Gypsum industry news

Ireland: Gyproc has launched what it says is the country’s first wallboard recycling service at its Kingscourt plant in County Cavan. The subsidiary of Saint-Gobain hopes to recycle 0.5Mt of wallboard by 2028. It has spent Euro1.5m on the upgrade to the plant and it has increased the number of employees to 220.

“We’re very proud to be the first and only plasterboard manufacturer in the country to offer recycling of our products on the island,” said Brian Dolan, Managing Director of Gyproc. “As a market leader in this sector we are determined to be at the forefront of innovation in new products and services, and in the sustainability and environmental benefits of those services.” The manufacturer sources gypsum from its Drummond mine in County Monaghan.

Belarus: Knauf Gips plans to invest around Euro70m in a gypsum wallboard plant at Gatovo near Minsk. The decision follows the announcement that Knauf has acquired a 50% share in the charter capital of Volma’s operations in Belarus, according to the Belarusian Telegraph Agency. Knauf arranged to become a joint-owner of Belgips with Russia’s Volma in early 2017

Construction of Belgips’ new plant started in late 2015. Once completed the unit plans to produce 30Mm²/yr of gypsum wallboard, 0.5m²/yr of gypsum partition blocks and 0.1Mt/yr of dry building mixtures. Products made at the plant will be used domestically and for export.

Australia: Clean TeQ plans to build a 2Ml/day DeSALx mine water treatment plant for Fosterville Gold Mine for its mine near Bendigo in Victoria. The US$2.7m unit will use an integrated precipitation and continuous ionic filtration process (DeSALx) that will produce a gypsum-based by-product. This by-product will be compatible with Fosterville’s existing lime treatment plant. Equipment supply, installation and commissioning of the water treatment plant are scheduled for 2018.

The precipitation process removes arsenic and antimony from the mine water as a co-precipitate. The water is then treated by the DeSALx process to remove hardness, sulphate and other dissolved metals. Clean TeQ is also in talks with other mining companies to test its continuous ion-exchange systems for the treatment of process water treatment for recycling or environmental discharge.

Vietnam: USG Boral plans to invest US$20m towards upgrading its gypsum wallboard plant at the Hiep Phuoc Industrial Zone in Ho Chi Minh City. The project will increase the plant’s production capacity by 17Mm² to 47Mm² when it starts operation in September 2019.

"We have witnessed strong growth from this region so our decision to invest in the plant is a strategic one. We remain committed to building USG Boral's presence in Southeast Asia. This expansion will see USG Boral utilising our latest Sheetrock technology to provide superior building solutions for the Vietnam market," said Frederic de Rougemont, CEO of USG Boral.

USG Boral started wallboard production in Vietnam in 2006. It produces the Sheetrock, FireBloc, Durock and Firerock brands.

South Korea: Wacker Chemie has broken ground on a new expansion project at its Ulsan plant. The group is building a new spray dryer for dispersible polymer powders at the unit, which will have a total capacity of 80,000t/yr. It is also constructing an additional reactor for dispersions based on vinyl acetate-ethylene copolymer (VAE), which are needed as the raw material for the spray dryer to produce dispersible polymer powders. Wacker says that the Ulsan’s plant complex, which covers the entire production chain from VAE dispersions to dispersible polymer powders, will be one of the largest of its kind in the world. Investments will total around Euro60m and production is scheduled to start in the first quarter of 2019.

The expansion is intended to meet growing demand for its binder products in the construction industries in South Korea and Southeast Asia. Wacker dispersions and dispersible polymer powders are used in a variety of construction industry applications including modifying gypsum plasters and fillers.

US: USG plans to upgrade its Jacksonville gypsum wallboard plant in Florida. As part of the investment, a new production line will be added to manufacture USG’s Securock ExoAir 430 panels. Investments will be made at the site to improve overall plant efficiency, including upgrades to modernise process mill equipment.

Construction and plant updates are expected to be completed by the end of 2018. The company also plans to add approximately 20 new jobs as a result. The addition of the high-speed, automated production line in Jacksonville is intended to allow USG to distribute Securock ExoAir 430 to more customers throughout the US and Canada.

US: USG’s Washingtonville gypsum wallboard plant in Pennsylvania plans to spend US$8m towards automation upgrades in 2017. Plant manager Nicholas Latkovic told the Daily Item newspaper that the company also expects to spend US$8m or higher in 2018. The upgrade will include 20 automated guided vehicles and automated board handling equipment to speed up the production process by 20%. The investment is also expected to add four or five people to the total workforce of 125.

US: Continental Building Products' Palatka wallboard plant in Florida has endured Hurricane Irma without any serious damage to the facility. The site is about 30 miles inland of St Augustine and it employs over 125 workers. It closed for the storm to allow employees to prepare themselves and their families. However, it didn't lose power and 'sustained essentially no known damage'. Continental Building Products has announced it will donate US$25,000 to the American Red Cross to support the relief effort.

Turkey: Hamburger Turkey, part of Austria's Prinzhorn Group, has signed a land purchasing agreement to set up a third paper mill at Kütahya.

The new paper machine will have state-of-the-art technology, a width of 7.80m and an annual production capacity of 480,000t containerboard, mainly light-weight Testliner and Fluting. The Euro300m investment will create 500 new jobs and is planned to be finalised in 2020.

"Turkey is an important market for us and this investment shows our strong commitment to this fast growing region. If all relevant factors, such as governmental permissions and political stability, show a green light we are happy to proceed with the next project steps." said Cord Prinzhorn, chief executive officer (CEO) of Prinzhorn Group.

Hamburger Turkey is part of the Hamburger Containerboard Division of Prinzhorn Group with a total of seven paper mills in four countries and 2Mt/yr of produced containerboard. The two existing paper mills in Turkey are based in Corlu and Denizli.

India: Thomas Paul, the operations director of USG Boral, has met with the chief minister of Andhra Pradesh, N, Chandrababu Naidu, to discuss building a plant in the state, according to the Hindu newspaper. Earlier in 2017 the wallboard producer said that it was building a 30Mm2/yr wallboard plant near Chennai in Tamil Nadu.