Raw Gypsum for Alpha Gypsum Production involves careful processing to achieve high purity and quality for industrial applications. Below are the key technical details:
1. Composition of Raw Gypsum
• Chemical Formula: CaSO₄·2H₂O (Calcium Sulfate Dihydrate).
• Purity:
• Minimum 93-95% gypsum content is ideal for alpha gypsum production.
• Lower impurities (less than 2-3%) such as silica, iron oxides, and clay.
2. Key Physical Properties of Raw Gypsum
• Appearance: White to light gray rock or powder.
• Moisture Content: Should be below 1% for alpha gypsum processing.
• Particle Size:
• Typically crushed and ground to <150 microns for calcination.
• Gypsum rock with a minimum of 93% purity is chosen.
2. Crushing and Grinding:
• Raw gypsum is crushed to smaller particle sizes for even heating.
3. Calcination (Under Pressure):
• Raw gypsum (CaSO₄·2H₂O) is heated in an autoclave under steam pressure of 1-2 bar.
• The process occurs at 120-150°C.
• This controlled calcination produces alpha gypsum (CaSO₄·½H₂O), which has a denser, crystalline structure.
4. Drying and Packaging:
• The final alpha gypsum is dried to ensure low moisture content (<1%) and packaged.
4. Properties of Alpha Gypsum
• High Strength: Used in applications requiring enhanced compressive strength.
• Density: Higher than beta gypsum due to crystalline structure.
• Water Demand: Lower water-to-powder ratio compared to beta gypsum.
• Consistency: Uniform particle distribution for smoother applications.
5. Applications of Alpha Gypsum
• Molds and Moulding Plaster: Used for ceramics, dental, and decorative applications.
• High-Strength Plasters: For construction and industrial usage.
• Prefabricated Panels: In building materials requiring durable and strong components.
• Dental Stones: For precision molds and high-quality finishes.
6. Raw Gypsum Specifications for Alpha Gypsum
Parameter Required Value
Purity (CaSO₄·2H₂O) Minimum 93-95%
Moisture Content Less than 1%
Silica (SiO₂) Less than 2%
Iron Oxide (Fe₂O₃) Less than 0.5%
Particle Size (before calcination) <150 microns
If you require further details about equipment, processing parameters, or specific quality testing standards for raw gypsum to produce alpha gypsum, let me know! 🚧
Plaster of Paris (POP) is a quick-setting material made by heating gypsum (CaSO₄·2H₂O) to eliminate most of its water content, producing calcium sulfate hemihydrate (CaSO₄·½H₂O).
1. Chemical Composition
• Formula: CaSO₄·½H₂O
• Reaction with Water:
This exothermic reaction forms a hard, solid mass as it sets.
2. Production Process
1. Raw Material: High-purity gypsum (CaSO₄·2H₂O).
2. Calcination:
• Gypsum is heated at 150-180°C in a rotary kiln or autoclave.
• The process drives off 75% of the water, forming hemihydrate (POP).
3. Grinding and Packaging: The POP is finely ground to a consistent powder and packed.
3. Properties of Plaster of Paris
Property Details
Appearance Fine, white powder
Setting Time 10-15 minutes (quick-setting)
Density 2.6 g/cm³
Hardness Low (can be scratched easily)
Water Demand 50-70% (by weight of POP)
Compressive Strength 10-20 MPa (low strength)
Thermal Conductivity 0.22-0.30 W/m·K
pH Neutral to slightly acidic
4. Uses of Plaster of Paris
1. Construction:
• Wall coatings and interior decorative elements like false ceilings, cornices, and moldings.
• Surface Finishing: Provides a smooth finish for walls and ceilings.
2. Art and Sculptures:
• Making statues, molds, and intricate designs.
3. Medical:
• Orthopedic Plasters: POP bandages for immobilizing fractures.
4. Molding and Casting:
• Used for molds in ceramics and jewelry making.
5. Fireproofing:
• POP is fire-resistant and acts as a thermal insulator.
5. Advantages of POP
• Quick Setting: Hardens rapidly (10-15 minutes).
• Smooth Finish: Provides a fine, crack-free surface.
• Lightweight: Low density and easy to apply.
• Non-shrinkage: Minimal shrinkage on drying.
• Fire Resistance: Safe for indoor construction.
6. Limitations of POP
• Low Strength: Not suitable for load-bearing applications.
• Moisture Sensitivity: Softens and loses strength in humid conditions.
• Brittle Nature: Susceptible to cracks and damage.
7. Quality Specifications for POP
Parameter Value
Purity (CaSO₄·½H₂O) ≥ 95%
Fineness Retention <1% on 150-micron sieve
Setting Time Initial: 6-15 mins, Final: <25 mins
Compressive Strength ≥ 10 MPa
Water Demand 50-70%
Moisture Content <2%
8. Packaging and Storage
• Packaging: POP is typically packed in 25-50 kg bags.
• Storage:
• Store in a dry place to avoid moisture absorption.
• Shelf life is typically 3-6 months in sealed packaging.
Let me know if you need further details on applications, quality testing methods, or international standards for Plaster of Paris. 🏗️
Foundry sand is a high-quality silica sand used in metal casting processes to create molds and cores. Its unique physical and thermal properties make it essential for achieving precision and repeatability in foundry operations.
1. Composition
• Base Material: High-purity silica sand (SiO₂ content of 85-95%).
• Additional Components (based on binder and process):
• Clay (for green sand)
• Organic Binders (resins, phenolics, etc.)
• Inorganic Binders (sodium silicate, etc.).
2. Key Properties of Foundry Sand
Property Specification
Silica Content (SiO₂) 85-95%
Grain Shape Rounded or sub-angular
Grain Size 45-150 microns (varies by need)
Refractoriness >1,500°C
Thermal Expansion Low
Moisture Content <0.5%
pH Neutral to slightly acidic
3. Types of Foundry Sand
1. Green Sand:
• A mixture of silica sand, clay (bentonite), water, and additives.
• Economical and widely used for ferrous and non-ferrous casting.
2. Resin-Coated Sand:
• Coated with phenolic or furan resins for high precision molds.
• Ideal for complex cores and detailed casting.
3. Sodium Silicate Sand:
• Bonded using sodium silicate, hardened with CO₂.
• Used for cores and molds requiring high strength.
4. Ceramic Sand:
• Made from synthetic materials (e.g., mullite).
• High refractoriness and low thermal expansion for premium casting applications.
4. Benefits of Foundry Sand
• Thermal Stability: Withstands high temperatures without melting or deformation.
• Reusability: Can be recycled multiple times before degradation.
• Dimensional Accuracy: Ensures precise molds for accurate castings.
• Low Cost: Economical for large-scale production.
5. Applications
• Metal Casting:
• Molds and cores for iron, steel, aluminum, and copper alloys.
• Automotive Industry:
• Engine blocks, crankshafts, and cylinder heads.
• Aerospace:
• High-precision parts requiring strong, smooth molds.
• Machinery and Tools:
• Custom cast parts for heavy machinery.
6. Recycling and Environmental Use
• Reusability: Spent foundry sand can be cleaned and reused in molding processes.
• Alternative Uses:
• Construction materials (e.g., asphalt, concrete).
• Soil amendments for agricultural land reclamation.
• Road base or landfill cover materials.
Typical Specifications for High-Quality Foundry Sand
Parameter Value
SiO₂ Content >90%
Grain Size 45-150 microns
Loss on Ignition (LOI) <2%
Moisture Content <0.5%
Refractoriness >1,500°C
Acid Demand Value (ADV) Low
Let me know if you need further details on the production process, sand testing methods, or international specifications for foundry sand! 🏗️