Gypsum industry news

Hungary: Slovakia-based Stavmat Epitoanyag Kereskedelmi has produced its first batch of wallboard from recycled drinks cartons at its Kaposvar pilot plant in Somogy County. MTI – EcoNews has reported that the company plans to install two further production lines at the site by January 2023.

The full-scale plant will cost US$10.6m, employ 20 people and consume 50 – 70t/yr of waste drinks cartons. Stavmat Epitoanyag Kereskedelmi plans to establish a carton collection service across Southern Transdanubia. The present commissioning may lead to the establishment of a second, 10-line plant at a cost of US$21.2m.

US: ML Environmental Group has secured a strategic partnership and exclusive US distribution agreement with gypsum wallboard recycling technology producer Scott Equipment Company. Scott Equipment Company produces the GypStream paper backing removal system. Together, the companies say that they will expand the gypsum wallboard recycling solutions offering available to US customers.

Scott Equipment Company business development and product marketing manager Kevin Pedretti said "Our recycling systems, including both the food waste organics recovery system and the gypsum wallboard separation and recovery machines, position nicely with ML Environmental Group's vision to offer their customers an end-to-end solution.” He continued "We have been very impressed with the leadership and growth of ML Environmental and look forward to making the world a better place with this partnership."

US: CertainTeed has installed new recycling technology at its Silver Grove, Kentucky, gypsum wallboard plant which will enable the facility to divert 15,000t/yr of production scrap paper from landfill. The technology grinds gypsum-contaminated paper into fine pieces for separation. The subsidiary of France-based Saint-Gobain says that it will then be able to reuse both paper and gypsum in its wallboard production at the plant.

CertainTeed’s gypsum general manager and vice president Jay Bachmann said “This project allows us to reduce our waste and reduce our production costs in Silver Grove while also empowering us to increase the efficiency of our use of natural resources.” He added “We will continue to look for ways to minimise our environmental footprint while maximising our company’s positive impact for our customers and the communities where we do business.”

US: Canada-based Building materials recycling equipment supplier TORXX Kinetic Pulverizer has launched TORXX Kinetic, a new wholly owned subsidiary. The company’s headquarters are in Chattanooga, Tennessee. TORXX Kinetic Pulverizer chose the location in order to be closer to its customer base.

Vice president Terri Ward said that in 2021 “Covid-19 pandemic-related travel restrictions hindered growth, with our North American headquarters in Canada and most of our customers and new opportunities in the US.” Ward continued “We are maintaining a presence in Toronto with engineering and service resources. However, key personnel and new hires are now in the US, making it much easier to collaborate and respond to customer needs. We were attracted to the Scenic City because of its favourable manufacturing and transportation resources, proximity to our customers, and its appeal to our valued employees.”

TORXX Kinetic Pulverizer’s kinetic pulveriser is a waste processing technology which relies on aerodynamics and matter-on-matter collisions for particle size reduction. Vortices agitate feedstock, causing more brittle material to shatter while less brittle material remains larger. This size differential facilitates the liberation and mechanical separation of contaminants.

Germany: Knauf Gips has partnered with Canada-based lithium hydroxide producer Rock Tech Lithium and waste management company Papenburg Entsorgung Ost to found the Institute for Technologies and Economics of Lithium (ITEL) at Halle (Saale) in Saxony-Anhalt. The institute aims to develop an inter-sector, CO2-neutral recycling economy for lithium in Germany. This will include the use of gypsum from lithium hydroxide production in gypsum wallboard production. ITEL has appointed Martin Luther University Halle-Wittenberg academics Ulrich Blum and Ralf Wehrspohn as its managing directors.

ITEL said “The switch to electromobility will make Germany the central location for battery production in Europe and thus also for the production of the crucial precursor lithium hydroxide. The reduction and reuse of the by-products generated during the refinement of lithium is the focus of the institute's work. Another focus is research into new production steps to optimise by-product value creation.”

US: Saint-Gobain plans to invest a total of US$400m in expansions to its operations including gypsum operations at four US sites. The group says that the sites are located in California and the Southeastern US. It said that the new capacities will apply the most advanced available technologies for industrial performance, safety and sustainability. This will reduce waste by 50% and CO2 emissions by 20% from current levels, according to the company.

Saint-Gobain said it hopes that the investments will strengthen its leadership in North America and accelerate its growth in the region by enriching its comprehensive range of solutions for light and sustainable construction.

Belgium: Etex’s 2020 Sustainability Report has recorded the company’s progress towards its sustainability goals under four headings. Under the heading ‘carbon neutrality,’ it produced and purchased 72% of its electricity consumption renewably, compared to 14% in 2019. Under ‘health, safety and wellbeing,’ its lost-time accidents per million working hours fell by 36% year-on-year to 1.4 from 2.2. Under ‘waste management and circularity,’ it reduced its waste generation by 8.9% to 254Mt from 278Mt and reduced the share of its waste sent to landfill to 18% from 26%. Lastly, under ‘diversity and inclusion,’ 28% of the company’s newly hired staff were women, compared to a group total share of 19%.

CEO Paul van Oyen said “At Etex, we have a clear commitment to helping build a better, sustainable future. We seek to offer holistic value to our customers, employees, shareholders and other stakeholders, as we continue to decouple our growth from environmental and social impacts. To help achieve this, we focus on lightweight materials and prefabricated construction. These methods offer advantages such as reduced raw material use, energy consumption, waste and emissions. Even more, they contribute to enhanced long-term circularity by creating opportunities for deconstruction, reuse and recycling.”

Vietnam: Deputy prime minister Hoang Trung Hai has directed the implementation of solutions to treat waste at thermal power plants for energy conservation and environmental protection.

Trung Hai urged the concerned parties to more effectively implement Government Decision 1696/QD-TTg on measures to treat gypsum, ash and cinder from thermal power, chemical or fertiliser plants for the production of building materials. Special focus should be paid to the Vinh Tan in Binh Thuan, An Khanh in Thai Nguyen, Song Hau in Mekong Delta Hau Giang and Vung Ang in Ha Tinh thermal power plants, where waste treatment is a pressing issue.

He asked the Ministry of Industry and Trade and the Ministry of Construction to coordinate with localities to disseminate effective waste treatment models while supplementing and completing criteria on the quality of ash and cinder for recycling in cement and construction material production.

Vietnam is home to 19 operating thermal power plants with a total capacity of 14,480MW, which discharge about 15Mt/yr of ash and cinder. After 2020, the country is expected to have 43 thermal power plants with a combined capacity of 39,020MW, discharging over 30Mt/yr of ash and cinder.

New Zealand: Auckland's first comprehensive recycling facility for building industry waste, including wallboard, has been opened by the environment and building and housing minister Nick Smith, according to Live News.

"This new recycling facility is about greening the building industry, enabling 30,000t/yr of construction and demolition waste to be diverted from going to landfill. It will enable thousands of tonnes of wood, wallboard, steel, plastics and aggregates from the construction sector to be sorted and re-processed into a reusable form," said Smith.

The US$2.78m facility is part-funded by a government grant of US$1.39m from the Waste Minimisation Fund and has created 15 jobs in the local Onehunga community. The fund was established by the government from a US$6.6/t levy on waste going to landfill that was introduced on 1 July 2009. Over US$39.6m has been used to fund more than 100 projects in the past five years.

"The opening of this new facility is very timely with Auckland on the brink of its largest ever building boom. The house build rate has increased from 4000/yr to 8000/yr since 2011 and is expected to grow to over 12,000/yr. Each home constructed generates 4t of waste and it makes sense to recycle as much of this construction material as possible," said Smith.

Wood, plasterboard, steel, plastics, aggregates and cardboard are being targeted by CID Resource Recovery for recycling or reuse. Wood will be further processed into biofuel for industrial kilns, while old wallboard can be recycled for use as a soil conditioner. Scrap steel will be extracted by magnet and delivered to metal recyclers for processing and sale on the local or export markets. Various grades of plastic, card and paper will go to local recyclers for processing. Aggregates will be used locally for hardfill or drainage material on building or infrastructure projects.

"This sort of practical approach to recycling typifies the Government's Bluegreen approach to waste. We are partnering with business to find economically-viable ways to recycle waste and focusing on those areas where there are the biggest gains. This initiative is particularly significant as construction and demolition waste makes up half of New Zealand's total waste going to landfill," said Smith.

UK: A waste company has been ordered to pay Euro18,968 in fines and costs for illegally handling, storing and depositing wallboard. The case was brought by the Environment Agency.

In October 2012 approximately 60t of broken wallboard from Tawmix Timber Products Ltd was found tipped on a site known as Poppy's Field beside an old airfield at Winkleigh, Devon. The material was contaminated with construction and demolition waste. A special permit is needed to treat and store this type of waste. In July 2013 similar wallboard was illegally used to construct a new fence at Tawmix Timber Products' business premises at Unit 2, Winkleigh Airfield.

North Devon Magistrates' Court heard that Tawmix Timber Products was permitted to store, sort, separate, screen or crush waste wood at its site in Winkleigh. However, it did not have permission to accept gypsum based construction material such as wallboard, which requires specialist handling, treatment and disposal. The company had received advice and guidance from the Environment Agency on plasterboard and was aware it needed a 'variation' to its permit before it could accept this material.

"Wallboard should only be recycled and recovered by specialist companies," said Environment Agency spokesman Sue Smillie. "Tawmix Timber Products did not hold the necessary permits to store, shred and deposit this material. By accepting wallboard on Poppy's Field and depositing wallboard at its main site, the company was in breach of its permit."

Tawmix Timber Products Ltd was fined a total of Euro15,167 and ordered to pay Euro3713 costs for two offences under the Environmental Permitting Regulations 2010, including the illegal storage and use of chipped wallboard at Poppy's Field and Unit 2, Winkleigh. The company pleaded guilty to both charges at an earlier hearing.