THE GYPSUM MARKET - Usage of Synthetic Gypsum in Europe. ASHTRANS EUROPE 2013 Copenhagen, Denmark. Dr. Frank Galka, Knauf Gips KG
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1 THE GYPSUM MARKET - Usage of Synthetic Gypsum in Europe ASHTRANS EUROPE 2013 Copenhagen, Denmark Dr. Frank Galka, Knauf Gips KG ASHTRANS EUROPE 2013 Dr. Galka/CR 1
2 Agenda 1 The European Gypsum Market 2 Flue-Gas Desulfurization (FGD) Gypsum Production Quality Volumes 3 Gypsum Logistics ASHTRANS EUROPE 2013 Dr. Galka/CR 2
3 Key Figures of the European Gypsum Industry ca. 10 Billion Euro annual turnover 160 quarries in Europe 218 plants in Europe: Plasterboards 100 Plaster powder 65 Plaster blocks 15 Gypsum fibre boards 8 Gypsum ceiling tiles 30 Number of employed: direct indirect workers using the Gypsum products Three main players operating worldwide with European know-how Source: Eurogypsum 2012 ASHTRANS EUROPE 2013 Dr. Galka/CR 3
4 Overview of Building Materials Made of Gypsum Product Range Gypsum Plaster Systems Floor Systems Drywall Systems Machine applied plaster Manually applied plaster Finishes Special plasters Floor screeds Dry flooring units Accessories Plasterboards Gypsum fibreboards Cement-based boards Profiles and accessories ASHTRANS EUROPE 2013 Dr. Galka/CR 4
5 Different Kinds of Plasterboard Applications Gypsum plasterboards Source: Eurogypsum 2012 ASHTRANS EUROPE 2013 Dr. Galka/CR 5
6 Sources and Demand of Gypsum in Europe Natural Gypsum Synthetic Gypsum FGD Gypsum Chemical Gypsum (Phosphogypsum, Citrogypsum, Titanogypsum, etc.) Recycling Gypsum ca. 8 Mio. t/a ca. 15 Mio. t/a The focus of the following slides is FGD gypsum ASHTRANS EUROPE 2013 Dr. Galka/CR 6
7 FGD Gypsum Usage and Sustainability Usage of FGD Gypsum is highly sustainable and contributes to the objectives of the European Waste Framework Directive Primary raw material resources can be saved and resource efficiency can be increased Waste production can be prevented and consequently landfilling can be reduced ASHTRANS EUROPE 2013 Dr. Galka/CR 7
8 Agenda 1 The European Gypsum Market 2 Flue-Gas Desulfurization (FGD) Gypsum Production Quality Volumes 3 Gypsum Logistics ASHTRANS EUROPE 2013 Dr. Galka/CR 8
9 Production of FGD Gypsum out of SO 2 Flow Sheet of a FGD System Limestone/water suspension SO 2 Flue gas (SO 2, etc.) Fresh limestone slurry (CaCO 3 ) Oxidation air O 2 Absorber Clean flue gas Back to absorber Waste water treatment 2-4 % solids 15 % solids Hydrocyclone station Process water Prozeß water 50 % solids FGD process: By adding limestone (CaCO 3 ) SO 2 of the flue gas is transformed into CaSO 4 * 2H 2 O (gypsum). Fresh wash water 10 % moisture Vacuum belt filter Wash Filtrate water to KNAUF Transport to Gypsum Factory Process Prozeß water Waste water treatment treatment Waste water treatment Waste water treatment FGD Gypsum ASHTRANS EUROPE 2013 Dr. Galka/CR 9
10 Standard for Quality Set by EUROGYPSUM/VGB/Ecoba Watersoluble salts Source: ASHTRANS EUROPE 2013 Dr. Galka/CR 10
11 FGD Gypsum Analyses and Typical Results Scanning Electron Microscopy Size Analysis ASHTRANS EUROPE 2013 Dr. Galka/CR 11
12 Production Volumes of FGD Gypsum EU-15 Development of FGD Gypsum Production from Hard Coal and Lignite in EU-15 from 1994 to 2010 Source: Feuerborn (Ecoba), 2013 WOCA Conference, Lexington/KY (USA) ASHTRANS EUROPE 2013 Dr. Galka/CR 12
13 Utilisation and Disposal of FGD Gypsum in 2009 (EU-15) 76 % (8.1 million tonnes) used in the construction industry 9.1 % on temporary stockpile as raw material for production plants Only 7.4 % on disposal (0.8 million tonnes) for different reasons Source: Feuerborn (VGB), Eurogypsum 2012 Krakow Congress ASHTRANS EUROPE 2013 Dr. Galka/CR 13
14 Production Volumes of FGD Gypsum - Germany FGD Gypsum Production Volumes from 2001 to 2010 and Forecast until 2030 for Germany Source: Die Nachfrage nach Primär- und Sekundärrohstoffen der Steine-und-Erden-Industrie bis 2030 in Deutschland Bundesverband Baustoffe - Steine und Erden e.v., April 2013 ASHTRANS EUROPE 2013 Dr. Galka/CR 14
15 Agenda 1 The European Gypsum Market 2 Flue-Gas Desulfurization (FGD) Gypsum 3 Gypsum Logistics ASHTRANS EUROPE 2013 Dr. Galka/CR 15
16 FGD Gypsum Logistics Different Strategies to Follow Strategy I Construction and operation of gypsum factories in proximity to coal-fired power plants: short transportation routes supply of steam and electrical power Strategy II FGD gypsum transportation to gypsum factories some of which are located far away from power plants by using sophisticated concepts of logistics (railway, vessels, in particular). Prerequisite favourable market conditions for gypsum-based products ASHTRANS EUROPE 2013 Dr. Galka/CR 16
17 Logistic Strategy I Production Site Schwarze Pumpe/Germany Wallboard plant close to the Vattenfall Power Station FGD gypsum storage Lignite-fired power station Belt conveyor Wallboard plant ASHTRANS EUROPE 2013 Dr. Galka/CR 17
18 Logistic Strategy I Production Site Jaworzno/Poland Plaster plant close to Power Station Jaworzno III Power station FGD gypsum storage Plaster plant ASHTRANS EUROPE 2013 Dr. Galka/CR 18
19 Logistic Strategy II Production Site Iphofen/Germany FGD gypsum deliveries by railway from Power Station Schwarze Pumpe ASHTRANS EUROPE 2013 Dr. Galka/CR 19
20 Logistic Strategy II Production Site Engis/Belgium FGD gypsum transport by truck and ship from Saar Power Stations ASHTRANS EUROPE 2013 Dr. Galka/CR 20
21 Thank you for your attention! Knauf Gips KG, Iphofen/Germany ASHTRANS EUROPE 2013 Dr. Galka/CR 21
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