Gypsum industry news

Eurogypsum added its views on the European Union’s (EU) proposed Critical Raw Materials Act (CRMA) last month. It wants gypsum to be added to the bill’s list of critical and strategic raw materials. It is not surprising that the European federation of national associations of producers of gypsum products might want to do this. However, when compared to rare earth minerals of the sort required to manufacture batteries for electric vehicles (EV), gypsum doesn’t seem all that, well, rare.

What may be rare though is people’s patience with new gypsum mines. The association’s argument is that gypsum is indeed abundant in the EU but that accessing it is increasingly becoming difficult. The EU’s sustainability agenda has made the energy efficiency of buildings as important as reducing CO₂ emissions from the transportation sector. Gypsum and other materials used to make lightweight building materials are a way of renovating existing buildings and improving energy efficiency. Therefore it suggests that the act should either recognise gypsum as strategic or introduce a new ‘essential’ category. This would then make the process of extracting gypsum more easy.

This approach ties back to initiatives such as one by the Federal Commission on Geosciences (BLA-GEO) in Germany, which previously started to compile an inventory of the nation’s gypsum deposits with the intention of putting this in front of policy makers. Nor is the gypsum sector alone in targeting the potentially lucrative retrofit market. In May 2023 Daikin, Danfoss, Knauf Insulation, Rockwool, Saint-Gobain, Signify and Velux signed an agreement to promote building energy efficiency in Central and Eastern Europe (CEE). Radek Bedrna, Knauf Insulation’s managing director for Eastern Europe and Middle East, noted that two thirds of the 43.6m homes in single- and multi-family houses in the CEE region were reportedly built before 1989 and are energy inefficient. The European Commission places transport-related greenhouse gas emissions at about 25% of the region’s total. Renovating buildings fully, by contrast, could save up to 5% of the EU’s emissions. Targeting transport emissions may be a higher priority for the EU but the savings from retrofitting are not trivial either.

Then - on cue in mid-June 2023 - there was an example of the difficulties gypsum product producers can face with building new quarries or enlarging old ones when expansion plans for a gypsum quarry supporting Placoplatre’s wallboard plant in Chambéry in France were scaled back from local opposition. The subsidiary of Saint-Gobain met similar issues in late 2022 when a public enquiry started examining its plans to build a new quarry at Fort Vaujours, Seine-Saint-Denis. This site is intended to serve the Vaujours gypsum wallboard plant as a replacement for its Bernouille quarry after the latter closes in 2026. This one has a happier ending, for the gypsum sector at least, since the project received an environmental permit in late May 2023. One of the key issues that came up in the enquiry was a disagreement over the means of extraction. A local environmental group favoured underground mining but an open-cast approach was preferred by the producer as it would yield much more gypsum. The latter was eventually approved.

What this suggests is that making gypsum an ‘essential’ raw material in Europe requires engagement with the general public as much as legislators. Some people may not like having a wind farm built near where they live but the chances are that there will be less opposition than building a new coal mine. Digging up new gypsum deposits should be presented as more like the former than the latter. Whizzing around in a new EV is generally seen as being more fun than bragging about how great the lamba factor is for one’s house. However, this may change if energy prices keep ticking upwards. Gypsum may not be rare but Eurogypsum and others can make a strong case for it being essential.

Kazakhstan: Germany-based Knauf has signed a deal with the government of the Zhambyl region to build a gypsum wallboard and dry building mixtures plant. The project has a cost of around Euro30m, according to InterFax. Completion is scheduled by 2026. Local subsidiary Knauf Gips Taraz is now developing design and estimate documentation for the construction of necessary infrastructure. Products from the proposed plant will be sold in the domestic market. The project is one of nine agreements between organisations from Germany and Kazakhstan announced during an official visit by German President Frank-Walter Steinmeier.

US: Albér Gypsum has developed an adhesive gypsum-based plaster ‘board’ product that can be used in place of traditional gypsum wallboard. Using the new process gypsum powder is first mixed with water into a mixture lightweight cement sprayer. The company has also designed a special spray gun for this purpose. The plaster is then sprayed onto the wall construction or/and insulation, evened out and left to dry for up to six hours. A patent is currently pending for the new method.

The developer says that the gypsum-based plaster product eliminates air pockets in a wall, covers electrical wires and tubes thereby reducing fire risk and is stronger than traditional wallboard. It takes half the installation time of regular wallboard and does not require fittings such as bolts or nails. The company says that the sprayable plaster creates less waste, is easily recyclable and does not use paper. Not using paper also prevents any cases of black mould. The gypsum mix used can be modified to create a harder or softer surface depending on the desired room acoustics.

China: Saint-Gobain has inaugurated a new 37Mm²/yr gypsum wallboard plant in Yuzhou, Henan province. The site will also produce 150,000t/yr of plaster. The plant will also use over 400,000t/yr of industrial by-products to increase its sustainability. Other initiatives include using renewable electricity, installing solar panels, using electric-powered forklift trucks and recycling all of the plant’s gypsum waste.

France-based Saint-Gobain has been present in China since 1985 and it employs more than 8000 people. The Yuzhou plant is the company’s sixth unit in the country. Construction of the site was supported by a green financing loan, implemented with BNP Paribas.

Italy: Assogesso, the Association of Italian Gypsum Producers, has appointed Gaetano Terrasini as its president. Terrasini is the chief executive officer (CEO) of Saint-Gobain Italia. He has held the position of CEO since 2020. Prior to this he has worked for Saint-Gobain and related companies for over 20 years.