KEY COMPONENTS

1. Synthetic Gypsum:
   - Synthetic gypsum is typically derived from flue-gas desulfurization (FGD), a process used by coal-fired power plants to reduce sulfur dioxide (SO₂) emissions. The process involves scrubbing the flue gases with limestone or lime, resulting in the production of gypsum (calcium sulfate dihydrate, CaSO₄·2H₂O).
   - Properties: Synthetic gypsum has the same chemical composition as natural gypsum but is often purer and more consistent in quality. It is a white, powdery material that can be processed into various forms, such as fine powders or granular aggregates.

2. Binders and Additives:
   - To enhance the performance of synthetic gypsum in aggregate form, various binders (e.g., polymers, cements) and additives (e.g., plasticizers, hardeners) may be used. These materials improve the structural integrity, moisture resistance, and durability of the aggregate.
   - Additives can also be used to control setting times, improve mechanical strength, and modify the aggregate’s response to environmental factors such as temperature or humidity.
 

Properties and Benefits

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1. Consistency and Purity: Synthetic gypsum is often more consistent in chemical composition and physical properties than natural gypsum, which can vary depending on the location of extraction. This consistency results in a higher-quality aggregate that performs reliably in various construction applications.

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2. Lightweight: Synthetic gypsum is relatively lightweight, especially compared to traditional aggregates like crushed stone or sand. This makes it suitable for use in lightweight construction materials, helping to reduce the overall weight of buildings and other structures.

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3. Fire Resistance: Gypsum, whether natural or synthetic, is known for its fire-resistant properties. When exposed to heat, the water molecules in gypsum are released as steam, helping to retard the spread of fire. This property makes synthetic gypsum aggregates ideal for use in fire-resistant construction materials, such as drywall and plasterboard.

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4. Environmentally Friendly: Synthetic gypsum is a byproduct of industrial processes, meaning it helps to reduce waste from coal power plants. By recycling and repurposing this material, synthetic gypsum aggregates are considered an environmentally friendly option that reduces the need for mining natural gypsum, thus contributing to sustainability goals in construction.

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5. Moisture and Mold Resistance: Synthetic gypsum is naturally resistant to moisture and mold, especially when treated with additives. This property is particularly beneficial in building materials like drywall, where moisture resistance is critical for preventing mold growth in high-humidity environments.

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6. Cost-Effective: Since synthetic gypsum is produced as a byproduct of industrial processes, it is often more cost-effective than natural gypsum. This makes synthetic gypsum aggregates an attractive option for large-scale construction projects where material costs are a major concern.

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7. Cementitious Properties: Synthetic gypsum can act as a set retarder in cement, slowing down the hydration process and allowing for better workability of the concrete. This property makes synthetic gypsum aggregate useful in the production of cement, concrete blocks, and mortars.

Applications 

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1. Drywall and Plasterboard: One of the most common uses of synthetic gypsum is in the manufacture of drywall (gypsum board) and plasterboard. Synthetic gypsum aggregates are used to create the core of these boards, providing fire resistance, moisture resistance, and sound insulation for walls and ceilings.

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2. Cement and Concrete Production: Synthetic gypsum is used in the production of Portland cement as a retarder to control the setting time of the cement during curing. It is also added as a filler or additive in concrete mixtures and mortar, enhancing the workability and overall performance of the concrete.

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3. Soil Amendment: Synthetic gypsum aggregate is sometimes used in agriculture as a soil amendment to improve soil structure, reduce erosion, and enhance water infiltration. It also adds calcium and sulfur to the soil, which are essential nutrients for plant growth.

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4. Flooring and Plastering Compounds: Synthetic gypsum aggregate can be used as a base material in self-leveling flooring compounds and plastering mixes, where it provides a smooth, fire-resistant, and easy-to-apply surface finish.

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5. Fireproofing Applications: The natural fire-resistant properties of gypsum make synthetic gypsum aggregate a popular choice for use in fireproof coatings and fire-rated construction materials. These materials are used in walls, ceilings, and other structural components to help prevent the spread of fire in buildings.

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6. Lightweight Blocks and Panels: Synthetic gypsum aggregates can be incorporated into the production of lightweight concrete blocks and insulating panels. These materials are used in both residential and commercial construction to reduce the overall weight of the structure while maintaining thermal insulation and fire resistance.

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7. Landfill Capping and Reclamation: Due to its stability and non-toxic nature, synthetic gypsum aggregate can be used in landfill capping and reclamation projects. It helps seal off landfills and prevent leachate from contaminating surrounding soil and water sources.

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A synthetic gypsum aggregate is a versatile and environmentally friendly material derived from industrial byproducts, offering many of the same benefits as natural gypsum. Its lightweight nature, fire resistance, moisture resistance, and consistency make it an ideal aggregate for use in drywall, cement, plastering compounds, and other construction applications. Additionally, its use contributes to sustainability efforts by repurposing waste from coal power plants and reducing the need for natural gypsum extraction.