Manufacturing Plant Profitability

The overall benefit of the process is that users of beta gypsum plasters, including gypsum board manufacturers, will have access to the beta type properties of gypsum plasters but will be able to use less than half the water typically needed. The result is a savings in drying or water reducing chemicals of about $3 per ton of plaster used. If the plaster is used in making board and the dryer is constraining capacity, then an additional $2-3 savings per ton of plaster can be achieved.

This scenario, alone, easily demonstrates the commercial value of Hi-PSI-G in that the overall plant capacity is increased and thus the overall profitability of the site increases accordingly. Utilizing this novel design is a more viable way to increase capacity rather than building completely new board plants.

By modifying the calcination equipment in accordance with this technology, companies will be able to speed up existing plants to match dryer capacity.  Figure 6 shows the return on capital that can be achieved by producing Hi-PSI-G.  An investment of $13M-$16M  yields 200,000 tons.  By comparison, the Wet Process requires an investment of $15M for 36,000 tons.

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Figure 6. Plant Profitability Using Alpha Hemihydrate to Increase Capacity

Hi-PSI-G process increases capacity from 400,000 msf/year to 650,000 msf/year

Figure 5. Unit Cost of Sales