Gypsum industry news

US: The US Geological Survey reported domestic natural gypsum production volumes of 16.3Mt during the first nine months of 2023, down by 0.3% year-on-year from 16.4Mt during the corresponding part of 2022. Meanwhile, calcined gypsum production volumes grew by 1.2%, to 14Mt from 13.8Mt. Throughout the period, the US imported 5.91Mt of crude gypsum, up by 35% year-on-year. Spain supplied 2.4Mt (41%) of imports, followed by Mexico with 1.7Mt (29 %) and Canada with 1.56Mt (26%).

Canada/US: Saint-Gobain has signed a 15-year renewable electricity supply agreement (PPA) with TotalEnergies for the purchase of solar power for its 125 industrial sites in the US and Canada. This 100MW PPA, known as the Danish Fields Solar Project (Danish Fields), is expected to offset Saint-Gobain’s North American CO₂ emissions from electricity (scope 2 emissions) by 90,000t/yr. The project is expected to come online by the end of 2024.

Danish Fields is the third PPA signed in North America by Saint-Gobain. The first PPA, with the Blooming Grove Wind Farm in Illinois, was signed in 2020, and the second, with TotalEnergies’ Cottonwood Bayou Solar Project in Texas, was signed in 2022. All three projects have been supported by Edison Energy, a leading energy and sustainability advisory that consults with the largest commercial, industrial and institutional energy users.

Mark Rayfield, the chief executive officer of Saint-Gobain North America, said “With this agreement, Saint-Gobain North America will further reduce its CO₂ emissions, demonstrating how fast the manufacturing industry can transform when long term solutions are at hand. This renewable energy project is a new milestone on the way to meeting Saint-Gobain’s commitment to reduce scope 1 and 2 CO₂ emissions by 33% by 2030 - compared to 2017 - and to reach carbon neutrality by 2050.”

The three projects combined are expected to represent a reduction of more than 70% in Saint-Gobain North America’s scope 2 emissions, compared to 2017 levels.

North America: Saint-Gobain has signed a 100MW solar power purchase agreement (PPA), called Danish Fields, with TotalEnergies. The Danish Fields PPA will supply Saint-Gobain North America with solar energy for 15 years, commencing in 2024. Saint-Gobain says that it expects the PPA to eliminate 90,000t/yr of CO₂ emissions across its operations. This is the group’s third deal of its kind.

Saint-Gobain North America CEO Mark Rayfield said “With this agreement, Saint-Gobain North America will further reduce its CO₂ emissions, demonstrating how fast the manufacturing industry can transform when long term solutions are at hand. This renewable energy project is a new milestone on the way to meeting Saint-Gobain’s commitment to reduce Scope 1 and 2 CO₂ emissions by 33% by 2030 compared to 2017, and to reach carbon neutrality by 2050.”

One can tell that gypsum wallboard is a popular product because companies keep trying to devise alternatives to it. A recent one is Breathaboard. The company making it, Adaptavate, announced in August 2023 that it had generated around Euro2.3m in its latest investment round. It is building a pilot production line in Bristol in the UK and attempting to licence its Breathaboard product, amongst other plans. Its take on wallboard is being marketed as a sustainable substitute that is made from crop waste, that sequesters CO₂ and that then can be composted at the end of its life. It is also promoting the product’s breathability and moisture buffering capabilities, hence the name.

Another new contender hoping to steal some of the gypsum wallboard market is Xeriant’s Nexaboard product. This one uses plastic waste as its alternative to gypsum. Florida-based Xeriant said in July 2023 that it had started to buy equipment and raw materials, was running pilot production and was testing its first samples. It too is working on getting its product used in pilot construction projects.

Both of these examples, and others over the years, have taken a pop at wallboard’s sustainability credentials. Adaptavate is rather quieter about what happens to all of that sequestered CO₂ when its product is composted and Xeriant does not mention the environmental impact of making the plastic it uses in the first place. Yet, it is a valid question to ask how sustainable is gypsum wallboard? This column has covered issues with the supply of raw gypsum from either natural, synthetic or recycled sources previously, so we will stick to the general picture here.

The late-lamented consultant Bob Bruce pulled together data from various studies for the Global Gypsum Conference in 2019 to estimate the CO₂ emissions from wallboard production. He estimated that the global average of CO₂ production by wallboard was around 2.4kg/m², equating to 24Mt/yr of CO₂ for the global wallboard industry. For reference, it is estimated by the Center for International Climate and Environmental Research - Oslo (CICERO) that the process emissions from clinker production alone released around 1.6Gt/yr of CO₂ in 2022. When compared by mass (as opposed to area) to other building materials, wallboard has a lower carbon intensity than many products such as glass, cement (made from clinker), plastics, steel and plywood. Timber, concrete and brick are all better than wallboard though. However, as Bruce pointed out, a lot more concrete is manufactured than wallboard. Bruce came up with a handful of suggestions for how wallboard production could reduce its CO₂ emissions such as the reduction of slurry water, local delivery, co-generation, increasing drying efficiency and so on.

The two big sustainability trends from the sector over the last year have been the drive to support higher recycling rates of gypsum and a move towards ‘greener’ sources of energy. This can be seen in the growing use of electrical energy from renewable sources such as the production of net zero CO₂ gypsum wallboard at Saint-Gobain’s Fredrikstad plant in Norway from April 2023. The group’s Montreal plant looks set to follow in 2024 following an upgrade, potentially making it the first net zero wallboard plant in North America. Chiyoda-Ute in Japan has also started using renewably-sourced electricity at its plants in Japan, but it is uncertain what other energy sources these sites are using. China-based BNBM also claimed in its half-year results that it had built four “nearly zero emission” gypsum board production lines in the reporting period.

Wallboard's market position in North America, Europe and elsewhere seems secure. However, it is in dynamic tension as it is both a potential replacement for more carbon intensive building materials and it could also be susceptible to new emerging products that can improve on its own emissions. The manufacturers of Breathaboard and Nexaboard are clearly hoping for the latter. Yet, as is often pointed out, giving more market share to wallboard from other common building materials could reduce CO₂ emissions from construction massively. The diversification of traditional heavy building materials companies such as Holcim into light building materials in recent years suggests that some businesses are seriously preparing for this possibility. No doubt, if global wallboard usage does start to rise significantly, the pressure will grow to make wallboard more sustainable and to devise even more alternative board products.

US: Data from the United States Geological Survey (USGS) show that the sale of gypsum board products fell by 5% to 1.25Bnm² in the first half of 2023, from 1.31Bnm² in the same period in 2022. The total supply of crude gypsum grew by 9% to 20.4Mt. Notably, supplies of imported and synthetic gypsum increased in the reporting period. However, the USGS noted that on a quarterly basis “...variances are often the result of differences in weather conditions, which can impede or encourage construction activities, coupled with market demands that are often driven by residential and commercial building activity. Use of uncalcined gypsum remained stable, but consumption of calcined gypsum fell by 33% to 7.86Mt, due to reduced utilisation in board products. Spain, Canada and Mexico remained the main sources of import of crude gypsum. However, imports from Türkiye more than doubled to 195,000t.

Canada: Gypsum industry veteran Bob Bruce has died at the age of 72.

Bob Bruce worked in the gypsum sector for over 40 years. He obtained a PhD in chemistry from McMaster University in the 1970s and then worked for various gypsum companies, including BPB, in North America and Europe. He later became a consultant in the late 1990s when he founded Innogyps, before setting up NuGyp Corp in 2008. Bob Bruce was well-known as an author, speaker and mentor. He attended and spoke at many Global Gypsum Conferences over the years, and had many contacts and friends around the world. He was the Global Gypsum Personality of the Year in 2007.

Bruce's family will hold a celebration of his life in Toronto, Ontario on 28 July 2023, and have invited donations to the Joseph Brant Hospital Foundation, the CAMH Foundation and the Canadian Cancer Society in lieu of flowers. Online condolences can be made here.

Canada/UK: Canada-based Solex Thermal Science has purchased UK-based Econotherm for an undisclosed sum. The acquisition is intended to expand Solex’s capacity to help its customers reduce the primary energy consumed to produce industrial goods
Lowy Gunnewiek, the chief executive officer at Solex, said “We at Solex are passionate about working with customers to understand their operational needs. Today’s announcement broadens our overall business portfolio to provide our global client base with an even deeper suite of best-in-class, sustainable solutions that align with their respective environmental, social and governance strategies.”

Solex Thermal Science sells indirect heat exchange products for the heating, cooling and drying of free-flowing granular materials such as solid granules, pellets, beans, seeds and particles. Since 1989 the company has installed more than 900 heat exchangers in more than 50 countries worldwide with applications such as fertiliser, oilseeds and industrial materials such as minerals, sands, chemicals and polymers. More recently it has expanded into the energy-transition sector with collaborations on decarbonisation applications such as industrial waste heat recovery, concentrated solar power and carbon capture.

Econotherm manufactures heat pipe waste heat recuperators, economisers, pre-heaters, steam generators and steam condensers. The company’s patented super conductor heat pipe technology is used in a wide range of applications across many industrial sectors. Its references include supplying a gas to air heat pre-heater on a gypsum kettle exhaust to British Gypsum.

US: The US gypsum wallboard industry produced 623Mm² of gypsum wallboard during the first quarter of 2023, down by 1% year-on-year and by 1.2% quarter-on-quarter. The industry exported 20.1Mm² of gypsum wallboard in the quarter under review, corresponding to 19% year-on-year growth. Canada received 19Mm² of the product, 94% of total exports for the quarter.

United States Geological Survey (USGS) data show 4% year-on-year growth in US gypsum wallboard imports. The country imported 23Mm² during the year, 20.9Mm² (91%) of it from Mexico and 1.84Mm² (8%) from Canada. Total calcined gypsum consumption was 4.66Mt in the US in the first quarter of 2023, up by 9.9% year-on-year from 4.24Mt in the first quarter of 2022.

Canada: USG Corporation subsidiary Canadian Gypsum Company (CGC) plants to restart operations at its 2Mt/yr-capacity Little Narrows gypsum quarry in Nova Scotia. Construction Canada News has reported that the company expects the commissioning to take until early-mid 2026. Work includes the construction of a new crusher and conveyor systems, as well as a dock and ship loader, and the purchase of new mining equipment, including drills, loaders, excavators and haul trucks. When operational, the quarry will ship gypsum to markets along the east coast of North America, including Montréal, Québec.

USG Corporation CEO Chris Griffin said “This investment will cement our long-term commitment to the Canadian market and our dedication to providing the best experience for our customers across North America. CGC has a proud history of operations at the Little Narrows gypsum quarry, which was active from 1954 to 2016. We are deeply connected to Little Narrows and Cape Breton, and thrilled to return to drive economic growth and support the local community as a neighbour and partner.”

Canada: GMS has acquired Jawl Lumber Corporation, a leading producer of lumber and associated building materials on Vancouver Island, British Columbia. GMS says that Jawl Lumber Corporation's offering complements its own existing range.

Group president and CEO John Turner said “This acquisition will further strengthen our ability to serve our customers and provide an opportunity to expand our tools and fasteners offerings to a new customer base, reinforcing our existing market position on Vancouver Island.”