Gypsum industry news

Kazakhstan: Switzerland-based EuroChem has signed an agreement with China National Chemical Engineering for the design, construction and commissioning of a chemical complex in Janatas, Jambyl Region. The third phase of the ongoing project will see the building of a site that will produce synthetic gypsum and calcium chloride as byproducts of the main processes. These byproducts will then be used used in construction materials and as reagents for the road construction, coal and hydrocarbon industries.

During Phase I, a phosphate mining complex was built and commissioned. As part of Phase II, a contract has been signed and the company has started construction of a sulphuric acid facility to be commissioned in 2026. Following the realization of Phase III, in 2027, the group will launch a chemical complex. The combined total investment to date and planned capital expenditure will exceed US$1bn and the project is included in the Integrated Kazakhstan Industrialization Roadmap.

Oleg Shiryaev, the Group President of EuroChem, said “The total annual output will exceed 1Mt/yr of mineral fertilisers and associated industrial products. The products from the new complex will be in high demand in Kazakhstan, other Central Asian countries, as well as in China, Russia and European countries.”

EuroChem is a global fertiliser company that manufactures and supplies nitrogen, phosphate and potash products. It employs 32,000 people worldwide.

Germany: Knauf Gips has started an upgrade at its Iphofen gypsum wallboard plant to switch its use of synthetic gypsum to natural gypsum. The project is taking place to prepare the unit for the local phase out of coal-fired power plants by 2038 at the latest. Early work at the site has involved using a 700t crane to lift material over the Würzburg-Nuremberg railway line, during planned renovation to the transport link in late July 2023. The company described the cost of the upgrade as a “mid-double-digit million sum.”

World: Market research and consulting services provider Exactitude Consultancy has projected a composite annual growth rate in global gypsum demand of 4.2% between 2022 and 2029. The consultancy forecast that the market would reach US$2.14bn in value at the end of the period, up by 45% from US$1.48bn in 2021.

Earlier this month the German Gypsum Association (GIPS) gave its approval for an inventory of natural gypsum deposits in Germany that was presented at the Conference of Economics Ministers that took place in early July 2022. The Federal Commission on Geosciences (BLA-GEO) had previously been given the job of taking an inventory of deposits and this was then put in front of the policy makers. The association’s stance was all about securing future supplies. In its view there will be no large-scale alternatives to natural gypsum supplies in the foreseeable future due to low recycling rates and falling production of flue gas desulfurisation (FGD) gypsum as coal power plants are shut down. So a list of where natural gypsum might be found is the start of conversations about which ones might be mined. Readers who are interested can download the inventory of German gypsum deposits here.

Security of supply of raw materials has been in the air since the end of the coronavirus lockdowns started to cause supply chain disruption around the world and the Russian invasion of Ukraine further exacerbated this and rocked energy markets. Part of the reaction to this new reality could be seen in a conference that the Federal Institute for Geosciences and Natural Resources (BGR) and the German Resource Research Institute (GERRI) ran, also in early July 2022. The state of German gypsum supplies was presented at this event too. The BGR-GERRI conference came up with a ten-point plan to strengthen the supply of raw material. Some of these recommendations were to grow domestic raw material extraction, expand recycling and the circular economy and keep supply chains closer internationally, ideally within Germany and Europe.

A focus on gypsum supplies isn’t restricted to Germany though. The issue arose in late July 2022 during an earnings call for US-based Eagle Materials’ first quarter results. These kinds of questions from analysts about supply of raw materials are common for a public company but it reinforces the general declining trend around the world of synthetic gypsum supplies. Craig Kessler, the chief financial officer of Eagle Materials, mentioned that a scarcity of synthetic gypsum might be creating cost pressures for other gypsum wallboard producers. Although he was quick to describe his company as a “natural gas or natural gypsum oriented business.” The wider picture in the US is that the ratio of natural to synthetic gypsum production has grown over the last decade. United States Geological Survey (USGS) data shows that it was 37% / 49% in 2011 compared to 53% / 32% in 2021, with the remainder imported in each year.

One more point to make here is that many of the new gypsum wallboard plant projects announced in the over the last few months have involved recycling in one form or another. For example, Siniat’s forthcoming wallboard plant in Bristol in the UK aims to achieve 30% post-consumer gypsum recycling. CertainTeed’s current upgrade plans for its Palatka plant in Florida are also recycling-based. Similarly, the subsidiary of Saint-Gobain also completed an upgrade in June 2022 to allow more recycling at its Nashville plant in Arkansas.

Finally, some of the thinking in Germany and elsewhere has been influenced by the current geopolitical situation in Ukraine. However, one potential consequence of prolonged disruption to European energy markets could be a delay to the decline of coal power plants as plant lifespans are elongated or even new ones built. This in turn could mean more synthetic gypsum supplies in Europe in the short to medium term. How all of this plays out in the placement of new gypsum wallboard plants in Europe over the next few years will be interesting to observe.

Romania: Belgium-based Etex invested Euro1m on upgrades to the logistics capacities of its Turceni gypsum wallboard plant and its Aghiresu plaster plant. It also started work on a Euro6m sludge drying unit at coal-fired power plant in Oltenia that will supply synthetic gypsum for use at Turceni, according to See News. The company operates locally under the Siniat Romania brand. It reported a 20% year-on-year rise in turnover to Euro59.6m in 2021.

US: The United States Geological Survey (USGS) reports that total gypsum board product sales grew by 4% year-on-year to 2.54Bnm² in 2021 from 2.43Bnm² in 2020. 22.4Mt of gypsum was mined in 2021, a 1% rise from 21. Synthetic gypsum supply decreased by 10% to 13Mt from 14.4Mt. Imports declined by 11% to 25,700t from 29,000t but exports grew by 11% to 98,800t from 89,300t.

US: The US Geological Survey (USGS) reports that 17Mt of gypsum was mined in the first three quarters of 2021, a rise of 9% year-on-year from 15.6Mt in the same period in 2020. Imports grew by 14% to 5Mt but synthetic gypsum supply declined by 10% to 9.75Mt. Total gypsum board product sales grew by 8% to 1.94Bnm2 from 1.80Bnm2.

World: Market researcher Future Market Insights (FMI) has estimated that the global market for gypsum for all applications will record a compound annual growth rate (CAGR) of 5% between 2022 and 2030. FMI said that this will be due to a global rise in construction, driven by digitisation and technological advances. In order for growth to return, economic activity must first return to ‘normal’ in the wake of the Covid-19 outbreak, according to FMI.

Research agency Technavio has also given its forecast for growth in the synthetic gypsum market between 2020 and 2024. It has predicted a CAGR of 4%, with total growth of US$320m over the period.

US: The United States Geological Survey’s (USGS) Gypsum in the First Quarter 2021 report has shown a 2% year-on-year increase in sales of gypsum-based board products to 624Mm² in the first quarter of 2021 from 609Mm² in the same period in 2020. Calcined gypsum used by board producers rose by 3% to 5.6Mt from 5.5Mt. Natural gypsum production fell by 4% year-on-year to 5.0Mt from 5.2Mt, synthetic gypsum production remained level at 3.6Mt and gypsum imports rose by 14% to 1.6Mt from 1.4Mt.

Indonesia: Semen Baturaja has signed a memorandum of understanding with Huadian Buket Asam Power. Under the agreement, Semen Baturaja will supply the power company with limestone for its flue gas desulfurisation (FGD) process in exchange for gypsum, fly ash and bottom ash. The agreement will last for two years until March 2023.

The cement producer’s managing director Sumsal Saifudin said “This collaboration is a form of synergy between the two companies to improve competitiveness, which is much-needed in facing an increasingly competitive industrial environment, by taking advantage of opportunities for the creation of new revenue streams and cost transformation.”