Process for preparing calcined gypsum

Claim 2

A continuous process for manufacturing gypsum board characterized by using a reduced amount of water to fluidize calcined gypsum in forming the gypsum slurry which is fed to the board making machinery and therefore requiring less energy to dry the wet board which comprises: (1) supplying calcined gypsum feed to be conveyed to a gypsum slurry mixer; (2) diverting a portion of said calcined gypsum to a blender, said portion being at least about 50% by weight of the total calcined gypsum feed; (3) blending a small amount of water with said calcined gypsum portion in said blender, said water ranging from about 1% to about 8% by weight of the total calcined gypsum feed; (4) recombining the wetted diverted portion of said calcined gypsum with the dry, undiverted portion to form a homogeneous mixture of calcined gypsum; (5) allowing the recombined homogeneous mixture of calcined gypsum to heal; (6) feeding the healed mixture of calcined gypsum to the gypsum slurry mixer; (7) adding additional water to the healed mixture of calcined gypsum in the slurry mixer, said additional water being added in an amount sufficient to provide from about 65 to about 85 parts of water, including water added in the blender, per 100 parts of the calcined gypsum, which results in reducing the amount of water to be evaporated from the wet board; (8) mixing the healed mixture of calcined gypsum and water in the slurry mixer to form a homogeneous slurry; (9) feeding the slurry to a gypsum board making machine to form a wet gypsum board; (10) passing the wet gypsum board to a kiln to dry the board; and (11) recovering dry gypsum board consisting essentially of calcium sulfate dihydrate.

Claim 3

The process of claim 1 in which the small amount of water blended with the calcined gypsum portion in step (3) ranges from about 2% to about 16% by weight of the calcined gypsum portion with which it is blended.

Claim 4

The process of claim 1 in which the portion of calcined gypsum diverted to the blender ranges from about 50% to about 75% by weight of the total calcined gypsum feed.

Claim 5

The process of claim 1 in which the temperature of the kiln used to dry the board in step (10) is substantially reduced from the normal kiln operating temperature required to dry a wet gypsum board containing 85 to 100 parts of water per 100 parts of the calcined gypsum at the same rate of passing the wet board to the kiln as a result of the lower water content in the gypsum slurry.

Claim 6

The process of claim 1 in which the rate the wet gypsum board is passed through the kiln in step (10) is faster than the normal rate required to dry a wet gypsum board containing 85 to 100 parts of the calcined gypsum at the same operating temperature as a result of the lower water content in the gypsum slurry.

Claim 7

The process of claim 1 in which the water content of the recombined homogeneous mixture of calcined gypsum in step (4) is about 3% free water by weight of calcined gypsum.

Claim 8

A continuous process for manufacturing gypsum board characterized by using a reduced amount of water to fluidize calcined gypsum in forming the gypsum slurry which is fed to the board making machinery and therefore requiring less energy to dry the wet board which comprises: (1) supplying calcined gypsum feed to be conveyed to a gypsum slurry mixer; (2) conveying the calcined gypsum feed to a blender; (3) blending a small amount of water with said calcined gypsum, said water ranging from about 1% to about 8% by weight of the calcined gypsum feed; (4) allowing the wetted calcined gypsum to heal; (5) feeding the healed calcined gypsum to the gypsum slurry mixer; (6) adding additional water to the healed calcined gypsum in the slurry mixer, said additional water being added in an amount sufficient to provide from about 65 to about 85 parts of water, including water added in the blender, per 100 parts of the calcined gypsum which results in a substantially reduced amount of water to be evaporated from the wet board; (7) mixing the healed calcined gypsum and water in the slurry mixer to form a homogeneous slurry; (8) feeding the slurry to a gypsum board making machine to form a wet gypsum board; (9) passing the wet gypsum board to a kiln to dry the board; and (10) recovering dry gypsum board consisting essentially of calcium sulfate dihydrate.

Claim 9

A continuous process for manufacturing gypsum board characterized by using a reduced amount of water to fluidize calcined gypsum in forming the gypsum slurry which is fed to the board making machinery and therefore requiring less energy to dry the wet board which comprises: (1) supplying calcined gypsum feed to be conveyed to a gypsum slurry mixer; (2) conveying the calcined gypsum feed to a blender; (3) blending a small amount of water with said calcined gypsum, said water ranging from about 1% to about 8% by weight of the calcined gypsum feed; (4) allowing the wetted calcined gypsum to heal; (5) feeding the healed calcined gypsum to the gypsum slurry mixer; (6) adding additional water to the healed calcined gypsum in the slurry mixer, said additional water being added in an amount sufficient to provide from about 65 to about 85 parts of water, including water added in the blender, per 100 parts of the calcined gypsum which results in a substantially reduced amount of water to be evaporated from the wet board; (7) mixing the healed calcined gypsum and water in the slurry mixer to form a homogeneous slurry; (8) feeding the slurry to a gypsum board making machine to form a wet gypsum board; (9) passing the wet gypsum board to a kiln to dry the board; and (10) recovering dry gypsum board consisting essentially of calcium sulfate dihydrate.

Claim 10

The process of claim 7 in which the temperature of the kiln used to dry the board in step (9) is substantially reduced from the normal kiln operating temperature required to dry a wet gypsum board containing 85 to 100 parts of water per 100 parts of the calcined gypsum at the same rate of passing the wet board to the kiln as a result of the lower water content in the gypsum slurry.

Claim 11

The process of claim 7 in which the rate the wet gypsum board is passed through the kiln in step (9) is faster than the normal rate required to dry a wet gypsum board containing 85 to 100 parts of water per 100 parts of the calcined gypsum at the same operating temperature as a result of the lower water content in the gypsum slurry.

Claim 12

A continuous process for manufacturing gypsum board characterized by using a reduced amount of water to fluidize calcined gypsum in forming the gypsum slurry which is fed to the board making machinery whereby a kiln used to remove water from the wet gypsum board is operated at a lower temperature which comprises: (1) supplying calcined gypsum feed to be conveyed to a gypsum slurry mixer; (2) diverting from about 50% to about 75% by weight of said calcined gypsum to a blender; (3) blending from about 2% to about 16% by weight of water with said calcined gypsum portion in said blender whereby the amount of water by weight of the total calcined gypsum feed ranges from about 1% to about 8% by weight; (4) recombining the wetted diverted portion of said calcined gypsum with the dry portion to form a homogeneous mixture of calcined gypsum; (5) allowing the recombined homogeneous mixture of calcined gypsum to heal; (6) feeding the healed mixture of calcined gypsum to the gypsum slurry mixer; (7) adding additional water to the healed mixture of calcined gypsum in the slurry mixer, said additional water being added in an amount sufficient to provide from about 65 to about 85 parts of water, including water added in the blender, per 100 parts of the calcined gypsum, which results in reducing the amount of water to be evaporated from the wet board by at least about 20%; (8) mixing the healed mixture of calcined gypsum and water in the slurry mixer to form a homogeneous slurry; (9) feeding the slurry to a gypsum board making the machine to form a wet gypsum board; (10) drying the wet gypsum board in a kiln whose operating temperature is substantially reduced from the temperature required to dry a wet gypsum board containing 85-100 parts of water per 100 parts of the calcined gypsum at the same rate of passing the wet board to the kiln as a result of the lower water content in the gypsum slurry; and (11) recovering dry gypsum board consisting essentially of calcium sulfate dihydrate.

Claim 13

A continuous process for manufacturing gypsum board characterized by using a reduced amount of water to fluidize calcined gypsum in forming the gypsum slurry which is fed to the board making machinery whereby a kiln used to remove water from the wet gypsum board is operated at a lower temperature which comprises: (1) supplying calcined gypsum feed to be conveyed to a gypsum slurry mixer; (2) diverting from about 50% to about 75% by weight of said calcined gypsum to a blender; (3) blending from about 2% to about 16% by weight of water with said calcined gypsum portion in said blender whereby the amount of water by weight of the total calcined gypsum feed ranges from about 1% to about 8% by weight; (4) recombining the wetted diverted portion of said calcined gypsum with the dry portion to form a homogeneous mixture of calcined gypsum; (5) allowing the recombined homogeneous mixture of calcined gypsum to heal; (6) feeding the healed mixture of calcined gypsum to the gypsum slurry mixer; (7) adding additional water to the healed mixture of calcined gypsum in the slurry mixer, said additional water being added in an amount sufficient to provide from about 65 to about 85 parts of water, including water added in the blender, per 100 parts of the calcined gypsum, which results in reducing the amount of water to be evaporated from the wet board by at least about 20%; (8) mixing the healed mixture of calcined gypsum and water in the slurry mixer to form a homogeneous slurry; (9) feeding the slurry to a gypsum board making the machine to form a wet gypsum board; (10) drying the wet gypsum board in a kiln whose operating temperature is substantially reduced from the temperature required to dry a wet gypsum board containing 85-100 parts of water per 100 parts of the calcined gypsum at the same rate of passing the wet board to the kiln as a result of the lower water content in the gypsum slurry; and (11) recovering dry gypsum board consisting essentially of calcium sulfate dihydrate.

Claim 14

A continuous process for manufacturing gypsum board characterized by using a reduced amount of water to fluidize calcined gypsum in forming the gypsum slurry which is fed to the board making machinery whereby the rate of passing the wet gypsum board to a drying kiln is increased which comprises: (1) supplying calcined gypsum feed to be conveyed to a gypsum slurry mixer; (2) diverting from about 50% to about 75% by weight of said calcined gypsum to a blender; (3) blending from about 2% to about 16% by weight of water with said calcined gypsum portion in said blender whereby the amount of water by weight of the total calcined gypsum feed ranges from about 1% to about 8% by weight; (4) recombining the wetted diverted portion of said calcined gypsum with the dry portion to form a homogeneous mixture of calcined gypsum; (5) allowing the recombined homogeneous mixture of calcined gypsum to heal; (6) feeding the healed mixture of calcined gypsum to the gypsum slurry mixer; (7) adding additional water to the healed mixture of calcined gypum in the slurry mixer, said additional water being added in an amount sufficient to provide from about 65 to about 85 parts of water, including water added in the blender, per 100 parts of the calcined gypsum, which results in reducing the amount of water to be evaporated from the wet board by at least about 20%; (8) mixing the healed mixture of calcined gypsum and water in the slurry mixer to form a homogeneous slurry; (9) feeding the slurry to a gypsum board making machine to form a wet gypsum board; (10) passing the wet gypsum board to a kiln at a rate faster than the normal rate required to dry a wet gypsum board containing 85-100 parts of water per 100 parts of the calcined gypsum at the same operating temperature as a result of the lower water content in the gypsum slurry; and (11) recovering dry gypsum board consisting essentially of calcium sulfate dihydrate.

Claim 15

A continuous process for manufacturing gypsum board characterized by using a reduced amount of water to fluidize calcined gypsum in forming the gypsum slurry which is fed to the board making machinery whereby the rate of passing the wet gypsum board to a drying kiln is increased which comprises: (1) supplying calcined gypsum feed to be conveyed to a gypsum slurry mixer; (2) diverting from about 50% to about 75% by weight of said calcined gypsum to a blender; (3) blending from about 2% to about 16% by weight of water with said calcined gypsum portion in said blender whereby the amount of water by weight of the total calcined gypsum feed ranges from about 1% to about 8% by weight; (4) recombining the wetted diverted portion of said calcined gypsum with the dry portion to form a homogeneous mixture of calcined gypsum; (5) allowing the recombined homogeneous mixture of calcined gypsum to heal; (6) feeding the healed mixture of calcined gypsum to the gypsum slurry mixer; (7) adding additional water to the healed mixture of calcined gypum in the slurry mixer, said additional water being added in an amount sufficient to provide from about 65 to about 85 parts of water, including water added in the blender, per 100 parts of the calcined gypsum, which results in reducing the amount of water to be evaporated from the wet board by at least about 20%; (8) mixing the healed mixture of calcined gypsum and water in the slurry mixer to form a homogeneous slurry; (9) feeding the slurry to a gypsum board making machine to form a wet gypsum board; (10) passing the wet gypsum board to a kiln at a rate faster than the normal rate required to dry a wet gypsum board containing 85-100 parts of water per 100 parts of the calcined gypsum at the same operating temperature as a result of the lower water content in the gypsum slurry; and (11) recovering dry gypsum board consisting essentially of calcium sulfate dihydrate.