Gypsum industry news

Spain: Saint-Gobain Ibérica’s Sorbas gypsum quarry has marked a record of 17 years without any accidents. The local subsidiary of Saint-Gobain has gone 6500 days without incident. The milestone was recognised as the company signed an agreement to join a workplace health promotion program with the local government.

US: USG has submitted a purchase application to the Michigan Department of Natural Resources (DNR) to expand its operations for its gypsum quarry at Alabaster, Michigan. The wallboard producer wants to buy 580 acres of state property adjacent to the sitem according to the Associated Press. The DNR says it will study the company's plan, considering issues involving forestry, wildlife, fisheries, recreation and minerals. It also will consult with tribal governments and host a public meeting.

USG founded the Alabaster quarry in 1902 and it employs 20 workers at the site. Customers for gypsum from the mine include LafargeHolcim cement plant in Alpena, Michigan and St Marys Cement’s cement grinding plant in Detroit. It says it wants to expand the quarry in order to extend its life span.

UK: Formula, a brand of Saint-Gobain, has awarded a five-year contract to Darlington-based Banner Contracts to extract high purity gypsum from its opencast mine in Newark, Nottinghamshire. Banner Contracts was chosen after a tender process involving eight potential suppliers.

The opencast mine, known as Bantycock, produces around 230,000t/yr of gypsum. Nottinghamshire County Council agreed a revised restoration scheme at the site following consultation. So far this has seen the backfilling of 25 acres with overburden completed and covered with topsoil in 2016.

"Banner's professionalism and expertise is second to none so we are delighted to announce this contract. Its experience in mineral processing was a key factor in its selection as it will help us continue to improve our yield of useable gypsum versus the amount of rock we extract. This improved yield helps maximise the reserve life, whilst operating in a safe and sustainable manner. We look forward to a mutually beneficial relationship over the duration of the contract," said Saint-Gobain Formula Plant Manager Mark Yates.

Banner Contracts Director Jo Banner added that the contract is a large one for the company and that it has invested in a new plant and equipment. New installations at the site include a Hercules trommell commissioned especially for the application, a number of Tesab machines including a 800i jaw crusher, a TS1860 scalping screen, a TS2430 screen and a Trackstack radial conveyor and a sizer from MMD.

Argentina: Demetra Minerals, the joint venture partner of Canada's Centurion Minerals, has entered into a purchase agreement for both a primary crushing facility and a secondary crushing unit for its Ana Sofia gypsum-mining project in Santiago del Estero. Once operational the pilot plant will process up to 40,000t/yr of gypsum for agricultural markets.

At present, upgrading and refurbishing of the primary crusher is underway and manufacturing of the secondary crusher is on-schedule. Demetra anticipates the crushers will be transported to the project site in early October 2016. Site preparation, including clearing, compaction and access road is nearing completion and concrete foundations are being installed in preparation for mounting of the crushing facility.

All mining extraction, environmental and export permits are in place to operate the plant and Demetra's fertiliser distributor in Paraguay has reconfirmed an off-take agreement to purchase up to 50,000t/yr of agricultural gypsum material at the current market price.

"We are extremely pleased with the advances our Argentine partner has made in designing and developing a low cost pilot plant operation. This initial plant facility will allow us to fine-tune the material delivery, crushing and processing operations while we complete initial and subsequent resource estimates of the property. Having a sales distribution arrangement in place will allow us to generate revenue offsetting the cost of resource delineation, operational expenses and processing expansion," said Centurion CEO, David Tafel.

The Ana Sofia project comprises two mining concessions of 50 hectares in size within a larger (approximately 500 hectare) exploration permit area. Trenching and test pit sampling work completed by joint venture partner Demetra Minerals in 2014 - 15 and Centurion in 2016 identified multiple, high grade, near surface gypsum layers. Small scale producers located in the vicinity are currently extracting agricultural gypsum and selling to fertiliser distributors and farmers.

Canada: The Canadian Gypsum Company has stopped gypsum mining for the summer at its Little Narrows quarry in Cape Breton. A local councillor quoted by the Cape Breton Post newspaper said that mining has now stopped for the year. However he didn't believe that the company had yet decided whether to shut down the site completely. He added that synthetic gypsum taken from the power plants was replacing natural gypsum at gypsum wallboard plants along the east coast of the US.

In January 2016 the subsidiary of USG laid off 14 winter maintenance workers at the site.

Honduras: Knauf International has acquired Caspian International in Honduras. Caspian International operates a gypsum wallboard plant in Choloma. The transaction also includes Cateras de Sula, a gypsum quarry in Honduras, and Caspian Panama, a commercial office.

"After our two recent acquisitions in Colombia, we are extremely pleased to strengthen our geographical footprint in the central American market... We are convinced that this acquisition is the beginning of a strong evolution in Central America and in the Caribbean Islands. As we have done in other countries, we will bring our expertise in plasterboard manufacturing to Central America, but also in other construction fields such as Aquapanel cement board, ceilings, jointing and Cleneo, our decorative boards," said Serge Azaïs, member of the Knauf Management Committee and CEO for South America. "Knauf Honduras will benefit from the strong knowledge of our Argentinian team, leading the integration process of the former Gypcen brand."

Canada: The Canadian Gypsum Company, a subsidiary of USG, has laid off 14 winter maintenance workers at its Little Narrows quarry in Cape Breton, according to the Canadian Press. Mine manager Byron MacMillan said that company officials have yet to make a decision on the future of the quarry. The company is looking at market conditions and is reducing spending until a decision is made. The layoffs follow winter closing since 2008.

The quarry has operated since 1935 producing gypsum and natural rock. Traditionally it has shipped its products down the eastern seaboard.

US: USG Corporation has announced it has partnered with Honeybee Robotics, a spacecraft technology and robotics company, for the field testing of Honeybee's Planetary Deep Drill System. The field testing, which will take place at USG's Plaster City gypsum quarry in Salton Sea, California is part of Honeybee's broader Mars exploration program, which aims to better understand the planet and the capabilities needed to send humans to the planet by the 2030s.

"We are honored to be the only company in our industry to play a role in this innovative endeavour to advance planetary exploration and the broader field of science," said Dominic Dannessa, Senior Vice President of Operations and Chief Technology Officer at USG. "We believe innovation comes from inspired thinking inside our company and outside of it, so sharing our geotechnical expertise with Honeybee was a natural fit."

USG's Plaster City gypsum quarry was selected by Honeybee as the ideal site to test the Planetary Deep Drill due to gypsum's similarity to cryogenic ice observed on Mars, Enceladus, Europa and other planetary bodies. Honeybee will drill 100 feet into the depths of the gypsum quarry, which is significantly deeper than drills previously deployed to Mars were capable of accessing. The field test will assess the functionality of the Planetary Deep Drill and provide data for future improvements and enhancements. Scientists have suggested that inside gypsum crystals may be the ideal environment for life to exist on the surface or near surface or Mars.

Drilling at Plaster City will take place from mid-November 2015 until mid-December 2015.

Canada: National Gypsum Canada Ltd is looking to make what it calls 'the largest gypsum quarry in the world' even bigger. The quarry in Milford, Nova Scotia currently covers about 3.01km². The plan is to expand operations by 1.44km², 1.35km² of which would be used for mining activities.

"We want to ensure that we have an adequate gypsum supply and the market is better than it has been," said Nancy Spurlock, company spokeswoman. An increase in US housing starts of about 1m units in 2014, up 8% from 2013, continues to drive demand for wallboard products.

National Gypsum has registered its proposed mine extension project for environmental assessment with the province as required under the Environment Act. "The anticipated average production rate for the expanded mine facility will be at the 20-year average of 3.1Mt/yr, depending on market demand," said an environmental report prepared by Stantec Consulting Ltd for National Gypsum.

The Milford-area mine has produced more than 134Mt of gypsum since it opened in 1954. National Gypsum employs 60 people at the mine and more workers will be needed if mining operations and the volume of product pulled from the ground increases, according to Spurlock. The quarry, one of eight the company owns and its only one outside the US, would grow over the next 35 - 40 years, depending on market demand. "It's a long-term forecast, and we need to nail down the source of our gypsum, that's why we're doing it," said Spurlock.

The proposed extension area includes forest, wetland, clear-cuts and some agricultural land. Six wetland areas would be protected by an ecological buffer zone. If the project is given the go-ahead, National Gypsum would open up areas as needed. The minister has until 9 April 2015 to grant a conditional approval of the environmental assessment.