Fully automatic production line for semi-dry gypsum blocks

Equipment Features

This equipment features a unique design, simple operation, a small footprint, fast production speed, and high output. Its scientifically sound and well-optimized production process serves as an alternative to gypsum block manufacturing using the casting method, with product performance metrics that surpass those of cast products.

It boasts a distinctive mixing mode, intelligent water addition via secondary atomization, an accurate material distribution system, coordinated compression ratio and pressure settings, smart electrical control with one-touch start-up, low-noise high-pressure operation, no need for drying, and AI-powered palletizing and brick collection.

Analysis and Comparison Between Semi-Dry Formed Gypsum Blocks and Traditional Phosphogypsum Blocks

Traditionally, phosphogypsum blocks are produced using the casting method. This approach results in a high water-to-cement ratio, long drying cycles, and higher costs, which hinder large-scale, continuous production of gypsum products. It also fails to meet the demands of construction projects and cannot accommodate the large-scale utilization of industrial by-product phosphogypsum. Although cast gypsum hardens with relatively low density, it suffers from long drying times, poor hardness, low strength, high breakage rates during handling, and limited market acceptance. These factors severely constrain the development of phosphogypsum-based building materials, leading to low overall resource utilization and reduced economic benefits for related industries. Therefore, reducing the water-to-cement ratio, cutting drying costs, shortening production cycles, enhancing product strength and quality, and expanding market acceptance have long been the goals of manufacturers. In contrast, semi-dry gypsum block production uses primarily construction-grade gypsum and a small amount of Qisheng’s proprietary additives. These additives fine-tune the hydration reaction and crystal nucleation of construction gypsum, enabling the formation of stronger blocks through a unique molding process. The resulting hydrogen bonds and crystal nuclei work synergistically to boost block strength, with all performance indicators far exceeding the requirements of JC/T 698-2010. The key to semi-dry gypsum technology lies in lowering the water-to-cement ratio of phosphogypsum blocks to around 30%. This intensifies the hydration reaction compared to traditional casting methods, raising the temperature by approximately 10 degrees Celsius and effectively shortening the drying cycle. During this process, carefully selected admixtures are added to regulate crystallization, disperse particles, and ensure complete, efficient hydration. By reducing the water-to-cement ratio, this semi-dry production technique allows finished gypsum products to be packed and shipped directly without further drying or air-drying, significantly cutting both production time and costs. Meanwhile, the successful development of HF admixtures equips gypsum binders with functions such as crystal regulation, setting adjustment, dispersion, and anti-cracking, enabling tailored formulations to meet specific production and performance needs. As a result, semi-dry gypsum products exhibit superior performance at lower costs, opening up new possibilities for their application. Their range of uses is quite broad, including standard bricks, hollow bricks, composite panels, fireproof boards, and paper-faced gypsum boards. Since semi-dry processing leverages the mechanism of gypsum hydration and hardening while breaking away from the conventional casting method’s reliance on excessive water, future applications may extend to antistatic flooring core materials and various other hardened gypsum products, offering promising prospects for continued growth.

Specially Designed Mixer

This mixer incorporates German technology, delivering smooth overall transmission, high mixing efficiency, and excellent homogeneity (eliminating dead zones). Its unique sealing system prevents material leakage, ensuring durability, easy internal cleaning, and ample maintenance space.

Performance Characteristics of Semi-Dry Gypsum Blocks

With a void ratio of 52%, these blocks exhibit a bulk density of less than 760 kg/m³, a fracture load exceeding 5,000 N, a compressive strength greater than 5 MPa, and a softening coefficient above 0.7.