Nordgyp Labs
IndexProductsProcessCommissioningPlatformPatentsToolkitLibraryWeekly IntelGlossaryLabContact
§ Plant Toolkit

Four calculators built from chemistry, not from marketing.

Each tool below uses only stoichiometry, mass balance, or line geometry. No empirical coefficients from unpublished trials. Every formula is printed under the result so you can audit it against Wirsching, EN 520, ASTM C472 or your own data.

01 · Calcination water release
STOICH
Water released
157.0 kg
Hemihydrate out
843.0 kg
Latent heat
354.2 MJ
Vaporisation only — add sensible heating and losses.
ƒ CaSO₄·2H₂O → CaSO₄·½H₂O + 1.5 H₂O · M = 172.17 / 145.15 / 18.015 g·mol⁻¹ · ΔH_vap = 2257 kJ·kg⁻¹ (NIST)
02 · Rehydration water demand
STOICH
Stoichiometric water
186.2 kg
18.61 % of stucco mass — the absolute minimum for full hydration.
Excess water to evaporate
563.8 kg
Kiln load share
75.2 % of gauging
ƒ CaSO₄·½H₂O + 1.5 H₂O → CaSO₄·2H₂O · min W/S = 1.5·M(H₂O) / M(hemi) = 0.1861
03 · Line output & stucco requirement
GEOM
Board area rate
4320 m²/h
Core mass rate
36720 kg/h
Excludes facing paper mass.
Stucco requirement
33048 kg/h
ƒ ṁ_core = width · speed · thickness · ρ_core · 60 · fraction — pure geometry (SI units)
04 · Foam draw for target core density
GEOM
Unfoamed cured density
1628 kg/m³
From dihydrate + retained free water at this W/S.
Required void fraction
60.7 %
Foam draw
1659 L / t stucco
≈ 99.56 kg foam / t stucco at your foam density.
ƒ ρ_nofoam = (m_dihydrate + m_free) / (V_dihydrate + V_free) · ε = 1 − ρ_target/ρ_nofoam · V_foam = ε/(1−ε) · V_solid
Sources
  1. [1]Gypsum — Ullmann's Encyclopedia of Industrial Chemistry (Wirsching) — Wiley-VCH
  2. [2]EN 520:2004+A1:2009 — Gypsum plasterboards. Definitions, requirements and test methods — CEN / European Committee for Standardization
  3. [3]ASTM C1396/C1396M — Standard Specification for Gypsum Board — ASTM International
  4. [4]ASTM C472 — Standard Test Methods for Physical Testing of Gypsum, Gypsum Plasters and Gypsum Concrete — ASTM International
  5. [5]NIST Chemistry WebBook — Water, enthalpy of vaporization — National Institute of Standards and Technology (USA)

Outputs are theoretical values from mass balance and geometry. Actual plant behaviour depends on impurity levels, calciner efficiency, admixture chemistry and paper. Use these as a sanity check on line data — not as a prescription.