Gypsum Technology

Introduction to Grenzebach

Grenzebach Gypsum Division Scope of Supply

EUGENE NEWNAN

MAIDENHEAD PARIS

HAMLAR BAD HERSFELD EGGENSTEIN

SHANGHAI SINGAPORE

SAO PAULO

GRENZEBACH has achieved its leading position as an acknowledged specialist in handling and processing technology through our intensive know how and long experience in the Gypsum Industry. As a global supplier, we design, manufacture and deliver complete lines for the processing of gypsum from raw material to finished plasterboard as well as individual machines and specialist equipment for gypsum and cement fibreboard production, ceiling tiles and added value products. Grenzebach is also a principal supplier of cold end technology for the production of flat glass and specialist equipment for cutting and drying of veneers. 2

The combination of manufacturing lines with good control technology creates an overall concept of high operational safety, efficient production and maximum yield. Our theme Open to new ideas provides the catalyst for continuous new development in all aspects of our business and promotes creativity in the development of special purpose machinery. Our reputation for reliable equipment satisfies the high expectations of our customers.

Sales Contact Centres GRENZEBACH gypsum experts are only an email message or phone call away. While taking full advantage of modern communications technology, GRENZEBACH places special emphasis on maintaining personal contact with our customers and business friends. Our affiliates throughout the world offer design and manufacturing facilities close to your vicinity: Grenzebach Maschinenbau, Asbach-Bumenheim/Hamlar, Germany Grenzebach BSH, Bad Hersfeld, Germany Grenzebach Frdertechnik, Eggenstein, Germany Grenzebach Corporation, Newnan GA, USA Grenzebach AKI Corporation, Eugene OR, USA Grenzebach Shanghai Ltd., Shanghai, P.R. China

You can also obtain competent advice from our representative offices: Grenzebach BSH do Brasil Sao Paulo, Brazil Grenzebach BSH, Asia Pacific Pte, Singapore C.F.B., Paris, France Grenzebach UK, Maidenhead, U.K.

The GRENZEBACH Gypsum Division offers our customers a comprehensive range of both standard and specialist equipment from rock handling, milling and calcining through all stages of wallboard manufacture as well as bag plaster processing. Our scope of supply includes: Turn Key Plants Product and Market assessment Land procurement Factory Design + Build, Civil work, Machinery specification, design and manufacture, installation and commissioning, Operator training and Start-up support. Complete Wallboard Production Lines to meet customers own specification or to meet agreed production targets

Individual Machines for Plasterboard Manufacture: Rock-Handling and Mill Calcining Systems Preparation Area Mixing and Forming Wet End Technology Board Drying Take-off Cut to Size and Taping Stacking Stack Handling Support Services: Feasability Studies Raw Material Analysis Upgrade of existing equipment After Sales Services Maintenance Contracts

Special Equipment:

Ceiling Tile Manufacture

Gypsum Fibre Board Manufacture

3 Gypsum Wallblock Production

Grenzebach Calcining Systems

Grenzebach BSH designs and builds plants for the treatment and conversion of natural and synthetic gypsums. The finished products obtained can be used for a variety of applications. Aside from the processing of natural gypsum, the utilisation of synthetic gypsum has become increasingly important throughout the world. New concepts for calcining synthetic gypsum, developed and implemented by Grenzebach BSH, have set standards in the gypsum industry world-wide. The calcining process is an important factor in the control of the product characteristics, because it substantially affects the plasters crystal structure and the phase composition of the final product.

Possible uses of natural and synthetic gypsum

Natural Gypsum / Synthetic Gypsum

Hemihydrate (stucco) for further processing Wall blocks Hemihydrate (stucco) for further processing Flooring plaster Anhydrite Alpha hemihydrate

Dihydrate briquettes for the gypsum and cement industries Soil conditioner for agriculture

Hard mold plaster for the ceramics industry

Ceiling tiles

Fixing and levelling plaster Hand and machine applied wall plaster

Hard mold plaster for the foundry industry Self-levelling floor plaster Dental plasters

Plasterboards

Compound partition panels Gypsum fibreboards

Grenzebach BSHs range of equipment covers all types of equipment and processes used by the industry. We build calcining systems for all product qualities; directly or indirectly heated, short or long residence time equipment, such as mill calciners, rotary kilns, calcining kettles, rotary tubular calciners and continous autoclaves for wet calcining of dihydrate into alpha-hemihydrate. With our proven and time-tried systems, we can provide solutions that are tailored to meet customers specific needs. The choice of calciner depends on the one hand, on the desired product quality, and on the other hand by such factors as availability, the cost of fuel and electrical energy, manning levels, the degree of automation required, the plant size and operating mode as well as the raw material available. Grenzebach BSHs specialists, who have gained their experience from projects in all parts of the world, will assist customers in selecting the most economical system. Rotary tubular calciner with integrated cooler

Different Drying and Calcining Technologies

Drying plants Flash dryer Paddle dryer Mill dryer

Calcining plants Ring roller mill (flash calcining) Hammer mill (flash calcining) Rotary kiln Rotary tubular calciner gas fired Rotary tubular calciner steam heated Gypsum kettle Autoclave (alpha hemihydrate)

Ring-roller mill for drying or mill calcining

Hammer mill for drying or mill calcining

Based on the raw material and the expected quality of the finished product, we offer the most suitable technology available. We are proud of the eighty or more plants built by BSH during the past 50 years, who rely on our know-how and competence.

Production of alpha-hemihydrate
1 Material feeding system 2 Material mixing system 3 Crystalization 4 Additives 5 Hot water storage 6 Dewatering 7 Drying 8 Fine grinding 9 Finished product storage 10 Heat generation 11 Filtrate

Grenzebach Board Dryers

Longitudinal Dryer The Grenzebach longitudinal dryer sets the standard for the gypsum wallboard industry. As the standard workhorse of the plasterboard industry the Longitudinal Design dryer is available from a basic two zone version to a high-efficiency 2-Stage model with large-scale heat recovery. Features such as large, easyopening doors and bearings mounted outside the drive sprockets make for easy maintenance of the Grenzebach dryer. Multiple delivery deck dampers easily adjusted during normal dryer operation allow for uniform drying, thus providing better quality through a uniform drying profile.

Cross-Flow Jet Dryer Drying gypsum plasterboard with Grenzebach BSH jet-type dryers has been common practice in the industry for over 20 years. This dryer concept is particularly suited for factories planning future expansion. The modular design allows the jet-type dryer to be optimally adjusted to the required capacity, and it can be easily extended by adding further sections if necessary. The cross-flow configuration allows multiple airflow zones with short flow paths allowing airflow and temperature characteristics that can be optimized for the best drying schedule for each individual product type. The flow pattern from the individual jet tubes has been carefully designed and tested to provide uniform drying conditions across the width of the board decks. Additional features such as adjustable tube height and damper sections allow further adjustments based on measured drying uniformity.

The combined experience of the Grenzebach Group brings decades of thermal and mechanical experience to the industry. With this know-how comes a well-tested array of standard design features and up to the minute innovation. The Grenzebach team can formulate a design that is customized to your process needs.

Options: Multiple zones 6 to 12 decks Conveying widths from 2900 mm to 4100 mm (115 in. to 161 in.) Natural Gas, Propane or Light Oil heating systems (including combination fuel) Steam or Thermal Oil heating systems. Exhaust energy optimization system Heat recovery system The jet-type dryer can have 6 to 12 decks and a useful width of 2900 to 4100 mm. The dryers functional principle is based on ultra efficient heat transfer through impinged air. The drying air flows vertically onto the boards from above and below through hole-type nozzles in the jet box. This arrangement protects the cut board edge from being burnt in the dryer. The design of the delivery plenum with matching nozzles coupled with easy adjustment devices, ensure that optimum board quality is achieved in the shortest possible drying time.

Several options are available to customize the Grenzebach dryer to your process needs: 2, 3 or multiple zones 6 to 14 decks Conveying widths as necessary for 2 or 3 board streams to 1372 mm (54") Single-Side or Double-Side delivery plenums

Hot or cold circulation fans Natural Gas, Propane or Light Oil heating systems (including combination fuel) Steam or Thermal Oil heating systems. Exhaust energy optimization system Heat recovery system

Rebuilds and Upgrades

Grenzebach has many years experience with rebuilds and upgrades for dryers from all manufacturers and of all configurations. Whether the goal is to increase production, improve board quality, reduce energy consumption or to correct the ravages of time, Grenzebach is uniquely qualified to provide expertise and appropriate equipment.

The drying air can be heated either directly by means of gas or light fuel oil, or indirectly via a steam or thermal-oil heat exchanger with oval finned tubes. All Grenzebach dryer designs result from years of industry experience combined with extensive testing in our laboratories and the application of the latest numeric analytical methodology. We are uniquely positioned to provide the best solution for your drying needs based on the nature of your raw materials, market demand and your operational philosophy.

Screen Dryer

The Grenzebach BSH Screen Belt dryer provides speciality drying for mineral fiber, gypsum fiber or other products having low strength when wet. The Screen Dryer provides the operational advantages of the Cross Ventilated Jet dryer with the unique carrying capabilities of the screen belt conveyor. Standard Grenzebach design features are included to provide uniform drying profiles, thermal energy efficiency and ease of maintenance.

Production Line for Gypsum Plasterboard

Wet End Transfer A typical example incorporating sample board lifter, acceleration conveyor, wet end reject, inverter and board re-grouping prior to the Dryer infeed tipple. Setting Belt Designed with board quality as a priority, Grenzebach setting belts incorporate good tensioning, optional cleaning, easy maintenance features. Calibration monitoring, walker wheels and edge conditioning are also available options. Preparation Area Feeding hoppers for additives, weighing and dosing equipment and screw feeders are supplied from proven manufacturers according to customer preference. Total control and complete mezzanine additive packages, based on proven technology, are available.

The Mill and Calcining Plant Handling of raw gypsum whether natural or synthetic, drying, milling and calcining is an integral part of Grenzebach technology. Drying and Calcining options can be found on page 4. The optimum system will be designed following extensive material testing in our laboratories.

Paper Handling Systems Our systems incorporate web loading devices, automatic paper splicing, tensioning and edge creasing or scoring. Pre-heating and pre-coating units are available options.

The Knife Controlled by the PLC according to production demand, the knife can cut single board lengths or longer boards as required.

Mixing and Forming Grenzebach Pin Mixers and/or Pinless mixers have been developed for varying types of natural and synthetic Gypsum. Our forming plate may be adjusted manually or automatically for accurate calibration of board thickness. Acceleration Conveyor Receives cut boards from the knife and accelerates them to form complete groups on the A Table. The board groups are then transferred at 90 degrees by belt conveyor prior to inversion. Board Dryers Further information on the range of Dryers available from Grenzebach can be found on pages 6 & 11. Multi-deck Longitudinal Dryers with two or more zones and Cross-flow Jet Dryers, each with optional heat recovery systems are designed to match production Emergency Reject-Refeed Boards may be rejected prior to the bundler, and can subsequently be fed back into the line.

Grenzebach offers their customers all possible options for the production of Gypsum Plasterboard from a low cost solution for producers entering the market, to highly sophisticated automated plants with very large capacity and high yield. Whether your need is for a single item of equipment, a full production line or a turnkey plant, you can be sure of expert advice, excellent technology, reliable equipment and start-up support. Our aftersales team are at your service, providing technical support, spare parts and advice, 24 hours each day. A hot-line teleservice enables us to solve many problems on-line.

All our systems have been proven through many years of experience in the Gypsum Industry. Technology is constantly updated by the introduction of practical solutions, often developed in partnership with our customers, and reflecting industry standards in motor and control technology. This schematic drawing provides an example of a typical plasterboard production facility. Actual plants may vary in a number of ways, depending on the type of gypsum used, required capacities, product differences and individual preferences.

capacities and related evaporative loads. Ease of maintenance and access are given a high priority. Grenzebach are expert in achieving successful dryer upgrades for additional capacity, to reduce energy consumption or to repair the ravages of time.

Board Stacking and Stack Handling Further details of Grenzebach handling systems with available options will be found on pages 12 and 13 of this brochure.

Web Handling and Paper Splicing Paper rolls can be mounted on the paper feed equipment using a dedicated lifting system. Automatic splicing is a standard option. Bundler Boards may be cut to exact length and divided using a centre cut saw. Bundlers incorporate automatic taping equipment to bind the ends of each pair of boards, when required.

We will be pleased to discuss special customer needs and any particular applications you may have. Grenzebach specialists are available for consultation at any time, world-wide.

Dry End Transfer Dry End Transfers will be sized according to specified board lengths and the cut-to size and stacking arrangements for the line. A moveable stop-bar and covered rollers ensure exact board positioning and quiet transfer.

Board Booker Boards may be paired face up or booked face to face in multiple widths according to production requirements. Particular care is taken to protect the board edges.

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Paper Creasing or Scoring Pre-heater A Creasing or Scoring unit is incorporated as part of paper handling. A pre-heater is available as an option.

Grenzebach Handling Systems

Double length boards will need to be cut into singles and end trimmed to size prior to taping and/or stacking. Accurate saw systems designed and manufactured by Grenzebach can also be provided with scoring and end chamfering. Handling of Plasterboard after the extruder, during setting, prior to drying and at the take-off has been a key element in the Grenzebach programme for over 30 years. The investment in Gypsum processing, and drying of the board is carefully considered to ensure optimum board quality. By choosing handling equipment specially designed to ensure the board quality is maintained from the setting belt to the warehouse, Grenzebach customers can achieve the highest possible yield. The development of even faster lines has required special cutting equipment and multi-stacking systems to match the higher capacities.

Grenzebach offers a range of stacking options ranging from single stacks when boards are taped, to stackers creating stacks side by side directly after the saw station. Stack changing is accomplished effortlessly using a rake system which enables stacking to continue while the preceding stack is cleared from the stack table.

Multiple stacking enables Fork Lift Operators to collect 2 or 3 stacks in one visit. Our automatic multi-stacking device is positioned just prior to the Fork Lift take-off point.

Automatic Pallet Feeders to inject a new pallet during each stack changeover, can also be supplied.

Boards requiring taping will be trimmed and taped in a Bundler. A separate taping machine, including automatic tape slicing and roll change, may be installed behind the saw system.

Stack handling can be managed directly in line on an endless chain plate or stacks can be transferred through 90 degrees on rollers or using a shuttle system.

Options include: Edge Printing, Automatic Cull Application and Multi-stack building using a fully automatic static fork lift system to place 2 or 3 stacks one above the other.

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Controls Technology for each level of Automation

Depending on line concept and the required degree of automation Grenzebach turnkey sytems are offered on the following basis.

For complex building panel production lines, Grenzebach offers state-of-the-art control technology with an intelligent operation structure characterised by fast reaction, reliability and user friendly application. Process control systems Simulation Visualisation Operation with high user acceptance Line control systems CNC controls with CAD application Inspection systems Administration systems Order management Stock management Quality management to ISO 9002 Optimization Training Teleservice/hotline 24 hour service

Controls Technology A combination of highly sophisticated software and highly developed host computer software is available from Grenzebach. You gain the advantage of our years of experience in developing systems specifically for the Gypsum Wallboard Industry. Our systems are user friendly, based on established industry standards with graphics and

information clearly displayed on strategically placed monitors on a control deck and along the line. Varying levels of access may be granted through a password system. Users can read the actual state of production in real time. Operation of individual stations and of the full production line can be made via push-buttons, mouse or touch screen, locally or from the network.

PPC Production BDE Mode / PDA Production Data Acquisition / Feed Back of Production and Statistics PPC Production Plant Computer Interfacing / Direct Customer Order Input and Delivery Details PPC Production Process Computer Production Planning Product Management, Batch Formation PPC Production Process Computer Stack and Pattern Optimization

Calcining

Preparing Station

Dryer

Customer Benefit

PPC Production Process Computer Product Flow Synoptic PPC Production Process Computer Plant Synoptic HMI and Visualization PLC Programming Line Control NC/CNC Numeric Control MC Motion Control Decentralized I/O / Field Bus Machine Wiring / Instrumentation / Sensors Low Voltage Power Distribution Medium Voltage Power Distribution

TeleService
Ethernet

Server 1 Print Server

Server 2

Engineering

OLM
Siemens
P1 D A P2 C D LS 1 LS 2 LS 3

Industrial Ethernet

Dryer Outlet

Dryer Inlet

Degree of Automation

Calcining
Siemens Siemens
P1 D A P2 C D LS 1 LS 2 LS 3 P1 D A P2 C D LS 1 LS 2 LS 3

Dryer Inlet
Siemens
P1 D A P2 C D LS 1 LS 2 LS 3

Preparing Station

Optical Ring Calcining and Boardline

Keyboard Keyboard Dryer
Siemens
P1 D A P2 C D LS 1 LS 2 LS 3

Industrial Ethernet

Dryer Outlet
Siemens
P1 D A P2 C D LS 1 LS 2 LS 3

MS 3124-4

4TX1

PLC-LINE

2FXM2

4TX1

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to customer over DP-DP-coupler 1 D Drives n D

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Low voltage power distribution

Medium voltage power distribution

Other Building Materials technologies

Cement Fibreboard

Acoustic Ceiling Tiles

Composite Sandwich Panels

Thermal Insulation Boards (Mineral Wool)

GRENZEBACH Maschinenbau GmbH Albanusstrae 13, Hamlar 86663 Asbach-Bumenheim, Germany Phone: +49 (0)9 06/9 82-0 Fax: +49 (0)9 06/9 82-108 e-mail: info@grenzebach.com GRENZEBACH Corporation 10 Herring Road Newnan, Georgia 30265, USA Phone: +1 (770) 253-4980 Fax: +1 (770) 253-5189 e-mail: info.gn@grenzebach.com

GRENZEBACH BSH GmbH August-Gottlieb-Strae 5 36251 Bad Hersfeld, Germany Phone: +49 (0)66 21/81-0 Fax: +49 (0)66 21/81-613 e-mail: info@bsh.grenzebach.com GRENZEBACH AKI Corporation 29345 Airport Road Eugene, Oregon 97402, USA Phone: +1 (541) 688-4117 Fax: +1 (541) 688-3508 e-mail: info.ga@grenzebach.com

GRENZEBACH Frdertechnik GmbH Hauptstrae 135 76344 Eggenstein, Germany Phone: +49 (0)7 21/62 73 69-1 Fax: +49 (0)7 21/62 73 69-9 e-mail: info.gf@grenzebach.com GRENZEBACH Machinery (Shanghai) Ltd. Guanghua D-2, Minshen Industrial Garden Zone Songjiang District, Shanghai 201612, P.R. China Phone: +86 (21) 5768 4982 Fax: +86 (21) 5768 4984 e-mail: info@grenzebach.com.cn

www.grenzebach.com