Method and system for stucco conditioning
AssigneeNational Gypsum Properties, LLC
InventorsMatthew M. Hilken, David G. Peterson, JR., Joseph J. Bailey
Life of this patent
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Abstract
A process and system for manufacturing gypsum wallboard that aerates, conditions, and cools a portion of the stucco used in the manufacturing process. This conditioning of the stucco reduces the amount of water needed to manufacture the gypsum wallboard which in turn reduces the amount of energy and cost needed to manufacture the wallboard. The stucco may also be pretreated with water. This process may be carried out using a conveyor that agitates a moving bed of stucco while the top surface of the bed is subject to a low pressure water spray.
Claims27
A method for producing a stucco slurry, the method comprising the steps of:
- providing a mixer;
- providing a supply of stucco needed to create a stucco slurry;
- dividing the supply of stucco into a first portion of stucco and a second portion of stucco;
- aerating and/or wetting the first portion of the stucco prior to adding the first portion of stucco to the mixer;
- adding the first portion of stucco to the mixer;
- adding the second portion of stucco to the mixer without aerating and/or wetting the second portion of stucco;
- and
- producing the stucco slurry by mixing the first and second portions of the stucco with at least water.
A method of producing a stucco slurry, the method comprising the steps of:
- providing at least one mixer;
- providing a supply of stucco;
- providing at least one blender capable of being fed stucco at a variable rate;
- supplying a first portion of the stucco to the mixer without having the first portion of the stucco pass through the blender, wherein the first portion of the stucco will make up one portion of the stucco needed to create a stucco slurry;
- adding to the blender a second portion of the stucco needed to create the stucco slurry;
- operating the blender to aerate the second portion of the stucco;
- and
- supplying the first portion of the stucco, the aerated and/or wetted second portion of the stucco, and at least water to the mixer to produce a stucco slurry.
A system for manufacturing gypsum wallboard, the system comprising:
- an impact mill that supplies stucco to the system;
- a blender positioned in the system to receive a first portion of the stucco that will comprise the first portion of the stucco needed to create the stucco slurry;
- and
- a mixer positioned in the system to receive a second portion of stucco without the second portion of the stucco passing through the one blender, wherein the second portion of the stucco will make up the other portion of the stucco needed to create the stucco slurry.
Dependencies are inferred from the claim text.