Project Overview
A gypsum manufacturing facility faced a significant operational shift due to the upcoming shutdown of its existing flue gas desulfurization (FGD) gypsum supply produced by a nearby power plant. As the power plant transitions from coal to natural gas by 2028, the gypsum supply characteristics, particularly moisture content, will change substantially. To prepare for this transition, the facility identified a need to expand its existing calcination process to reliably handle higher-moisture incoming material while maintaining production capacity and operational efficiency.
Project Objective
The objective of this project was to provide P2-level engineering services to evaluate and support a calcination process expansion. The client sought to investigate two process design options focused on increasing throughput and accommodating higher-moisture gypsum. The engineering effort was intended to support cost evaluation related to new equipment, materials, and system installation, enabling informed decision-making before advancing into detailed design and execution.
Engineering Scope and Design Options
Two conceptual design options were developed to expand calcination capacity: one incorporating a new cage mill and the other utilizing an impact mill. Each option was evaluated at two production rates; 75 tons per hour and 120 tons per hour, to assess performance, constructability and cost implications. These concepts were developed with consideration for future operating conditions, including the anticipated change in gypsum moisture content and long-term system flexibility. After review, the client selected the 120 tons-per-hour option, determining that existing system redundancy reduced the need to execute the full scope initially envisioned.
Coordination and Schedule Management
Timeline expectations required active management throughout the project. The client initially targeted a firm design by the end of July; however, limited upfront information from equipment vendors posed a potential risk to schedule certainty. To mitigate this, vendor coordination was expedited to obtain critical technical and budgetary inputs, allowing engineering progress to continue without delay. Through proactive communication and responsiveness, the project remained on schedule and met the agreed delivery timeline.
Client Relationship and Project Continuity
This project built upon a long-standing relationship with the client, creating a strong foundation of trust and transparency. That relationship enabled a smoother transition into the next project phase, minimized surprises during scope development, and supported clear alignment on expectations. The ability to move efficiently into subsequent phases highlighted the value of consistent delivery and strong communication across multiple engagements.
Conclusion
This plant expansion study provided the client with a clear, well-supported path forward for adapting its calcination process to future gypsum supply conditions. By evaluating multiple design concepts, accommodating long-term operational changes, and maintaining schedule discipline, the project delivered actionable insights to support informed capital planning. The effort reinforced the value of proactive communication, strong client relationships, and disciplined financial coordination in delivering successful plant expansion projects.
