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DCI builds gypsum stucco production lines from 30,000 to 200,000 t/y on the calcining-before-grinding route. Gypsum rock is crushed to 30–40 mm and fed to a rotary kiln, where hot flue pipes through the centre and wall heat it evenly. The calcined rock is aged in a silo and then ground to finished stucco. Delivered turnkey with installation, commissioning and operator training, to GB/T 9776-2008.
DCI builds gypsum stucco production lines from 30,000 to 200,000 t/y on the calcining-before-grinding route. Gypsum rock is crushed to 30–40 mm, calcined in a rotary kiln, aged in a silo, and only then ground to finished stucco. Every line is delivered turnkey: process design, equipment manufacture, installation, commissioning and operator training.
DCI builds gypsum powder production lines on three process routes, and the route follows the raw material and the product requirement. This stucco production line covers the calcining-first route at mid capacity.
Route | Process order | Capacity | Calciner |
This line | Crush, calcine, age, then grind | 30,000–200,000 t/y | Rotary kiln |
Grinding-first line | Crush, grind, then calcine | 20,000–100,000 t/y | Boiling kiln or rotary kiln |
Large grinding-first line | Crush, grind, then calcine | 100,000–300,000 t/y | Boiling kiln or vertical kiln |
Gypsum rock is crushed in two stages to 30–40 mm. The crushed rock is lifted to a silo ahead of the kiln, measured, and fed into the rotary kiln for calcination. The kiln is the gypsum calcination plant in this route: hot flue pipes run through the centre and along the wall of the kiln, and as the kiln rotates the rock is heated evenly. The calcined rock then goes to a silo for aging, and is conveyed to a grinder mill to become powder. Finished stucco passes to a product silo and is bagged.
The order matters for what each machine has to handle. In this route the mill works on calcined material rather than raw rock, and the kiln works on lump rock rather than powder, which is why a separate aging silo sits between the two stages.
System | Function |
Crushing | Two-stage crushing of run-of-mine rock to 30–40 mm |
Kiln feed silo | Buffer and metering ahead of the rotary kiln |
Rotary kiln | Calcination with hot flue pipes through the centre and kiln wall |
Aging silo | Stabilises the calcined material before grinding |
Grinder mill | Grinds calcined rock to finished stucco fineness |
Product silo and packing | Finished powder storage and bagging |
This route uses a gypsum rotary kiln rather than a boiling kiln, and it is the only calciner offered on this line. The heating medium is carried in hot flue pipes distributed through the centre and the wall of the kiln; as the kiln turns, the rock tumbles through the heated zone and is calcined evenly rather than in batches.
Fuel can be natural gas, diesel, coal or heavy oil. The fuel actually used at a given plant depends on what is available and economical at the site, and is fixed during design rather than during commissioning.
Parameter | Specification |
Annual capacity | 30,000–200,000 t/y (customised by configuration) |
Process order | Crushing, calcination, aging, grinding, packing |
Calcination system | Rotary kiln |
Kiln feed size | 30–40 mm |
Control | Full automatic or semi-automatic, Siemens PLC |
Fuel | Natural gas, diesel, coal, heavy oil |
Raw material | Natural gypsum rock (CaSO4·2H2O content above 80%) |
Finished product | β-hemihydrate gypsum powder (β-CaSO4·1/2H2O), no admixture or additive |
Quality standard | GB/T 9776-2008 |
Technical data are taken from DCI's standard configuration for this capacity class and the product catalogue. Final configuration is confirmed against the customer's raw material analysis, fuel and site conditions.
The line is designed around natural gypsum rock with a CaSO4·2H2O content above 80%, conforming to the requirements of JC/T 700 for gypsum rock used in cementing materials, grade 3 or higher. DCI also configures powder lines for FGD gypsum and phosphogypsum; those routes change the feed preparation and drying stages, so the flow sheet is fixed only after the raw material is confirmed by analysis.
The finished powder is a gelled material made by dehydrating natural gypsum, with no admixture or additive, and it feeds gypsum board production as well as plaster powder and putty.
The division of work below is DCI's standard split for a line of this class. The final scope is written into the supply contract.
Party | Item | Responsibility |
Buyer | 1.1 | Machinery and tools for installation, commissioning and maintenance |
Buyer | 1.2 | Transport equipment: two forklifts |
Buyer | 1.3 | High-voltage power supply, substation and distribution station |
Buyer | 1.4 | Water supply, storage and drainage system |
Buyer | 1.5 | Civil engineering: buildings, equipment foundations including pre-buried parts, silos and pools |
Buyer | 1.6 | Material for machine platforms, supports, guide rails and ladders |
Buyer | 1.7 | Round-trip tickets and transport for the seller's workers |
Buyer | 1.8 | Accommodation and necessary allowances for the seller's workers during installation, commissioning and training |
Buyer | 1.9 | Large tools such as crane, forklift, welder and cutting equipment |
Buyer | 1.10 | Assistant workers to cooperate with the seller's team as required |
Buyer | 1.11 | Usage permission for special equipment |
Seller | 2.1 | Production equipment |
Seller | 2.2 | Installation guiding engineers and technical workers |
Seller | 2.3 | One team leader and one interpreter |
Seller | 2.4 | Foundation drawings and general arrangement drawings within 40 days of down payment |
Seller | 2.5 | Operation manual provided during training |
Seller | 2.6 | Assembly drawings, control cabinet wiring diagrams and PLC programs within 7 days of acceptance |
Seller | 2.7 | Commissioning and training, including full-scale testing and handover to the buyer's operators |
Seller | 2.8 | Free technical consultation within one year of the acceptance certificate |
DCI sends engineers and technical workers to site for full-scale testing, with the buyer supplying assistant staff to cooperate. The seller's team runs the line, explains the operation on site and answers questions from the buyer's technicians and operators.
Gypsum plant installation and commissioning is included in the turnkey scope. On a turnkey gypsum plant from DCI the buyer receives a running line, and every line carries a one-year warranty with technical consultation, remote support and continuing supply of spare parts.
Q: What capacity does this stucco production line cover?
A: 30,000 to 200,000 t/y, customised against the raw material and the required product.
Q: What is the difference between this line and a grinding-first line?
A: The order of the two main stages. Here the kiln takes 30–40 mm rock and the mill grinds calcined material afterwards. On a grinding-first line the mill works on raw rock and the kiln is fed powder.
Q: What calcination system does it use?
A: A rotary kiln, which is the only calciner offered on this route. Hot flue pipes run through the centre and wall of the kiln, and the rock is heated evenly as the kiln rotates.
Q: What raw material can the line process?
A: Natural gypsum rock above 80% CaSO4·2H2O, conforming to JC/T 700 grade 3 or higher. FGD gypsum and phosphogypsum are handled on configurations with the corresponding feed preparation.
Q: What standard does the finished powder meet?
A: GB/T 9776-2008. DCI also confirms the finished powder against the setting-time requirement agreed in the contract.
Q: What does the buyer need to prepare?
A: Civil works and foundations, high-voltage power supply and substation, water supply and drainage, large tools and local assistant labour, plus travel and accommodation for DCI's engineers. The full list is in the contract.
Send your target capacity, raw material analysis and available fuel, and DCI will return a flow sheet, a layout and a quotation for your configuration. Stucco production line cost depends on capacity, kiln size, fuel system and automation level, so the figure is quoted against a confirmed specification rather than from a table.
Hengshui Decheng Machinery & Equipment Co., Ltd. (DCI)
Email: dci@chinagypsummachine.com
WhatsApp: +86 13930110827 / +86 18203235588
Web: www.dcimachine.com
Related Products:Gypsum Board Production Line,Gypsum Powder Production Line,Gypsum Block Production Line,steel structural workshop.
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