Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: The present invention relates to an improved method for using heat energy in a gypsum board plant. More specifically, the method contemplates taking heat from a gasifier, or other alternative heat source, and using it to dry gypsum boards. In order to control humidity levels, this heat is delivered to one or more board dryers via a heat exchanger.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: Disclosed is an apparatus and method for capturing the hot humid gases from a gypsum board dryer and utilizing those gases in the production of a synthetic gas (referred to as “syngas”). The syngas produced can then be utilized within a gypsum board plant to reduce the amount of natural gas needed. The method utilizes the heated water vapor (H2O) and carbon dioxide (CO2) found within the flue gas of a board dryer. The H2O and CO2 are used in a gasification process to yield the syngas.

Abstract: Disclosed are various methods for reducing levels of elemental sulfur within gypsum products such as wall board. Gypsum sometimes includes increased levels of elemental sulfur. Such sulfur can be corrosive and otherwise harmful at elevated levels. The disclosure contemplates reacting the elemental sulfur with copper to copper sulfide. This reaction has the benefit of reducing the levels of elemental sulfur present within the final gypsum product. The copper can be added at any of a variety of locations in the manufacturing process. This is a very efficient method for reducing elemental sulfur in the production of gypsum products.

Abstract: Disclosed are various methods for reducing levels of elemental sulfur within gypsum products such as wall board. Gypsum sometimes includes increased levels of elemental sulfur. Such sulfur can be corrosive and otherwise harmful at elevated levels. The disclosure contemplates reacting the elemental sulfur with copper to copper sulfide. This reaction has the benefit of reducing the levels of elemental sulfur present within the final gypsum product. The copper can be added at any of a variety of locations in the manufacturing process. This is a very efficient method for reducing elemental sulfur in the production of gypsum products.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: Disclosed is an apparatus and method for capturing the hot humid gases from a gypsum board dryer and utilizing those gases in the production of a synthetic gas (referred to as “syngas”). The syngas produced can then be utilized within a gypsum board plant to reduce the amount of natural gas needed. The method utilizes the heated water vapor (H2O) and carbon dioxide (CO2) found within the flue gas of a board dryer. The H2O and CO2 are used in a gasification process to yield the syngas.

Abstract: The present invention relates to a system and method for the production of gypsum board using starch pellets. In accordance with the present disclosure, the starch necessary for board formation is provided in the form of starch pellets. These pellets are mixed with a gypsum slurry in a mixer. The pellets are initially insoluble and do not dissolve. However, during subsequent drying stages, the pellets become soluble and dissolve into the gypsum phase. This both provides the desired starch component and also results in the formation of voids within the set gypsum.

Abstract: The present invention relates to a system and associated method for the production of gypsum in manufacturing plant. More specifically, the invention relates to the production of alpha-type gypsum in a gypsum board manufacturing plant. The system yields increased efficiencies by capturing heat given off during processing steps and using that heat to reduce the energy needed for calcination. The invention finds particular application in the production alpha-type gypsum. The present invention is described in greater detail hereinafter in conjunction with the following specific embodiments.

Abstract: The present invention relates to a system and associated method for the production of gypsum in manufacturing plant. More specifically, the invention relates to the production of alpha-type gypsum in a gypsum board manufacturing plant. The system yields increased efficiencies by capturing heat given off during processing steps and using that heat to reduce the energy needed for calcination. The invention finds particular application in the production alpha-type gypsum. The present invention is described in greater detail hereinafter in conjunction with the following specific embodiments.

Abstract: A hydroseparator for separating particles based on the differences in settling rates such as for separating fly ash from gypsum includes a substantially cylindrical side wall closed at its bottom end by a floor. A laminar upflow is created through the hydroseparator by adding dilution water to the bottom of the hydroseparator and removing most of the added dilution water from the top of the hydroseparator. The remaining volume of liquid is removed in an underflow. The hydroseparator is divided into at least two sections by a baffle that extends about the interior of the side wall. An inlet is disposed in the center of the hydroseparator slightly above the baffle such that the material added to the hydroseparator to be separated is inserted into the section of the hydroseparator completely surrounded by the baffle.

Abstract: A method of purifying a flue gas desulfurization aqueous waste slurry containing calcium-sulfur salts and residual solid grits, fly ash, carbon and oils by supplying the aqueous waste slurry to a screening station to remove the grits, passing the grit-free aqueous waste slurry to a magnetic separator to remove fly ash components, and transferring the aqueous slurry to a floatation cell to remove carbon and oils therefrom. A purified aqueous slurry of calcium-sulfur salts is removed from the floatation cell which can be used in producing quality plaster, wallboard, or feedstock in producing &agr;-hemihydrate gypsum.

Abstract: A desulfurization process using magnesium sulfites in a clear solution has the discharge from a wet scrubbing unit passed to a reaction tank. A silica-containing solid particulate material, such as sand, is added to the reaction tank and lime is added to precipitate calcium sulfite solids onto the particulate material. The resulting solids, a calcium sulfite coated, silica containing solid particulate material is readily dewatered and may be used as a cement manufacturing process.

Abstract: A process for removing both sulfur dioxide and nitrogen oxides from a gaseous stream where the stream is contacted in a first wet scrubbing unit with an alkaline earth compound to remove sulfur dioxide and humidify the gaseous stream, passing of the humidified gaseous stream to a coronal discharge unit to convert NO.sub.x therein to nitric acid, and then contacting the gaseous stream to a second wet scrubbing unit and contacting the gaseous stream with an alkaline earth compound to remove the nitric acid as an alkaline earth nitrate prior to discharge of the gaseous stream to the atmosphere. The effluent from the first wet scrubbing unit is maintained separate from the effluent from the second wet scrubbing unit during the removal steps so as to provide pure recoverable by-products.

Abstract: Cement and elemental sulfur are produced by forming a moist mixture of a flue gas desulfurization process waste product containing 80-95 percent by weight calcium sulfate hemihydrate and 5-20 percent by weight calcium sulfate hemihydrate, aluminum, iron, silica and carbon, agglomerating the moist mixture while drying the same to form a feedstock, and calcining the dry agglomerated feedstock in a rotary kiln. Sulfur dioxide produced during the calcination is cooled and contacted with hydrogen and carbon monoxide to reduce the same to elemental sulfur.