Systems and methods for manufacturing calcined gypsum with reduced particle size and manufacturing gypsum board with same
AssigneeUnited States Gypsum Company
InventorsNaser Aldabaibeh, Mark K. Hemphill, Ali Pournaghshband Isfahani
Life of this patent
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Abstract
Embodiments of a system and a method for manufacturing calcined gypsum and for manufacturing a gypsum board can include a grinding system with a roller mill configured to reduce the particle size of calcined gypsum to an average particle size of fifteen microns or less. The grinding system can be located in one of the stucco or gypsum board manufacturing systems or distributed between the two systems.
Claims20
A system for manufacturing calcined gypsum, the system comprising:
- a calcination unit, the calcination unit including a calcining chamber and a heating unit associated with the calcining chamber, the calcining chamber including an inlet for receiving a supply of gypsum therethrough and into the calcining chamber and an outlet for discharging the supply of gypsum from the calcining chamber;
- a grinding system, the grinding system including a rotor mill in at least one of a position upstream of the inlet of the calcining chamber and a position downstream of the outlet of the calcining chamber, and the rotor mill configured to grind the supply of gypsum to an average particle size of fifteen microns or less.
A system for manufacturing a gypsum board, the system comprising:
- a mixer, the mixer being adapted to agitate calcined gypsum and water to form an aqueous gypsum slurry;
- an ingredient supply system, the ingredient supply system being configured to selectively feed at least water and calcined gypsum to the mixer, the ingredient supply system including a source of calcined gypsum;
- and
- a grinding system, the grinding system including a rotor mill interposed between the source of calcined gypsum and the mixer, the rotor mill configured to grind calcined gypsum from the source of calcined gypsum to an average particle size of fifteen microns or less to selectively deliver a feed stream of ground calcined gypsum to the mixer.
A method of manufacturing a gypsum board, the system comprising:
- grinding a supply of calcined gypsum in a rotor mill such that a feed stream of ground calcined gypsum having an average particle size of fifteen microns or less is produced;
- delivering the feed stream of ground calcined gypsum to a mixer;
- agitating at least water and the feed stream of ground calcined gypsum in the mixer to form an aqueous gypsum slurry.
Dependencies are inferred from the claim text.