Gypsum industry news

Germany: Canada-based New West Gypsum Recycling (NWGR) has announced that it will invest in a new gypsum recycling facility in Hürth / Cologne, Germany. NWGR, together, with its local joint venture partner Schulz Baustoffe GmbH, will build a state-of-the-art plant with a gypsum recycling capacity of 90,000t/yr. It will begin operations in January 2017.

NWGR says that the plant location allows easy access to the main industrial areas of Cologne, Düsseldorf, Dortmund and the south west of the Netherlands. It adds that the new plant will 'set the new standard in recycled gypsum, unmatched particle size and paper content, combined with the highest care for safety and the environment.'

100% of the recycled gypsum produced by the plant will be used in the production of gypsum wallboard in the Rigips plant in Scholven, Germany.

New Zealand: Auckland's first comprehensive recycling facility for building industry waste, including wallboard, has been opened by the environment and building and housing minister Nick Smith, according to Live News.

"This new recycling facility is about greening the building industry, enabling 30,000t/yr of construction and demolition waste to be diverted from going to landfill. It will enable thousands of tonnes of wood, wallboard, steel, plastics and aggregates from the construction sector to be sorted and re-processed into a reusable form," said Smith.

The US$2.78m facility is part-funded by a government grant of US$1.39m from the Waste Minimisation Fund and has created 15 jobs in the local Onehunga community. The fund was established by the government from a US$6.6/t levy on waste going to landfill that was introduced on 1 July 2009. Over US$39.6m has been used to fund more than 100 projects in the past five years.

"The opening of this new facility is very timely with Auckland on the brink of its largest ever building boom. The house build rate has increased from 4000/yr to 8000/yr since 2011 and is expected to grow to over 12,000/yr. Each home constructed generates 4t of waste and it makes sense to recycle as much of this construction material as possible," said Smith.

Wood, plasterboard, steel, plastics, aggregates and cardboard are being targeted by CID Resource Recovery for recycling or reuse. Wood will be further processed into biofuel for industrial kilns, while old wallboard can be recycled for use as a soil conditioner. Scrap steel will be extracted by magnet and delivered to metal recyclers for processing and sale on the local or export markets. Various grades of plastic, card and paper will go to local recyclers for processing. Aggregates will be used locally for hardfill or drainage material on building or infrastructure projects.

"This sort of practical approach to recycling typifies the Government's Bluegreen approach to waste. We are partnering with business to find economically-viable ways to recycle waste and focusing on those areas where there are the biggest gains. This initiative is particularly significant as construction and demolition waste makes up half of New Zealand's total waste going to landfill," said Smith.

UK: Mid UK Recycling Limited plans to extend its Wilsford Heath waste management facility at Ancaster, South Kesteven in Lincolnshire. If its plans are approved, the plant would recycle up to 350,000t/yr of waste mattresses and plastics.

Chris Mountain, managing director, said that the investment could run into 'multiple millions' of Euros. "We are an existing business, we employ 350 people in Sleaford, Caythorpe and the Ancaster site," said Mountain. "We will put in the main planning proposal in the next three months and as soon as we get the green light we'll start straight away." He said that initially the company wants to start by the end of December 2015, although it may take three years to complete the expansion. "We have been four years developing the site next-door, which is full to capacity now," he said. "The range of products we produce is getting wider and wider. It makes no sense to export those jobs out of the county."

There would be a building for machinery that could break down mattresses into resalable parts. Leftovers would form solid recovered fuel (SRF) products, which could by cement plants and power stations. Another building would be created for packing and storing gypsum from recycled wallboard, which would be sold to supermarkets as cat litter. The business would also bring in a new way of recycling rigid plastics, breaking them down into granules to sell to Lincolnshire manufacturers of drainage pipes, water pipes and car parts.

US: Wallboard recycler USA Gypsum has opened its US$3m wallboard recycling plant and corporate headquarters in the West Cocalico Township, Pennsylvania. The company said that the new buildings and equipment will produce better quality products more efficiently and will help USA Gypsum to divert even more wallboard waste from landfills.

The recycling plant also includes renovated buildings for packaging, storage and offices. In the past 10 years, USA Gypsum has diverted more than 225,000t of wallboard from landfills, converting it to beneficial use by farmers in the form of gypsum fertiliser, soil conditioners and amendments and gypsum animal bedding. In spite of this growth, USA Gypsum has estimated that less than 10% of wallboard scraps generated in Pennsylvania are recycled. USA Gypsum ships its gypsum products across the US and Canada.

Europe: The GtoG project (The perfect loop - the path to a circular economy: A European collaborative approach between the recycling industry, the demolition sector and the gypsum industry) has developed a film that presents in detail the project objectives and results.

Gypsum products like wallboard and blocks are among the very few construction materials where closed-loop recycling is possible. The recycling process separates gypsum from paper and both materials can be re-used to repeatedly produce the same products. The overall aim of GtoG is to transform the gypsum demolition waste market to achieve higher recycling rates of gypsum waste, thereby helping to achieve a resource-efficient economy.

The newly-launched film enables the audience to gain insight on the project developments and is part of the consortium's willingness to enhance the quality and availability of information to all industry professionals and to its stakeholders. The film includes contributions from professionals covering not only the entire gypsum supply chain (demolition, recycling and production), but also the full range of organisations represented in the project (universities, consulting agencies and demolition, recycling and manufacturing companies).

Vietnam: DAP Joint Stock Company has found a solution to deal with gypsum created during production processes. The public has criticised the company for many years because of the 'acid leaking from its gypsum dumping ground.' However, the problem will be solved as DAP has found a way to recycle gypsum, turning it into artificial plaster to be used as a cement additive.

Since 2009 DAP has produced some 2Mt of gypsum, which is being kept at its temporary dumping ground. The ground is surrounded by clay and stone embankments with high-density polyethylene (HDPE) stratum to ensure that the water does not leak. There is a reservoir to collect acid from the waste and pump it back to the plant for use. When the pH content falls below the allowed level, the gypsum will be relocated to a major gypsum gathering ground, covering an area of 0.4km², where it will be recycled into cement additives. A monitoring report from 30 September 2014 showed that the waste water was within the safety limits in accordance with the Ministry of Natural Resources and the Environment (MONRE) QCVN 09:2008/BTNMT standard on underground water quality.

Dinh Vu Gypsum JSC was established in 2010 following initial success in gypsum recycling tests. The company has finished the construction of a gypsum recycling plant and has installed 25% of the processing lines, with a capacity of 150,000t/yr per line. The plant, now in its trial run, has provided 10,000t of artificial plaster to the But Son Cement Plant in Ha Nam Province.

DAP has also joined forces with the Vietnam Cement Corporation (Vicem) to develop a project on processing gypsum. The two sides have signed a cooperation agreement, under which Vicem would be responsible for the consumption of the resulting cement additive.

UK: Cuddy Recycling Ltd, a start up company that is supported by the Welsh Government, plans to invest Euro1.49m to create the first wood, wallboard and gypsum recycling centre in South Wales. It will create 22 jobs.

Backed by Euro285,000 from the Welsh Economic Growth Fund, the purpose-built centre will be based on the former Wern Works site in Briton Ferry, Neath Port Talbot which, subject to planning, will be partially demolished and redeveloped. The new centre will process and recycle demolition aggregate from construction and demolition projects across Wales, as well as waste timber and wallboard from the construction industry and civil amenity sites.

It aims to provide a green alternative to landfill with waste timber used for animal bedding, panel board manufacture and biomass fuel, with the option of introducing a garden mulch product at a later date.

Aggregates will be sorted for reuse in construction companies. Wallboard will, where possible, be taken back to wallboard manufacture, or the gypsum recycled as a soil conditioner for agricultural purposes. There is also potential for use as a cement additive.

"This project supports two of our key economic sectors, providing a specific service for the construction sector while the new business will operate in the energy and environment industry, one of the fastest growing sectors in the Welsh economy with waste management - the largest sub sector," said economy minister Edwina Hart. "Companies working in this area are not only making a significant contribution in terms of job creation and financial impact, but by reducing waste to landfill they are helping us achieve recycling targets and ensure that we create a sustainable environment for future generations. The proposed new centre will provide an important facility to deal with construction and demolition waste and I am pleased to support this new start up through the Economic Growth Fund."

Japan: Daiseki Eco. Solutions subsidiary Green Arrows Kyushu has opened a wallboard recycling plant in the suburbs of Fukuoka, Fukuoka Prefecture. The recycling plant will separate used and dismantled wallboard, collected from construction sites, into plaster powder and paper for sale to wallboard and paper manufacturers, respectively. The plant will begin with 15,000t/yr of processing capacity, which will be raised to 36,000t/yr.

Daiseki entered the wallboard-recycling business in 2009 through a subsidiary named Green Arrows Central, based in Tokai, Aichi Prefecture. Its Tokai plant currently recycles 30,000t/yr of used wallboard from the local area.

China: The Ministry of Industry and Information Technology (MIIT) has released China's 12th five-year (2011-2015) plan for major industrial solid waste. The plan will target US$80bn from recycling solid waste with a comprehensive utilised volume of 1.6Bnt by 2015.

Under the plan, which will cover industrial by product gypsum, gangue, coal ash smelting slag, red mud and carbide slag, China is expected to generate 2.5 million new jobs in the field of industrial solid waste management. In the case of gypsum, it is likely that the by-product will be used in the production of wallboard.

MIIT predicts that China will generate an incredible 15Bnt of industrial solid waste in total during 2011-2015.

UK: Eastern Waste Disposal Ltd has won a Euro0.85m multiple awardees contract award from Essex County Council to provide services for the collection and recycling of gypsum.

According to the description, "In accordance with its duties under the Environmental Protection Act 1990, Essex County Council sought services in relation to the collection and recycling of waste gypsum and tyres sourced from recycling centres for household waste in Essex and waste collection authority/waste disposal authority premises, including transfer stations, in Essex."

The contract period will be 21 months from October 2011 until June 2013 with options for the council to extend.