THE ECHO - Ferrostaal

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38 projects & contracting 01 PRODUCTION PLANTS FOR GYPSUM PLASTER BOARDS IN INDIA AND MALAYSIA GYPSUM BOOM IN ASIA The market for gypsum plaster boards is booming in Asia. British Plaster Board (BPB) is therefore increasing its capacity with two new production plants in India and Malaysia. No sooner had the MAN Ferrostaal/Grenzebach/BSH consortium handed over the first gypsum and gypsum plaster board plants to BPB than plans for two more plants in India were underway.
In May 2004, a consortium led by MAN Ferrostaal signed the contracts for the delivery, assembly and commissioning of the process equipment for gypsum and gypsum plaster board plants in Mumbai in India and Port Klang in Malaysia. The customers are the subsidiaries of British Plaster Board plc, England. The assembly and commissioning of the two plants were planned and realised within three months of each other. The plants manufacture gypsum plaster boards for finishing the interiors of private and commercial buildings. In the gypsum plant, natural or synthetic gypsum is converted into stucco through calcination (dewatering). Stucco is the raw material for the manufacture gypsum plaster boards and can be mixed with chemical additives to produce plaster. In the gypsum plaster board plant, the stucco is mixed with water and other additives and poured into 02 03 04 a mould made of special board to give a continuous running sheet of plaster board. This sets as it passes along a conveyor belt, at the end of which an electronically controlled cutter is used to cut the strand into gypsum plaster boards of any length. These are fed through a continuous-flow 10-deck drier with a length of approximately 90 meters. Once they have passed through the drier, the gypsum plaster boards are adjusted and then automatically stacked and grouped together in packages ready for loading and distribution. The plant in India has the capacity to produce 12.8 tons of stucco per hour and 1,610 meters of gypsum plaster boards per hour. In Malaysia, 14.2 tons of stucco are produced per hour and 2,343 metres of gypsum plaster board. The process equipment was supplied by European, Chinese and local manufacturers. 05 THE ECHO 1/2006 39 Precise planning and coordination with both the customer and the authorities were required to ensure a seamless implementation of the machinery and equipment. The mechanical assembly began in India in January 2005 and in Malaysia in April 2005 and ran according to schedule in both cases, although the construction site in India presented some problems due to the weather conditions (the heaviest rainfall for decades) and the isolated rural location. The provisional acceptance (take-over) of the two plants took place in December 2005 and February 2006 respectively, as per the project plan. Jan Uder, Walter Sante 01. Assembly of the calcination unit in India 02. The gypsum plaster board plant in Malaysia 03. The calcination unit in Malaysia 04. The drier outlet, India 05. Cross conveyor and drier inlet for gypsum plaster boards, Malaysia
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