Gypsum industry news

UK: Associated British Ports (ABP) has proposed the construction of a new gypsum wallboard plant at the Port of Newport. The project is at the planning stage with the submission of an environmental impact report to the local government. The 14,000m³ unit will be built on brownfield land south west of the port’s South Dock. It will include a simple warehouse-type structure enclosing production lines, conveyor belts, storage loading areas and two hoppers. No cost for the project has been disclosed.

Gypsum for the production line will be delivered by ship and unloaded into a quayside storage facility. Plasterboard products will be distributed from the proposed plant mainly by road although export markets by sea could be possible. It is anticipated that around 70 jobs would be created by the plant.

Australia: Boral says that it may be ready to announce its plans with its USG Boral joint venture in August 2019. It is currently conducting due diligence on the joint venture’s operations in Asia following Knauf’s acquisition of USG in early 2019, according to the Australian newspaper. Forward options include established a new Asian joint-venture with Knauf or buying USG Boral’s gypsum wallboard business in Australia, New Zealand, Papua New Guinea and islands in the South West Pacific. However, Boral’s chief executive officer (CEO) Mike Kane said that there might not be enough time to arrange a deal by the publication of Boral’s full year results in August 2019.

Australia: Senex Energy has agreed a deal with CSR Gyprock to supply natural gas to its gypsum wallboard plant at Coopers Plains in Queensland. The agreement also covers gas supplies to CSR’s brick and insulation plants in the state. Under the initial three-year agreement, Senex will supply CSR Building Products, a subsidiary of CSR, with 0.65PJ/yr of gas, starting on 1 January 2020. CSR can extend the agreement by up to a further two years, taking the total contract quantity to 3.25PJ. Gas will be supplied at the Wallumbilla Gas Hub in Queensland at a fixed price in line with current market levels, indexed annually.

Mexico: Saint-Gobain has completed the acquisition of Knauf Mexico for an undisclosed sum. Knauf operates a 26Mm² gypsum wallboard plant at Queretaro that it purchased from PPG in 2017.

Egypt: Dahab Sinai for Manufacturing and Building Materials has ordered a gypsum plant from Germany’s Claudius Peters to be built in the Suez region. The new plant will be used for the production of basic plaster for wall and ceiling plaster products. Construction is scheduled to start in early 2020 with commissioning to follow in the the third quarter of the year. No value for the order has been disclosed.

Claudius Peters will supply a grinding and calcining plant with a EM47 type mill with a stucco throughput capacity of 25t/hr. A homogeniser for product optimisation is connected behind the calcining process. After the cooling process the produced basic gypsum can be adapted to the market requirements by adding setting regulators and hydrated limestone. This part of the plant is also included in the scope of supply. The finished product is bagged by means of a four spout packer RotoFill type R6/4L with a capacity of 1137bags/hr. Various silos, a truck loading and unloading plant, the complete electrical equipment and control systems as well as the raw material handling with corresponding conveying technology are also part of the delivery.

The new plant will be used to supply the local market but exports to Africa and Europe are also planned. The plant is designed in such a way that further plant equipment can be installed at a later stage. The mixing plant can be extended with the admixture of further additives. Furthermore, a reserve space for the later retrofitting of a bag applicator with loading equipment has been taken into consideration.

Romania: France’s Fives has supplied a new FCB TSV1600 MF for Etex’s calcined gypsum grinding plant in Aghires. The project is part of an upgrade to the unit to close the existing open circuit. Commissioning took place in late January 2019.

US: Continental Building Products says that its Buchanan gypsum wallboard plant in New York state has reopened at full capacity. The unit shut in January 2019 following a ‘significant’ equipment malfunction. Continental's plants in Silver Grove, Kentucky and Palatka, Florida increased their production to offset a portion of Buchanan's lost volumes.

China: Wengu Chemicals plans to build a 10Mm²/yr wallboard production line at its gypsum plaster plant in Guizhou province. It plans to commission the new line by the end of 2019, according to CCM. The company has stockpiled over 38Mt of phosphogypsum in the province. It is using this to produce a variety of gypsum products.

Peru: Eternit plans to upgrade its gypsum wallboard plants at Cercado in Lima and Huachipa. Wallboard consumption is 0.4m²/yr per capita in Peru compared to 2.7m²/yr per capita in Chile, according to the Gestión newspaper. The subsidiary of Belgium’s Etex plans to increase its revenue from wallboard to 50% from 40% at present.

US: Stacy Kuszmaul, a plant manager at Delavan, Wisconsin and Deirdre Brockwell, staff researcher at Libertyville, Illinois have been recognised by the Manufacturing Institute as part of its annual Science, Technology, Engineering and Production (STEP) Ahead Awards. This marks the fifth consecutive year a USG employee has received this honour for her contributions to the manufacturing industry. The STEP Ahead Awards honour women who have demonstrated excellence and leadership in their careers and represent all levels of the manufacturing industry, from the factory-floor to the executive level.

Kuszmaul, a plant manager with more than 15 years' experience at USG, has been recognised for her operational acumen - particularly on new line startups - and has been a key driver in the company's Performance Materials division. Brockwell, a researcher in USG's ceilings lab, develops early stage concepts and conducts research that helps to expand USG's ceilings portfolio and respond to demands from architects, designers and contractors. She is also a Lean Six Sigma (LSS) Green Belt.

The Manufacturing Institute will recognise Kuszmaul, Brockwell and their fellow STEP Ahead award recipients during a reception in April 2019 in Washington, DC.