems with UNICHEM designs, gypsum Calcined Rotary Kiln units allow plaster to be obtained in the range of grain required for Plaster, Satin and Plaster plate. With the help of the spindle mills, the gypsum is brought to the range of 0-1000 μ, and 0-100 μ product is required for the satin gypsum after the dynamic separator. Our Dynamic Separators allow to separate the 85% of the separable material in the material to be separated and reach the desired grain size in the range of 50 μ to 400 μ.
Dosing and Weighing
In dosing and weighing systems, Gypsum and Filling Materials (Calcite, Perlite, Lime) are weighed according to the mixture capacity in the previously entered values and the weighing mixture prepared after the mixer process is sent to the mixture. Prescriptions are stored with automation software, both production follow-up is provided and the product that you produce many years ago is re-produced.
Mixing
The main machine of the unit, mixers are specially designed for gypsum systems with the possibility of mixing the homage to the anchor systems. It can be coordinated with the laboratory by the possibility of sampling. Depending on the plant capacity and product specification, you can obtain the best product with the dimensions and structural changes in the mixers. With high capacity turbo coupling or soft starter support, the loads that may come into the engine in the first arm are absorbed and any kind of failure is prevented. Thanks to product inputs from different points, it will contribute to your arge work.
Packaging
UNIKEY units that are coupled to our systems can be applied as Linear or Rotary Packaging according to your capacity needs. Optionally, our packaging is available with Rotor or Air filling. Our packaging machines are PLC controlled and they carry out the process with a precision of ± 2% in world standards. Our linear packagings can be reached in 250-300 bags / hour in single packaging and our Rotary packaging can reach a maximum capacity of 2800 bags / hour.
Dedusting
Each unit is equipped with filter systems with air flow rate calculated according to separate capacity, place of use and dust load. These systems prevent dust leaks in Gypsum Plants and provide recovery to the system. In this way, the working environment is made available to the system to gain a positive gain. The pressure balance of the system can be easily controlled by the valves in each suction point.
Perlite Expansion
The perlite in the range of 0-600 μ allows expansion between 17 and 24 times depending on the chemical structure of the crude active perlite in the expansion plant. In this way, perlite air gap structure contributes to the insulation of plaster. Expansion systems can be designed according to the active or passive characteristics of crude perlite , grain size and fuel type. The facility of gypsum plant can be designed in more capacity and the possibility of transportation to different markets can be provided.
Micronized Calcite Grinding and Separation
Facilities designed to meet the filling material requirements of gypsum plants. Calcite, which is in need of every kind of gypsum found in Gypsum Plant product range, is met. Gypsum is added to give surface hardness, easy mixing and strength. Calcite O (fine calcite) 0-90 800, Calcite 1 (thick calcite) 0-800 90, Calcite 3 (thick calcite) 90-1200 ler is obtained for use in Gypsum plants. The facility of gypsum plant can be designed in more capacity and the possibility of transportation to different markets can be provided. In addition, units can be added to gypsum plants which will save labor and time in order to minimize the cost of gypsum production.
Micro Dosing
Because chemical additives are low on grams and kilograms based on prescriptions, doing this process with manpower often leads to errors. These errors are returned to clients in time, capacity, labor and cost. Therefore, Micro dosing systems designed by Gypsum Plants by UNICHEM will return to you as a profit. Therefore, Micro dosing systems designed by Gypsum Plants by UNICHEM will return to you as a profit. The chemicals are prepared for each charge according to the recipe and the mixture time is shipped to the mixer. This process is done automatically with the help of automation does not allow human errors.
Automatic Palletizing
UNICHEM Fully Automatic Palletizing Machine, which we designed as UNICHEM for our businesses with our experience in the dust and mining sector, eliminates the labor and time losses in the palletizing process in the Gypsum Plants. PP, PE and Kraft bags can also be used in pallet lines.
