Gypsum
TECHNIK
We know how
Front cover:
Gypsum granules magnified x100.
© Claudius Peters
gypsum technik
About
Since its founding in 1906, Claudius Peters has become one of the world’s
most respected engineering houses and an innovative world leader. Its German
Contents
Technikum 3 engineering excellence continues to set benchmarks for the design, manufacture
and commissioning of materials handling and processing systems for the
Calcining & Grinding
gypsum, cement, coal, alumina, steel and bulk-handling industries.
EM Mill 4
SmartGyp Homogenizer 6 From conception and installation through to commissioning and after-sales
Horizontal Impact Calciner 7
support, Claudius Peters provides world-class service to the world’s biggest
Flash Calciner 8
Kettle Calciner 9 bulk materials producers.
Reclaim Crusher 9
The Claudius Peters Group GmbH is headquartered in Buxtehude near Hamburg,
Cooling Technik 10
Germany, with regional offices in the Americas, Asia and Europe.
Turnkey Techniks 11
2 Claudius Peters’ headquarters, Buxtehude, Germany.
Technikum
Standing as a true leader within the gypsum industry, Claudius Peters is able to
engineer tailor-made solutions that meet any desired product qualities and
State-of-the-art
system performance requirements.
technology to
meet any calcining
Claudius Peters continues to remain at the fore-
front of materials handling and processing
requirement
technology by maintaining a vigorous research,
development and test program at the
headquarters’ Technikum (Technical Center) in
Germany. Trial and testing facilities ensure that
every new application is fully evaluated before
proceeding to full-scale plant.
Specific technologies include:
n Tailor-made gypsum calcining systems
n Natural gypsum & synthetic gypsum
Technikum interior with calcining test plant.
n Post-calcining treatment
n Stucco handling and packaging
n Raw material preparation
Gips AD gypsum processing plant, Bulgaria. 3
calcining & grinding
EM Mill
The Claudius Peters EM Mill is the preferred grinding and calcining technology for the
production of finished products such as gypsum wallboard.
Maintenance-free
grinding system
At the heart of its calcining system is the EM produces highly uniform product quality with
with an outstanding Mill, bringing the functions of grinding, drying the fully automated control system managing
service life and classifying together into one compact unit. the complete production cycle from start up to
shut down.
The EM Mill’s high inlet gas temperature and
direct heat transfer from the hot gas to the Unlike traditional stationary milling rollers, the
material, yields lower gas volumes, which in Claudius Peters EM Mill contains grinding balls
turn leads to optimal energy consumption. which move freely, like giant ball bearings,
between the grinding rings. In continuous
Low material time within the mill enables fast operation, a material bed forms between these
reaction times from the control circuits. This balls and the grinding ring but when the mill
EM Mill grinding elements.
4 Claudius Peters EM Mill.
shuts down, the bed subsides and the balls The grinding elements are almost entirely
sweep away the remaining material from the maintenance and adjustment free. And, when
milling track. employing highly resistant materials, the EM Mill Achieving ever
can achieve a service life of over 40,000 hours.
greater reliability
The EM Mill’s durable grinding system can
withstand oversized particles without having to and energy
stop. Any shock force resulting from the balls efficiency
moving over these obstacles is completely
absorbed by the tensioning springs, while
foreign particles on the grinding ring track are
automatically rejected, with the scraper conveying
them to the reject box.
Constant movement ensures that the grinding
balls maintain their perfectly spherical shape
through the entire service life of the grinding set,
delivering consistent mill performance throughout
the grinding element’s life cycle. This movement
also provides the most even distribution of raw
gypsum into the upcoming hot gas stream,
leading to maximum product quality and stability.
EM Mill at Fassa, Calliano, Italy.
EM Mill:
n Simple operation and maintenance
n Highest availability
n Maintenance free grinding elements EM 17
EM 23
n Constant product quality
EM 29
n No bearings inside mill
EM 36
n Optimal performance with inlet EM 42
temperatures of up to 650°C
EM 47
n Highest lifetime of grinding elements EM 53
n Ultrafine grinding with optional EM 59
dynamic classifier EM 65
n Simple integration of other Claudius EM 73
Peters equipment to provide EM 80
maximum flexibility
0 10 20 30 40 50 60 70 80
Capacity (tonnes per hour)
Capacity range for EM Mills.
5
calcining & grinding
SmartGyp Homogenizer
Claudius Peters’ SmartGyp Homogenizers produce plaster of optimum quality with
maximum efficiency. It further extends the Claudius Peters calcining range, improving
Improves product production quality and reducing production costs at the same time.
quality while
reducing costs The key component in this process is the The homogenizer consists of a vertical reactor,
Claudius Peters Homogenizer. It can be operated where the reactor floor is covered by a fabric
in a standard configuration under ambient pressure, allowing even distribution of the fluidization gas.
or in an extended version, where the homogenizer The gypsum bed then floats freely in the reactor
runs under pressurized conditions. Fresh calcined making contact with the carried moisture. In
gypsum is taken directly and continuously from addition, a central nozzle receives extra fluidized
the calciner at full calcining temperature and air that allows the gypsum to be transported
introduced into the homogenizer. from the floor of the reactor to the upper section
of the homogenizer. This intensifies both the
product mix and homogenization.
SmartGyp Homogenizer:
As indicated previously, processing pressure is
n Suitable for virtually any calcining system
one of the key conditions that significantly
n Homogenizing product quality influences product characteristics. The Claudius
n Stabilizes the product Peters SmartGyp process, by utilizing a
n Optimizes board production pressurized homoginizer, maximizes product
n Improves the water demand improvement and provides a continuous
operation processes where, under controlled
n Reduces production cost
conditions, the aging process can take place.
n Improves plaster production
n Efficient production of high strength plaster
Claudius Peters Homogenizer.
6 Schematic diagram of homogenizer. Claudius Peters calcining process with integrated homogenizer.
Horizontal Impact Calciner ( HIC )
The Claudius Peters Horizontal Impact Calciner has been specially developed for the
calcining of synthetic gypsum, where fine raw materials with a high degree of free
moisture, eliminates the need for grinding. Direct calcining
technology for
The Horizontal Impact Calciner is state-of-the- fine raw material
Horizontal Impact Calciner (HIC):
art technology capable of processing up to 100 processing
tonnes of product per hour in a single calciner n Processing up to 100 t/h in single
unit. Allowing direct, full calcining, it offers the calciner unit
added benefits of high stucco quality, efficiently n Direct full calcining in proven mill circuit
calcined in one stage. without a pre-heating process
n High reliability
At the heart of this process is the calciner housing n Downstream stucco treatment in
design based on the reliable EM Mill. This CP homogenizer
enables product to be evenly fed into the hot n Stable and consistent stucco quality
gas stream via the impact plate where crushing suitable for gypsum wallboard and
then takes place. In addition, the integrated plaster manufacturing
classifier ensures the most suitable retention n High stucco quality with low water demand
time of the product within the calciner, delivering
synthetic gypsum of the highest quality.
Calcining synthetic gypsum in Horizontal Impact Calciner. Claudius Peters Horizontal Impact Calciner.
7
calcining & grinding
Flash Calciner
For high temperature calcination of pulverized gypsum, the Claudius Peters Flash
Calciner is a highly efficient and reliable processing unit. Its ability to produce multi-phase
High energy plaster qualities with shorter setting times makes it ideal for wall plaster manufacturing.
efficiency for
optimum plant The Claudius Peters Flash Calciner consists of The ‘low burned gypsum’ produced by the mill
performance single or multiple cyclone stages and contains is partially metered into the calcincer’s flash
no internal moving parts. This allows direct heat pipe for processing at temperatures of around
treatment at temperatures of over 500˚C that 500˚C allowing the formation of defined anhydrite
produces a defined gypsum anhydrite. II – ideal for multi-phase plaster.
This calcining system, when used in conjunction 100% of the exhaust gases from this process
with the Claudius Peters EM Mill, provides the are recirculated into the calcining system for
optimum solution for the production of ‘basic enhanced fuel performance. This continuous
plaster’ – the ideal basis for machine applied heat recirculation minimizes exhaust gas losses
gypsum wall plaster. and results in excellent plant performance
and efficiency.
Air supply for Flash Calciner.
Claudius Peters calcining process with Flash Calciner.
Claudius Peters Flash Calciner.
8
Kettle Calciner
Claudius Peters’ Kettle Calciners are used for the production of high-quality plasters
and the processing of synthetic and natural gypsums.
High quality
output of both
Claudius Peters Kettle Calciner systems, in The kettle works using indirect heat transfer. natural and
combination with the Claudius Peters mills are The crushed raw gypsum is heated and calcined by synthetic gypsums
characterized by their homogeneous product adding heat through the bottom, the walls and
qualities – particularly stuccos with increased the flue passes. The constant mixing process
setting time requirements, solidity and water/ within the kettle helps homogenize the material
gypsum ratios. Their high availability, long life to be calcined and leads to a high quality product
cycle and easy maintenance, combined with through an even warming of the gypsum.
fully automatic operation reflect the latest in
state-of-the-art technology.
In order to minimize energy costs, the exhaust
gases from the kettle process are used for the
pre-drying process, so that an additional hot
gas generator may not be required. In addition,
they can run both continuous or batch operations
and can offer a fully automatic, continuous
operation system.
Claudius Peters Kettle Calciner.
Reclaim Crusher
The Claudius Peters Wasteboard Crusher is a technology specially developed
for the recycling of rejected gypsum boards.
Wet and dry waste products are loaded at the The crusher consists of a heavy duty housing with
top, while slowly rotating screws break them up counter-rotating reversing screws. Each screw is
into chunks ideally sized for blending with raw independently driven by a motor through a shaft-
gypsum or for further processing in other mounted gear reducer and electronic
handling units. frequency drive.
Claudius Peters Reclaim Crusher.
9
cooling technik
Cooling Solutions
Post calcining, materials at processing temperatures of approx. 150ºC must be
reduced to lower temperatures for further processing. Claudius Peters offers a choice
Efficient of fast and efficient cooling solutions, based on proven technology:
cooling systems
customizable for The Rotary Drum Cooler Direct Cooling Systems
any plant The Claudius Peters Rotary Drum Cooler can Claudius Peters also offers direct cooling
yield up to 100 tonnes of product per hour. It systems, ideal for smaller scale plants, whereby
works on the counter-current indirect principle, the product is cooled to required temperatures
with an air fan drawing the cooling air through a directly through ambient air drawn into
tube bundle, transferring the heat energy from the cooler.
the stucco into the air.
Materials are fed to the air flow, then separated
The heat energy of the cooling air in this process through a filter unit. The benefit of this system is
can be re-used as pre-heated combustion air, that it combines cooling with transportation.
providing a considerable reduction in plant These systems are of simple construction for
energy costs. increased reliability and are ideally suited to
plants with low to mid-range production capacity.
Material to be cooled is homogenized during
the cooling process, thus combining mixing
with cooling. The retention time allows effective
reduction of unwanted by-products such as
Claudius Peters suction cooling. soluble anhydrite and dihydrite.
Material inlet
Rotary Drum Cooler side view.
Air outlet
Air inlet
Claudius Peters Rotary Drum Cooler.
Material outlet
10
turnkey techniks
Maximum reliability combined with efficient operating costs, makes Claudius Peters
the ideal partner for your next gypsum project. From stockyard and materials handling
systems to pneumatic conveying, storage, mixing, packing and dispatch systems, Innovation and
gypsum producers can rely on Claudius Peters. know-how to
drive efficiency
Claudius Peters instill a real ethos of quality and and control for the entire production process, even further
care all the way down the line. From feasibility through to the modernization of existing facilities
studies such as plant and raw material evaluation to meet specific client and regulatory needs,
to process systems, including instrumentation Claudius Peters provides the complete package.
Claudius Peters techniks include:
Pneumatic conveying systems. Silo technology. Packing machines. Stockyard systems.
Control Systems
Claudius Peters supplies a full range of automatic
control and electrical systems, from basic eng- Communication to other
systems and/or remote access Operator Station
ineering and hardware selection or software for maintenance via modem Engineering
Station
development to the installation and commissioning
ETHERNET
of services. INDUSTRIAL ETHERNET OR FIELD BUS
Fully automated solutions, including up to date Central Control Central Control
CONVENTIONAL OR
network integration, give maximum flexibility FIELD BUS CONNECTION Sub-control
to the many aspects of plant operation. In Sub-control for complex tasks
addition, software-based machine interfaces (Cooler / Packer / Silo) FIELD BUS
Sub-control
provide user-friendly management and control
options, alarm records and preventative Field Bus Equipment Conventional
Field Equipment
maintenance systems to further enhance
operational efficiency. Claudius Peters control systems overview.
11
Claudius Peters Projects GmbH Claudius Peters Technologies SAS
Schanzenstraße 40 34 Avenue de Suisse
DE-21614 Buxtehude, Germany F-68316 Illzach, France
T: +49 4161 706-0 T: +33 3 89 31 33 00
E: [email protected] E: [email protected]
CALCINING Claudius Peters (do Brasil) Ltda. Claudius Peters (România) S.R.L.
Rua das Figueiras, 474 - 3 º andar - Edifício Str. Oituz Nr. 25C, et 2, 550337 Sibiu,
COOLING
Eiffel - Bairro Jardim - 09080-300 - Santo România
DISPATCH André / SP, Brazil T: +40 (0) 369 407 036
DOSING T: +55 (11) 4903 9230 E: [email protected]
E: [email protected]
DRY BLENDING Claudius Peters (Asia Pacific) Pte. Ltd.
DRYING Claudius Peters (China) Ltd. 25 International Business Park,
Unit 1706-1706, #01-65/66 German Centre,
GRINDING
17/F Laws Commercial Plaza, Singapore 609916
PACKING 788 Cheung Sha Wan Road, T: +65 6562 9100
PNEUMATIC CONVEYING Lai Chi Kok, Kowloon, Hong Kong E: [email protected]
T: +852 2544 1848
PULVERIZED FUEL SUPPLY Claudius Peters (Ibérica) S.A.
E: [email protected]
Paseo de la Habana, 202 Bis Bj,
SILO SYSTEMS
Branch Office: E-28036 Madrid, Spain
STOCKYARD SYSTEMS 7/F, Office Block, Hong Kong Macau Centre, T: +34 91 413 36 16
ALUMINA HANDLING SYSTEMS No. 2 Chaoyangmen Bei Da Jie, E: [email protected]
Beijing 100027, P. R. China
MARINE POWDER HANDLING Claudius Peters (UK) Ltd.
T: +86 10 6501 3831
TURNKEY PROJECTS Unit 10, Thatcham Business Village,
E: [email protected]
Colthrop Way, Thatcham, Berkshire,
Claudius Peters (India) Pvt. Ltd. RG19 4LW, United Kingdom
Unit 408, 4th Floor, Peninsula Plaza, T: +44 (0) 1635 872139
A/16 Fun Republic Lane, Off Link Road, E: [email protected]
Andheri West, Mumbai 400 053, India
Claudius Peters (Americas) Inc.
T: +91 (22) 2674 0045
445 W. President George Bush Highway
E: [email protected]
Richardson, Texas 75080, USA
Claudius Peters (Italiana) srl T: +1 972 386 4451
Via Verdi 2, I-24121 Bergamo, Italy E: [email protected]
T: +39 0 35 237 196
E: [email protected]
We know how
claudiuspeters.com
CP Gypsum Technik (GB) 10/2017 / Issue 2. Due to a policy of continued improvement, we reserve
the right to change any specification without prior notice. ERRORS & OMISSIONS EXCEPTED.
Printed on a Manroland R700 press.
