Gypsum industry news

Russia: Knauf has begun the construction of a Euro16.8m gypsum dry building mix plant in Chapayevsk, Samara. The plant is expected to be commissioned at the end of 2016. The 170,000m² plant area is under municipal ownership and will be leased by Knauf for 49 years. The plant will be Knauf's 15th production enterprise in Russia.

"In the region there is a raw materials base, which is important for Knauf. As there is quite a large amount of construction in the region currently, construction materials producers are needed. We understand that it is much more advantageous to localise production here, than to transport materials from other regions and engage in, in particular, international logistics," said Samara's Regional Economic Development Minister Alexander Kobenko. "It is planned for the plant to reach full capacity in two and a half years. It will produce about 240,000t/yr of gypsum binder and 130,000t/yr of building mixes. This is about Euro25m/yr," said Kobenko.

China: China National Building Materials' (CNBM) 45.2%-owned subsidiary Beijing New Building Material Public Limited Company (BNBM) has agreed to acquire a 35% equity interest in Taishan Gypsum Company through a private issuance of 369 million BNBM shares to Taishan Gypsum minority shareholders at US$1.79/share for a total of US$661m.

Upon completion, BNBM will directly and indirectly hold the entire equity interest in Taishan Gypsum. Taishan Gypsum minority shareholders will hold 20.7% of the enlarged issued share capital of BNBM after the private issuance. The equity interest held by CNBM in BNBM will reduce from about 45.2% to 35.84%.

Upon completion of the transaction, Taishan Gypsum will be wholly-owned by BNBM, enabling CNBM to further integrate its internal resources, allowing BNBM to improve its operating results and further consolidate the group's market position.

US: Workers have been constructing a new facility to process by-products from FirstEnergy Corp's coal-fired power plant as the company makes a major change in how it disposes of industrial waste. Some of the plant's by-product is already sold and reused by National Gypsum, which takes about 500,000t/yr of synthetic gypsum for wallboard production.

The Ohio-based company plans to have the project ready for use at the end of 2016, when the company has agreed to halt the use of the residual waste impoundment known as Little Blue Run, which many neighbours have alleged has leaked hazardous waste and released noxious odours.

When the Bruce Mansfield plant removes sulphur dioxide from its emissions, it creates coal combustion by-products. FirstEnergy has been depositing much of the by-product in Little Blue Run, West Virginia. However, the state Department of Environmental Protection sued in 2012 over leaks and threats to groundwater. As part of a settlement, the company agreed to no longer use Little Blue Run by the end of 2016.

James Fitzgerald, Manager of major projects, said that new disposal sites for materials treated by the new dewatering facility will be different. "That landfill will have different regulations, different requirements. There are liners associated with it. So it's a whole different process," said Fitzgerald.

With the new facility, FirstEnergy will process 2.5 – 3.5Mt/yr of by-product, which consists of fly ash, sulphur and lime. It will be processed at the new facility, where water will be removed. The water from the process will then be reused at the plant, said Jim Graf, Director of the Bruce Mansfield plant. Once the new facility processes the by-product, it will be moved by barge to another site. The new project will cost more than US$200m.

Romania: Siniat Romania, part of Etex, has opened a gypsum plant in Turceni, Gorj, following a Euro50m investment from its own funds.

The gypsum wallboard plant encompasses 320,000m² of land and is the largest in Romania, according to the company. With a production capacity of 27Mm2 of wallboard, the unit serves a strategic purpose for Siniat Romania, covering 10 markets across south-east Europe.

The Turceni plant is the first in Romania that uses synthetic gypsum produced from the gas desulphurisation process from a power plant. The gypsum has high purity and consistency and is an excellent feedstock for wallboard. In addition, water used in the production process will come from rainwater collected from the roofs of the plant and drilled wells, thus limiting resource consumption, while waste water will also be internally recycled.

Siniat has also invested Euro1m in the construction of a new road that links the plant to the national road, limiting the impact of heavy vehicles on the local community. The plant provides 80 new employment opportunities for the local community, with the new employees being trained in Siniat plants in Romania, Italy and Germany.

"Siniat plays an active role in local communities. We particularly appreciate the labour force in Romania, with well-trained and motivated people. We constantly invest in technology and use high quality raw material. We develop in a stable economic environment with high potential. Our goal is to capitalise on this potential," said Marc-André Fritzsche, General Manager of Siniat Romania. Siniat Romania has two other plants in Bucharest and Aghiresu (Cluj).

Russia: Turkey's Erişim has completed another gypsum plant in Orenburg, Russia. The official opening of the gypsum plant Volma took place on 4 September 2015. The Orenburg Regional Governor, Yury Berg, the President of Volma, Alexander Malashkin and the Chairman of Board of Volma, Yury Goncharov, took part in the opening ceremony.

"Volma Orenburg is a modern, ecologically-safe project that will actively participate in the implementation of import replacement projects and in the cooperation between Eurasian Economic Union (EEU) countries," said Goncharov.

The new plant has been built with high-tech, environmentally-friendly technologies. The plaster production volume upon achieving its estimated capacity will be 120,000t/yr. From pre-engineering to commissioning, the plant has been completed in 16 months by Erişim.

Volma's other new gypsum plant in Adygeya, the 240,000t/yr Maikop plant, will be completed in the fourth quarter of 2015 and was also built by Erişim.