A leading gypsum supplier has undergone significant upgrades and expansions to its manufacturing facility, in an effort to boost its supply capacity and improve its gypsum quality.

Synthetic gypsum is produced from the phosphate waste-product of the fertilizer industry, supplying the cement, agricultural and industrial sectors. According to the company, it has upgraded and automated its washing plant, while also adding a kiln drier and a calcining plant.

Based in Potchefstroom in the North West province, OMV’s manufacturing facility was upgraded as part of its total quality management system.

The redesign of the washing plant included changing to a continuous lime batching system, in an effort to improve the controllability of the process and the product quality. According to the company, standard deviations of the pH levels, which are a primary control parameter, have been brought down to 0.2 pH points.

The washing plant was upgraded to full automation, for higher availability. It also includes a new laboratory, staffed with a chemical engineer and chemical technician to focus on quality control.

A key enhancement of the gypsum facility was the addition of a rotary drying kiln, to allow for a reliable supply to customers even during the rainy months. The kiln reduces the moisture content in gypsum, making year-round supply more reliable and saving on road transport costs.

An important part of the technology employed in the kiln is optimised fuel economy for lower carbon emissions. An undercover gypsum warehouse with 30 000 t capacity and dedicated stockpiles, has also been added.  

Most recently completed is the calcining plant, which produces Plaster of Paris and also includes certain automation elements. After extensive research into available technologies, the company was able to construct and commission the plant in less than a year.

With its upgraded facilities, the company aims to provide a consistent and dependable supply and standard of quality.