USO05743954A

United States Patent (9. 11 Patent Number: 5,743,954

Rowland et al. 45) Date of Patent: Apr. 28, 1998
54 METHOD FOR CONTINUOUS FOREIGN PATENT DOCUMENTS
REFRACTORYLESS CALCNNG OF
GYPSUM 169737 9/1904 Germany.
1018464 1/1966 United Kingdom.
75) inventors: George E. Rowland, Naperville, Ill.;
Michael L. Cloud, Canton; Daniel J. Primary Examiner Michael Marcheschi
Milligan, Watonga, both of Okla. Attorney, Agent, or Firm-Richard B. Hoffman; John M.
Lorenzen
(73) Assignee: United States Gypsum Company,
Chicago, Ill. 57 ABSTRACT

(21) Appl. No.: 382,612 A method and apparatus is disclosed for the continuous
calcining of gypsum material in a high-efficiency, refracto
(22 Filed: Feb. 2, 1995 ryless kettle preferably heated by a multiple series of sepa
rate immersion tube burner coils, each coil operating within
(51 int. Cl. ... C04B 11/00 a specific calcining zone inside the kettle. The lowest, i.e.,
52 U.S. Cl. .......................... 106/783; 106/772; 423/171; initial, burner tube coilis formed with a low profile to permit
423/172; 4231555; 432/14; 432/102; 432/197; use of a small initial gypsum charge, and hence, a quick
432/114 kettle start-up cycle. That low profile initial burner design
58 Field of Search ..................................... 106/772, 783; also helps keep the agitator motor's load at a minimum
423/172,555, 171; 432/14, 197, 102, 209, during cycle start-up. Due to the immersion tube burner coil
114 construction, no refractory structure for the kettle is .
required. Also, no separate hot pit structure is required, as
56) References Cited the kettle is used to merely hold the material being calcined
U.S. PATENT DOCUMENTS and no residual heat is present. Arelatively thinkettle can be
constructed, as it need only withstand relatively low oper
2261,872 11/1941. Choate. ating temperatures. The kettle's staged, interiorly-disposed
3,307,840 3/1967 Conroy, Jr. . burner tube coils act to directly transfer burner tube heat to
3,307,915 3/1967 Conroy et al. .......................... 432/209 the kettle's contents, and the coils exhaust exteriorly of the
3,669,435 6/1972 Silverberg. kettle. The present calcining method and apparatus permits
4,113,836 9/1978 O'Connor. substantially improved tonnage output of calcined material,
4,161,390 7/1979 Page et al. .............................. 432/102 for a kettle of a given size. A modification to the present
4,176,157 11/1979 George et al. .. 0 own a no own wo 423/171
apparatus includes structure for recovering and recycling a
4,188,186 2/1980 Ladwig.
4215,981 8/1980. von Dreusche, Jr. . portion of the spent burner gases, and also separate structure
4227.873 10/1980 Manshausen et al. . for forced aeration air, both preferably for introduction
4238,283 12/1980 Kinkade et al. ........................ 106/783 through the kettle bottom. One alternate embodiment con
4,522,587 6/1985 Miller. cerns a differently-shaped kettle design. Another alternate
4,576,573 3/1986 Ruehenbeck. embodiment concerns a modified kettle which uses a single
4,744,961 5/1988 Bounini .................................. 423,171 immersion burner tube coil to provide the total heating of the
4,915,623 4/1990 Ball et al. ................................ 432/14 kettle's contents, for use in certain calcining applications.
5,007,825 4/1991 Williams.
5,011,668 4/1991 Ball et al..
5,139,749 8/1992 White. 12 Claims, 7 Drawing Sheets
U.S. Patent Apr. 28, 1998 Sheet 1 of 7 5,743,954

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U.S. Patent Apr. 28, 1998 Sheet 7 of 7 5,743,954
 5,743,954
1. 2
METHOD FOR CONTINUOUS the method of staging the location of multiple immersion
REFRACTORYLESS CALCNNG OF tube burner coils within a calcining kettle; forming the
GYPSUM initial, i.e., lowest, burner assembly of a low profile design,
to permit quick kettle start-up; initially charging the vessel
This invention relates to a method and apparatus of 5 with gypsummaterial to substantially cover the lowerburner
calcining of gypsum, and more specifically, to a method and unit; energizing the lower burner unit to heat the initial fill
apparatus for continuous calcining of gypsum using a series of material; thereafter continuing to fill the kettle with
successive additional loads of material to cover the succes
of immersion tube burners within a refractoryless kettle. sive higher-staged burner tube assemblies; and energizing
BACKGROUND OF THE INVENTION O the successive higher burner tube assemblies to establish a
continuous cycle of ground gypsum material conveyed to
Calcining of crushed gypsum comprises converting cal and calcined in the kettle.
cium sulfate dihydrate by heating into calcium sulfate The present refractoryless calcining kettle utilizes a series
hemihydrate, better known as stucco. Prior calcining appa of immersion tube burner assemblies, preferably formed in,
ratus and methods have taken various forms. Traditionally, 15
but not limited to, horizontally-aligned, serpentine-like
the calcining of gypsum has occurred in a large kettle, coils, with each burner tube assembly located within a
having a thickened dome-shaped bottom, against which a specific calcining Zone within the kettle. Each burner tube
gas-fired flame is directed, with the kettle and burner flame exhausts exteriorly of the kettle to a commonflue stack. The
being enclosed in a suitable refractory structure. There is kettle is constructed of steel material of Sufficient thickness
usually an associated hot pit into which the calcined material 20
to withstand the calcining temperatures required, and is
is fed. The kettle must withstand temperatures in the preferably flat-bottomed. Thus, the kettle of the present
2,000-2,400° F range, hence requiring expensive fire box invention, and its associated housing structure, can be of less
steel plate on its domed bottom, which was typically 1% overall vertical dimensions, as no dome-shaped bottom
inches thick. U.S. Pat. No. 3.236,509 typifies this type construction or underlying burner apparatus is required.
construction. This approach had numerous disadvantages, 25
Further, no extra fire-box steel cladding is required for the
such as the extreme waste of hot burner gases, and the kettle bottom (such as was previously required to withstand
associated refractory brick enclosure which, when repairs or the highly elevated temperatures at which prior art kettles
kettle shut-down were needed, first required a lengthy cool had to operate). Since all heating of the gypsum material
down period. occurs within the kettle, and since there is no external heat
Other calcining kettles, of the general type described 30 applied to the kettle, no separate refractory structure is
above, have included supplemental submerged combustion required. Also, since no hot burner gases directly impinge on
designs where exhaust gases from the gas-fired burners were the gypsum material being calcined, but instead, the immer
discharged directly into the kettle contents. Here, the gas sion tube burner gases exhaust from the burner tube coils
flame directly impinged against the material being calcined, exteriorly of the kettle through a flue stack, low capacity
and there was an increased possibility of creating so-called 35
combustion air blowers can be utilized for the tube burners.
"dead burn” material, i.e., insoluble anhydrite. U.S. Pat. This results in reduced initial capital expenditures.
Nos. 4.176,157 and 4,238.238 typify that type approach. Further, because the present invention uses a series of
Additionally, other prior art calcining kettles, of the general coil-shaped immersion tube burner assemblies which are
type described above, included a series of cross tubes which mounted substantially within the calcining kettle, essentially
passed generally horizontally completely through the kettle, all the burner-generated heat is transferred to the kettle
allowing the hot gases within the refractory structure and contents, with attendant increased heat transfer efficiency.
surrounding the kettle to be supplementally directed through Further yet, since additional burners and heat exchangers,
the tubes, and thus, through the kettle contents to further heat i.e., burner tube coils, can be installed within the presently
the same. U.S. Pat. Nos. 3307,915 and 4,163.390 typify this disclosed kettle vessel, even more heat transfer area can be
type kettle construction. There have also been horizontally 45 installed in the same size kettle resulting in yet higher
aligned, rotary calcining structures; U.S. Pat. No. 3,871,829 tonnage output capacity for the kettle. Thus, a greater
typifies this type approach. tonnage output, for the same size kettle, can be achieved
Besides the above kettle constructions which normally with the present kettle and burner design than with any
require expensive refractory structure, there have also been known prior art design. As modifications to the present
refractoryless kettles using the submerged combustion invention, additional flue gas recycling and aeration equip
principle, including those having auxiliary draft tube struc ment can be installed adjacent the interior kettle bottom, to
ture encompassing the main burner tube, so as to reduce help with further heating and circulating of the kettle's
formation of dead-burned insoluble anhydrite. U.S. Pat. No. contentS.
4,626,199 typifies this type construction. Additionally, there An alternate embodiment comprises, instead of a series of
are so-called refractoryless conical kettles with various types 55 immersion tube burner coils, a single burner tube coil
of submerged combustion heating systems, again with the mounted interiorly of a kettle, and still exhausting exteriorly
attendant risk of creating non-uniform stucco and dead burn of the kettle, to provide the total heat transfer for the kettle's
material. U.S. Pat. Nos. 4,629,419 and 4,744.961 typify such contents. Such a single burner tube coil kettle is suitable for
conical kettle constructions. More recent calcining kettle use in specific applications where a smaller capacity kettle
modifications have included so-called "boost' burner is sufficient.
constructions, including electrical boost carods, see U.S. It is a primary object of the present invention to provide
Pat. No. 4,744.963, and gas-fired boostburner designs, both a calcining kettle utilizing at least one, interiorly-disposed
added as supplemental heaters to traditional refractory-type immersion tube burner coil, which coil exhausts to the
kettle constructions. kettle's exterior, and where the kettle's contents are sub
The presentinvention overcomes the disadvantages of the 65 stantially entirely heated by that burner tube coil or coils.
prior art calcining kettle constructions and calcining It is another object of the present invention to provide a
methods, in several respects. The present invention includes calcining kettle having multiple internally-disposed immer
 5,743,954
3 4
sion tube burner assemblies, each preferably formed as a kettle having a single immersion tube burner coil for certain
horizontally-aligned coil and operating in a separate calcin calcining applications.
ing zone within the kettle. DESCRIPTION OF THE PREFERRED
It is a further object of the present invention to utilize as EMBODIMENT
the lowest or initial immersion tube burner assembly one
which is of a low profile, serpentine-like coil design, so as Having reference to the drawings, wherein like reference
to permit quick initial start-up cycle for the calcining kettle, numerals indicate corresponding elements, there is shown in
as well as to require a lower horsepower for the agitating FIG. 1 an illustration of an improved calcining kettle appa
drive device during cycle start-up. ratus generally denoted by reference numeral 20. The
It is a further object to provide a calcining kettle having improved kettle apparatus 20 includes a calcining kettle 22
no separate refractory enclosure structure, and where the having a generally teardrop-shaped kettle shell 24 (in cross
kettle has reduced material requirements due to the substan section) and a flat bottom 26, mounted upon suitable struc
tially reduced temperatures at which it operates. tural supports 28. The kettle 22, for manpower safety
It is a yet further object of the present invention to have 15
reasons, preferably has its sidewall exterior covered with a
a calcining kettle that does not require a heavy duty, domed suitable protective insulation, see the sheathing 29 partially
bottom construction and eliminates any burner construction depicted in FIG. 1. The kettle apparatus 20 also includes a
beneath the kettle, such that kettle-bottom aeration can be matching teardrop-shaped kettle cover 30 (see FIGS. 1, 2
utilized. and 7). Cover 30 carries a kettle input riser 32 to receive a
It is a still further object to provide a calcining kettle 20 continuous charge of ground gypsum material 34, the latter
construction which permits a substantially increased ton being delivered by a conventional kettle feed conveyor 36.
nage output of calcined material, for the same size kettle. A dust collector riser port 37, connected to a dust collector
It is a still further object to provide a kettle design supply pipe 39, is also carried by cover 30. An overflow-type
substantially teardrop-shaped in cross section which permits outlet tube 38 partially extends through the side wall of
an elongated initial straight section for the respective immer 25 kettle shell 24 and terminates at its upper end in an overflow
sion burner tube assemblies. Alternatively, the kettle design outlet 40; together the outlet 40 and outlet pipe 38 comprise
a calcined material recovery means. During the calcining
could instead be of a circular cross section design, with process, the processed calcined gypsummaterial (designated
exteriorly-mounted burner boxes. by numeral 42 in FIG. 1), being lighter rises withinkettle 22
The means by which the foregoing and other objects of and overflows into outlet 40. In a conventional manner, the
the present invention are accomplished and the manner of outlet 40 acts to establish an upper level (designated by
their accomplishment will be readily understood from the reference letter "Y") for the calcined gypsum 42 within
following specification upon reference to the accompanying kettle 22.
drawings, in which: The outer or lower end of overflow discharge tube 38
FIG. 1 is a side elevation view, partly in section, of the connects with a suitable outlet tube 44. A kettle discharge
improved calcining kettle construction of the present 35 connector or dump gate 46 is mounted at the lower edge of
invention, with kettle support structure shown in phantom; kettle shell 24 (see right lower section thereof in FIG. 1) to
FIG. 2 is a plan view of the calcining kettle of FIG. 1, permit, when desired, discharge of the entire contents of the
shown with the kettle cover partially broken away, and kettle 22. This can be either through a material discharge
certain drive motor and burner tube apparatus removed, for tube or into an associated existing hot pit structure (neither
better viewing: shown).
FIG. 3 is a top plan view of the kettle shell of the present Amixing means is used to mix the kettle's contents during
invention; the calcining operation. More specifically, mounted atop the
FIG. 4A is a side elevation view of the lower burner tube improved kettle apparatus 20 of the present invention is an
coil of the calcining kettle of FIG. 1; 45 agitator drive assembly, generally denoted by reference
FIG. 4B is a top plan view of the lower burner tube coil number 48; it comprises a motor 50, a gear reducer 52, and
of FIG. 4A a drive shaft 54. The drive shaft 54 extends downwardly
FIG. 5A is a side elevation view of the middleburner tube through a bearing seal block 56 mounted on kettle cover 30;
coil of the kettle of FIG. 1; shaft 54 is rotatably mounted at its other end in a journal
bearing 58 affixed to the kettle bottom 26. A series of kettle
FIG. 5B is a top plan view of the middle burner tube coil 50 contents
of FIG. 5A; sweeps or mixer blades 60A, 60B, and 60C, each
axially tilted to force material downward, are respectively
FIG. 6 is a side elevation of the upper burner tube coil of mounted to the rotating drive shaft 54, each for agitating
the kettle of FIG. 1; operation within different calcining zones (described more
FIG. 7 is a top plan view of the cover of the kettle of FIG. 55 fully below) located within the kettle 22. A scraper bar or
1; rake 62, affixed to shaft S4, rotates adjacent the bottom of the
FIG. 8 is a side elevation view, with various parts kettle 22. The blades of scraper bar 62 are tilted so as to
removed for better viewing, of a modified embodiment of upwardly plow and mix the kettle contents located adjacent
the calcining kettle apparatus of FIG. 1; the kettle bottom 26 into the adjacent calcining zone.
FIG. 9 is a top plan view of an alternate embodiment of As best seen in FIGS. 1, 4-6, a series of burner tube
the calcining kettle apparatus of the present invention, with assemblies are disposed, preferably but not limited to being
certain components removed for better viewing, and depict horizontally-aligned, for operation withinkettle 22. They are
ing a differently-shaped kettle shell and a modified multiple generally denoted as the initial (or lower) burner tube or heat
immersion tube burner arrangement; and exchanger assembly 64, middle burner tube assembly 66,
FIG. 10 is a top plan view of yet another alternate 65 and upper burner tube assembly 68. As noted, each of the
embodiment of the present invention, with certain compo three burner tube assemblies 64, 66, and 68 are formed as a
nents removed for better viewing, and depicting a calcining coil-type assembly, and are each placed within a specific
 5,743,954
S 6
calcining zone of the kettle 22. For example, lower burner section 94 mounted via a mounting plate 96 for extension
tube assembly 64 operates within the lower calcining Zone through kettle shell wall 22 to connect with the outlet of the
denoted generally by reference letter A in FIG. 1, while middle burner 90. Coil 92 is formed of a taller, generally
middle burner tube assembly 66 operates within intermedi cylindrically-shaped central spiral section 98 having four
ate calcining zone B, and upper burner tube assembly 68 horizontally-aligned coil levels 100, as contrasted to essen
operates within the upper calcining Zone C. tially the more compact, two coil levels 82, 84 of the lower
burner tube coil 74. Middle coil 92 terminates in a vertical
Viewing FIGS. 1 and 4, the lower burner tube assembly riser 102 for connection to the common flue stack 81. Again,
64 comprises an immersion tube burner 70 mounted exte unlike lower burner coil 74, the middle burner tube coil 92
riorly of the kettle shell 24. The burner 70 produces a preferably does not utilize inner and outer coil sections 83,
gas-fired flame generally depicted by the arrows 72. An O
85
immersion burner tube coil, generally denoted by reference Finally, as shown in FIGS. 1, 2 and 6, the upper burner
numeral 74, comprises an initial tube section 76 which is tube assembly 68 comprises an upper immersion tube burner
connected to the output of burner 70 and sealably extends 106, mounted in vertical alignment with burners 70 and 90,
through the kettle shell wall 24. Burner tube coil 74 also has 15 and an upper burner tube coil 108. Coil 108 has an initial
an intermediate coil section 78 which terminates in a vertical
riser tube 80. Spent burner gases, which exhaust from the straight tube section 110, a central spiral tube section 112,
riser tube 80 extending above the kettle cover 30, are and terminates in a vertical riser 114, the latter connected
above cover 30 to the common fue stack 8. The initial
collected into a common flue stack 81 (see FIGS. 1 and 8). straight tube section 110 is mounted to the kettle shell wall
Preferably, the lower burner tube assembly 64 is formed 24 by amounting plate 116; it connects to the outlet of upper
in a serpentine-like, low profile design. This is in contrast to burner 106. Like middle burner tube coil 92, the upper
the taller, more cylindrically-shaped coil designs preferably burner tube coil 108 is generally cylindrically-shaped, and
used for the middle and upper burner tube assemblies 66, 68. horizontally-oriented, and comprised of essentially four coil
That is, lower burner tube assembly 64 is preferably formed levels 118. The upper burner tube coil 108, because of the
of a low profile design having, for example, as illustrated, 25 overall length of burner tubing provided by the four coil
only two coil levels, namely lower coil level 82 and upper levels 118, like middle burner tube coil 92, presents enough
coil level 84. Again, both coil levels 82, 84 are generally burner tube surface area to heat the gypsum located within
horizontally-aligned; they are connected by an intermediate kettle calcining zone C.
coil section 78. As seen in FIGS. 4A and 4B, each of the It will be understood that the present invention uses heat
lower and upper coil levels 82, 84 have inner and outer coil 30 Source means, heating means and circulating means to
sections, generally designated by numerals 83 and 85 (see circulate a heated media within the kettle 22 to entirely heat
FIG. 46). The result is that the lower burner tube assembly its contents. For example, the heat source means can com
64 has a squatter, tighter, more serpentine-like coil design, prise burners 70, 90, and 106, and the heating means and
whereby calcining Zone A is vertically shorter, i.e., more circulating means can comprise heat transfer apparatus in
shallow or "squat', than are zones B and C. 35 the form of the multiple burner tube coils 74,92, and 108.
Nevertheless, even though the lower burner tube assem Further, the heated media circulated within the burner tube
bly 64 has a compact vertical height (as located within the coils can comprise heated combustion gases (i.e., from
kettle calcining zone designated by letter A), there is still flames 72) circulated in coils 74, 92, and 108.
sufficient heating surface area provided by the configured As seen in FIGS. 2, 3, 4B and 5B, due to the preferred
lower burner tube coil 74 to transfer the required heat to substantially teardrop cross-sectional shape of kettle 22, an
calcine, or at least initiate the conversion of, the gypsum 34 elongated area for the initial burner tube piping is available.
deposited within calcining zone A. That is, the combination That is, the respective immersion tube burners 70, 90, and
of the two serpentine-like coil levels 82, 84, each with 106 are mounted adjacent the "point' of the teardrop-shaped
separate inner and outer coil sections 83, 85, results in kettle 22 (see FIG. 2), such that that teardrop kettle shape
sufficient overall heater tube surface area to allow the 45 allows the burners to be tangentially introduced to the kettle,
gas-fired heat generated by burner 70 to be substantially i.e., via a flat surface. In this way, the initial straight burner
transferred through coil 74 into the gypsum material 42 tube sections 76, 94, and 110, all preferably formed of
located in calcining Zone A. stainless steel pipe, are advantageously of sufficient length to
As seen in FIGS. 4A and 4B, the initial straight burner prevent the gas flames 72 from directly impinging on any
tube section 76 of coil 74 is supported at its inlet end by a 50 interior burner tube wall surface. This permits extended life
mounting plate 86 carried by kettle shell 24. Preferably, that and reduced maintenance for burner tube coils 74, 92, and
straight tube section 76 extends a sufficient distance into the 108.
kettle 22 such that the gas-fired flames 72 do not impinge In one embodiment designed in accordance with the
directly upon any cross wall portion of lower burner tube presentinvention, the overall vertical dimension of the kettle
coil 74. This acts to greatly reduce any unwanted wear and 55 22 (FIG. 1) was approximately 15 feet, and the diameter of
potential damage to the tube coil 74. That initial straight tube the kettle 22 was approximately 15 feet. Further, the thick
section 76 is preferably formed of a suitable stainless steel ness of the kettle shell wall 24 was approximately 3% inch, as
material, such as Stainless Schedule 80 pipe. The remainder was the thickness of the kettle bottom 26. The overal
of the burner tube coil 74, including the vertical riser tube diameter (denoted by dimension D in FIG. 5B) of the
80, is preferably formed of a mild steel material, such as respective burner tube coil sections 92, 108 (and of outer
Schedule 80 pipe. coils 85 of tube coi174) was approximately 8 feet, while that
The middle tube burner assembly 66 is depicted in FIGS. for the inner coils 83 (of Iower burner tube coil 74) was 6
1 and 5A, SB. As with lower burner tube assembly 64, a feet. The diameter of the tube sections making up the
middle immersion tube burner 90 is mounted for operation respective burner tube coils 74,92, and 108 was nominally
on the kettle shell wall 22 above, and in vertical alignment 65 8 inches. The sidewall thickness of such coil tube sections
with, the lower burner 70. A middle burner tube coil, was /2 inch. The length of the initial straight tube sections
designated by reference numeral 92, has an initial straight 76, 94, and 110 was approximately 5 feet, while the overall
 5,743,954
7 8
length of each of burner coils 74,92, and 108 was approxi approximately 1,600-1,800°F. Further, the temperature of
mately 75 feet. That resulted in eachburner tube coil 74,92, the spent burner gases exhausting from riser tubes 80, 102,
and 108 having a total useable exterior surface area for heat and 114 should be approximately 500-600°F.
transfer of approximately 23,000 sq. inches. The respective Gas-fired immersion tube burners are readily commer
immersion tube burner units 70, 90, and 106, each had an cially available, such as those made by the following com
approximate output of 5,000,000 BTUs. It is to be under panies: Pillard Combustion (Procedair), of Montreal, Que
stood that such a maximum BTU output for the burners 70, bec; Eclipse Combustion, of Rockford III.; Maxon
90 and 106 could readily change should higher capacity Corporation, of Muncie, Ind.; and Hauck Manufacturing
burners become commercially available. Co., of Lebanon, Pa. Preferably, the highest capacity gas
It is to be understood that one needs a certain length of O fired immersion tube burner is selected, which currently has
burner tube coil (74,92, 108) to contain sufficient hot gas in a capacity limitation of 5,000,000 BTU. Even larger immer
kettle 22 such that the resulting heat transfer from such sion tube burners could be used if commercially available,
burner coils' respective exterior surface areas will heat up such as 10,000,000 BTU capacity units, however none are
the material 42 in a given calcining Zone to a temperature presently known. The fuel for the burners 70, 90, and 106
range of 290° F to 310° F., and preferably 300° F. at 15 could be liquified petroleum, i.e., LP gas, or natural gas.
approximately "80% plus” burner tube efficiency. Also, it is They are not intended for use with coal or oil, since that type
known from prior experience and prior kettle design usage flame would create unwanted interior coatings to the burner
that the required amount of heat (perton of gypsummaterial tubes 44, 92, 108.
to be calcined) is typically around 750,000 BTUs perton of If desired, modifications in the form of recycling and
new material. Further, with prior art calcining processes and aeration means can be made to the improved calcining kettle
apparatus, the required so-called "retention time” for new apparatus 20 of the present invention, as best seen in FIG.8.
gypsum material 34 to be retained within the kettles, i.e., That is, one modification can take the form of apparatus for
material time in through material time out, was generally recycling a portion of the spent burner gases in exhaust flue
thought to be for a minimum period of 30 minutes. However, stack 81 through the kettle 22. More specifically, an auxil
in prior artkettles it was typically 80 to 90 minutes residence 25 iary recycle pipe 132 draws a portion of the spent flue gases
time to get uniform quality calcined gypsum. from stack 81. This occurs through the use of a flue gas
With the present invention that residence time is expected recycle blower 134 and a recycle supply pipe 136, which
to drop to approximately 40-45 minutes. When running at connects to a plenum 137 formed on the bottom of the kettle
full capacity, it is believed that each immersion tube burner 22. In this manner, much of the remaining heat in the spent
unit (70, 90, 106) would generate, through its respective 30 flue gases can be recovered and acts to supplementally heat
burner tube coil, (74, 92, 108) given the above surface area, the kettle contents 42. Such exhaust flue gases, which have
upwards of approximately 175 BTUs/hoursquare inch dropped to around 500-600 F, i.e., no longer at their
within its respective calcining zone in kettle 22, at 80% initial input temperature of 1,800° F., are of low enough
burner efficiency. It is also believed that the temperature temperature that they would not easily create unwanted dead
difference (between the kettle contents 42 and the respective 35 burn material within the kettle contents 42. However,
burner tube coils 74,92, and 108) decreases as the material because such recycled flue gases would now act to directly
being calcined moves up from calcining zones A to C. contact and bubble up through the kettle contents 42, via
It is to be understood that no separate hot pit structure is plenum 137 and pads 140, an enlarged dust collector (not
required for use with the improved calcining kettle apparatus shown) might be required to connect to the dust collector
20 of the present invention. This is because one typically 40 supply pipe 138.
does not need to "dump' the present kettle 22, such as at Alternatively, aheat exchanger could be used with recycle
kettle shut-off or for kettle exterior maintenance matters, pipe 132. For example, see the phantom-outlined heat
since unlike prior artkettles having refractory structures, the exchanger box in FIG. 8, generally denoted by reference
present improved calcining kettle 20 does not act as a large letters H.E., which could be used to heat fresh air with
heat sink, i.e., does not require a long cool-down period. 45 recycled heated combustion gases from flue 130, and supply
However, if the kettle apparatus 20 is to be constructed, such the heated fresh air to the recycle blower 134.
as a retrofit installation into an existing stucco kettle line, Further, if desired, direct kettle-bottom aeration of the
where a hot pit structure is already built and present, then the kettle contents can be added. This would provide increased
dump gate 46 on kettle shell 24 could discharge into such an fluidization of the kettle contents 42. That is, as best seen in
existing hot pit, if desired. 50 FIG. 8, a modification of kettle 22 for aeration purposes can
Importantly, the kettle apparatus 20 of the present inven be aeration means taking, for example, the form of the
tion operates at a substantially reduced external temperature aeration pads 140 formed on the interior surface of kettle
compared to those of prior art designs. As noted, prior art bottom 26; they would be supplied with forced, unheated
refractory-type kettle structures had to withstand significant aeration air via plenum 137, pipes 142 and blower 144. Use
elevated operating temperatures, such as 2,000-2400° F. 55 of such supplemental aeration apparatus might also require
On the other hand, the kettle apparatus 20 of the present use of an increased size dust collector (not shown), versus
invention, since the calcining heat is applied internally that size as used with kettle 22 when no aeration apparatus
within the contents via the immersion tube burner coils 74, or flue gas recycling equipment is present. Use of such
92, and 108, the kettle 22 need only retain, not heat, the forced aeration within a calcining kettle helps the gypsum
gypsum 42 being calcined. That is, all of the heat generated material 42 flow better within the kettle. This gives more
by the immersion tube burners is directed via the burner tube assurance that there are no so-called "heating dead spots'
coils to the kettle's contents, rather than against the kettle within the kettle. This modification would be particularly
itself. Thus, the kettle shell wall 24 and bottom 26 will helpful with material fluidity in those areas in kettle 22
normally operate at a much reduced temperature, i.e., of where the burner tubes straight sections 76,94, and 110 are
only approximately 300°F. This is the case, notwithstanding 65 in vertical alignment with one another. Importantly, such
the fact that the initial straight burner tube sections 76, 94, kettle bottom aeration was not available with the known
and 110 will be heated by the burners 70, 90, and 106 to prior art kettle designs which had refractory pits. That is
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10
because it would have interfered with the burners positioned Yet a further embodiment of the present invention is
underneath the prior artkettles, plus it was at a location too shown in FIG. 10, which concerns an improved calcining
hot to be operable. It will be understood that either or both kettle apparatus, generally denoted by reference numeral
such modifications (i.e., flue gas recycling and/or forced 170, but one which has only a single, rather than multiple,
aeration) can be used with the present improved kettle burner tube coil. That is, a kettle 172 (which is shown as
apparatus 20, as desired. circular in cross section, but which can take a teardrop or
Further, instead of using gas-fired immersion tube burners other shape), has a cover 174, a single immersion tube
70, 90, and 106, other sources of heated media (besides burner 176, an initial straight burner tube section 178, and a
heated combination gases) could be used for, i.e., circulated single (i.e., not multiple) burner tube coil 180. The single
in, the tube coils. For example, if the improved calcining 10 burner tube coil 180 (but having multiple coil levels)
apparatus 20 was located adjacentareliable supply of steam, exhausts above, i.e., exteriorly to, the kettle 172 and cover
Such as close to an electric generating plant, for example, 174 via a single exhaust riser tube 182 which connects to a
then steam could be used as the heated media circulated flue stack (not shown).
within the burner tube assemblies 64, 66, and 68. Even other The single burner tube coil-type kettle apparatus 170 of
Sources of heat could be used, such as heated oil. 15 the alternate embodiment of FIG. 10 can be utilized in those
As seen in FIG. 9, an alternate embodiment of the present calcining and gypsum processing and converting operations
invention concerns a differently-shaped calcining kettle where less tonnage output is needed, or where a smaller
apparatus, generally denoted by reference numeral 150, calcining kettle can be used, or where less overall BTU/hour
again provided with a multiple series of burner apparatus. is required. For example, such a modified, single burner tube
That is, the calcining apparatus 150 includes around-shaped 20 coil design could be used in a small capacity kettle having
kettle 152 (in cross section), and similar to the preferred an overall diameter of 5 feet and height of 6 feet.
embodiment's kettle apparatus 20, a multiple series of
vertically-aligned immersion tube burners and associated Nevertheless, although the alternate kettle apparatus 170 of
burner tube coils, the uppermost two of which burners are FIG. 10 has only a single burner tube coil 180, as compared
respectively generally denoted by reference numerals 154 to a series of multiple burner tube coils like used in the
and 155, and the uppermost burner tube coil denoted by 25 preferred embodiment's kettle apparatus 20 and the above
reference numeral 156. Each burner, such as the gas-fired described alternate embodiment's kettle apparatus 150, the
immersion tube burner 154, is mounted to the exterior of the operation, components, materials, and construction of modi
round kettle 152 by a gusseted anchor bracket 158. Each fied kettle 172 remains the same as that of kettle 22 and
burner tube coil, such as the cylindrically-shaped, kettle 152.
horizontally-aligned multi-level upper burner tube coil 156, 30 We turn now to the improved calcining method of the
is mounted interiorly of round kettle 152, yet exhausts present invention, whereby a specific staging, i.e.,
exteriorly of the kettle 152 and its cover 160 via an exhaust positioning, of the immersion tube burners and associated
riser tube 162. An initial straight burner tube section 164 burner tube coils within the kettle helps create a highly
connects the upperburner tube coil 156 through the sidewall efficient, quick start-up, and low maintenance-type continu
of the round kettle 152 to the immersion tube burner 154; 35 ous calcining process.
similarly, straight sections of the remaining ones of the More specifically, during calcining cycle start-up of the
series of underlying burner tube coils (not shown) connect to improved calcining kettle apparatus 20 of the present
their respective exteriorly-mounted burners (not shown, invention, the burners 70, 90, and 106 are turned off. The
except for a partial depiction of the next lower immersion empty kettle 22 is then partially filled, i.e., charged, with
tube burner 155 in FIG. 9). Preferably, the straight sections gypsum34 via feed screw conveyor 36 until it covers burner
164 are formed of stainless steel tubing. Otherwise the tube coil 74. The gypsum 34 being introduced into kettle 22
remaining structure, components, and cycle operation of the is at ambient temperature, i.e., 60-75°F., for example. Due
alternate embodiment's kettle apparatus 150 of FIG. 8 are to the preferably low profile design of the lowestburner tube
the same as that of the preferred embodiment's kettle assembly 64, the initial calcining zone A of kettle 22 is
apparatus 20. 45 relatively squat, and thus can be quickly filled for start-up
Importantly, however, such an alternate round kettle purposes. The lower immersion tube burner 70 is then
design could be used in retrofit situations where an existing energized, whereby the temperature within the burner tube
round-shaped calcining kettle is already present. There, the coil 74 reaches approximately 1,600°F. That continues until
existing jacketing and refractory brickstructure (not shown) the heat transfer via burner tube coil 74 raises the tempera
of an exiting prior art type kettle is removed, and a series of SC ture within that initial fill load of gypsum 34 to the range of
new burners, such as immersion tube burner 154, are exte approximately 290°F. to 310°F, and preferably to approxi
riorly mounted via brackets 158 to the exiting round kettle. mately 300°F. At this point, the middle calcining zone is
Further, a series of burner tube coils, including the upper filled with an additional charge of gypsum 34 until middle
tube coil 156, are interiorly-disposed within the existing burner tube coil 92 is covered. Middle immersion tube
round kettle, such as kettle 152, to be connected via straight 55 burner 90 is then energized, and this larger fill of material 34
tube sections such as section 164 passing through the in kettle 22 is again brought to a temperature of approxi
existing kettle's sidewall. mately 300 F. Then, the final charge of material 34 is
Thus, it will be seen that instead of building a wholly new introduced to allow calcining Zone C to fill up and cover
teardrop-shaped kettle 22 of the preferred embodiment, the over upper burner tube coil 108, which is then energized.
present invention can be built new, or retrofitted in existing Continued operation of the three burners 70,90, and 106, all
kettle structures, into round-shaped kettle configurations. preferably being run at full capacity, cause the entire con
Such retrofits are much more cost-effective, where existing tents 42 of kettle 22 to be maintained in the calcining
kettle structure per se can still be used with the improve temperature range of approximately 290° to 310 F., and
ments of the present invention. Yet even other cross sec preferably at the preferred calcining process temperature of
tional shapes of calcining kettles, instead of teardrop or 65 approximately 300° F. That temperature can be sensed by
round, can be used, as desired, without departing from the well known heat-sensing means, such as thermocouples 146
present invention. mounted in each of zones A, B, and C (see FIGS. 1 and 8)
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11 12
of kettle 22. Then, an ongoing charge of yet additional current residence time. It is further believed that the present
ground gypsum 34 is introduced to kettle input riser 32 via invention's kettle and burner design could even be operated
feed conveyor 36, to commence the continuous calcining to result in a material residence time of only 30 minutes, yet
cycle of the present invention. During the calcining cycle still result in a stucco product of sufficient high uniformity
there is continuous mixing of the contents 42 of the kettle 22 and homogeniety, i.e., minimum of under- or over-calcined
via mixer blade 60a, b, c and scraper bar 62. material.
In operation, as new ground gypsum 34 is introduced to Thus, there are numerous advantages with the improved
kettle 22, its denser weight causes it to fall to the kettle calcining kettle apparatus and method of the present inven
tion. One significant advantage is the highly efficient heat
bottom 26. This, in turn, causes the lighter fully-calcined 10 transfer being provided. That is, rather than losing heat to the
gypsum 42 (which has by now bubbled to the top, as its extra exterior refractory brick wall as occurred (with as much as
moisture content has been driven off via heating into steam a 10% heat loss) with prior art designs which were kettle
and dust through the dust collector supply pipe 39) to then bottom fired, the present invention directs and retains sub
overflow into discharge cone 40 of outlet tube 44. stantially all of the calcining heat (being transferred) within
Thereafter, continued, full capacity operation of burners 70, 15
the kettle and its contents. Further, the increased efficiency
90, and 106, coupled with accurate kettle temperature sens and generally even dispersion of heat transfer occurring
ing and control of the feed discharge rate via feed conveyor throughout the improved kettle apparatus 20, due to the use
36, establishes a continuous calcining process in the of staged coil-type gas immersion tube burners, is expected
improved kettle apparatus 20. The temperature of the cal to result in a higher uniformity of resulting stucco, i.e.,
cined material, i.e., stucco, exiting the kettle 22 via dis calcined gypsum, over prior art designs.
charge cone 40 is approximately 300°F, while the exhaust Additionally, because of the use of substantially evenly
gases exiting the riser tubes 80,92, and 114 is approximately distributed, i.e., staged, multiple burner coils, there is a
500°-600°F. significantly less chance to have hot spots in the kettle and
As seen, due to the above-described, improved calcining to over-calcine the material, and thereby create so-called
method of the present invention, the specific staging, i.e., dead burn material. As known, there was always a chance of
positioning and successive start-up energizing, of the creating dead burn material in the "hot zone” formed around
interiorly-disposed multiple immersion tube burner assem the domed-bottom area in prior art refractory-type kettles, or
blies allows for quick filling and quick start-up of the entire in prior art conical kettles adjacent the submerged combus
tion tube.
kettle apparatus 20. This is in great contrast to prior art kettle With the present improved invention, a dust collector (not
designs, where during start-up the entire kettle's contents shown) must be used, as connected to dust collector supply
(and refractory structure) had to be slowly heated to oper pipe 39 (FIG. 1). However, with the present invention it
ating temperature by one externally applied burner flame. works with substantially cleaner exhaust gases. That is, the
A significant advantage of the present method is that more dust and steam exhaust produced by the present calcining
calcined gypsum tonnage output can be achieved in a given apparatus and method is much cleaner than that of known
kettle space, in contrast to prior art designs. That is, the 35 prior art kettles. For example, it is anticipated that a dust
currently used, refractory-type kettle design of the prior art collector for a kettle made in accordance with the present
normally produces approximately 11 tons of stucco per hour. invention need only handle about 8,000 CFM. of dust. On
In actuality, the limiting factor in most prior art designs was the other hand, with prior art conical kettles having sub
not how much heat could be applied to the kettle, but what merged combustion, for example, the associated dust col
amount of heat the refractory kettle bottom could stand lector must be sized to handle approximately 40,000 CFM of
without unwanted, rapid deterioration. dust. That improvement alone in the present invention can
However, it is expected that the improved kettle design of result in significant energy savings, because of the smaller
the present invention will have a tonnage output of approxi dust collector. Pius there is less initial capital cost in
mately 18-20 tons per hour, for the same size kettle shell as installing the same, as well as reduced ongoing maintenance
used in the current prior art designs. Further, with the present 45 costs.
invention, if even higher capacity burners are used, or a As a further advantage, the present invention's low profile
larger number of multiple burners and associated burner for the initial, lowest burner tube coil permits a shallow
tube coils are used, one can get yet even higher tonnage material charge during cycle start-up. That, in turn, keeps the
output for the same size kettle. For example, with prior art load on the agitator motor at a minimum during cycle
burner and kettle designs, it is known to take approximately 50 start-up.
750,000 BTUs perton of gypsum to calcine gypsum. Thus, It is to be understood that the present invention, while
for 15,000,000 BTUs of heat applied (i.e., 3 immersion tube preferably intended for multi-burner operation (although
burner units at 5,000,000 BTUs per unit), the present inven only one large coil could be alternatively used), is not
tion will likely have at least an output of approximately limited to simply three burners. Neither is it limited to any
specific serpentine-coil design for each of the burner coils,
18-20 tons per hour. Thus, for the same size kettle shell, the 55
present invention should provide approximately twice the or to any specific alignment, such as horizontal, of the burner
hourly tonnage output over known, currently-used prior art coils. Further, the invention is not limited to any specific
kettle designs. Also, the efficiency anticipated with the BTU output per burner.
present design kettle should even lower the current require Besides improved efficiency of calcining processes as
ment of 750,000 BTU's per ton of material to be calcined. expected with the present invention, substantially reduced
The only remaining real limitation then, is what is the initial capital costs in constructing the present improved
required residence time for the gypsum material 42 within calcining process are anticipated, particularly since no
the kettle 22. The current prior art operating optimum often heavily-clad, domed-bottom kettle is required, or any sur
tons per hour results from approximately 80-90 minutes of rounding refractory structure. Further, a shorter building.
material residence time within a known kettle. However, 65 i.e., kettle housing structure, can be built, due to the lack of
with the present improved calcining invention, the residence any of the prior art's exterior burner structure underlying the
time is expected to be only 40–45 minutes, i.e., only half the kettle.
 5,743,954
13 14
Experience with calcining kettle operations has shown then, circulating aheated media through said lower burner
that a substantial percentage, i.e., approximately 90–95%, of tube coil so as to heat said initial gypsum charge;
all maintenance done on prior art refractory-type kettle then, once said initial gypsum charge reaches a tempera
designs was in conjunction with the kettle's dome-shaped ture in the range of approximately 290 to 310 F,
bottom. Yet the present invention totally eliminates such feeding a second charge of ground gypsum material
costly and time-consuming maintenance problems. into said kettle until said upper burner tube coil is
From the foregoing, it is believed that those skilled in the covered;
art will readily appreciate the unique features and advan then, circulating aheated media through said upper burner
tages of the present invention over previous types of meth tube coil so that the entire charge of said gypsum
ods and apparatus for calcining gypsum. Further, it is to be O
reaches a temperature in the range of approximately
understood that while the present invention has been 290° to 300° F and becomes calcined; and
described in relation to particular preferred and alternate
embodiments as set forth in the accompanying drawings and then, maintaining the temperature of said calcined gyp
as above described, the same nevertheless is susceptible to sum in the kettle at a temperature in the range of
change, variation and substitution of equivalents without 15 approximately 290° to 310°F, while introducing more
departure from the spirit and scope of this invention. It is gypsum material into said kettle so that the calcined
therefore intended that the present invention be unrestricted gypsum in said kettle overflows into a recovery means
by the foregoing description and drawings, except as may for receiving said calcined gypsum from said kettle,
appear in the following appended claims. thereby providing a continuous calcining operation.
We claim: 4.The method of claim3 in which said steps of circulating
1. A method of calcining gypsum comprising the steps of: a heated media through said burner tube coils include
feeding ground gypsum into a calcining kettle which circulating heated gasses through said burner tube coils.
includes at least one interiorly-disposed heating means 5. The method of claim 4 further comprising the step of
for circulating a heated media throughout an interior exhausting said heated gasses from the burner tube coils,
chamber of said kettle without allowing said heated 25 said heated gas exhausts exteriorly of said kettle.
media to contact contents in said kettle, said calcining 6. The method of claim 5 in which said exhausting step
kettle further including a plurality of distinct calcining includes exhausting exhaust gasses from said burner tube
zones, each calcining zone having its own interiorly coils through riser pipes connected to a common flue stack.
disposed heating means, and where said heated media 7. The method of claim 6 comprising the further step of
provides the heat required to calcine said kettle's 30 partially recycling said exhaust gasses by removing a por
contents, said gypsum being fed into the kettle until tion of said exhaust gasses from said commonflue stack and
said heating means is covered; recirculating said removed exhaust gasses through said
then, circulating said heated media through said heating gypsum within said kettle so as to further heat said gypsum.
means to heat said gypsum material in said kettle to a 8. The method of claim 2 in which said step of recircu
calcining temperature in the range of about 290° F to
35 lating said removed exhaust gases comprises introducing
about 310 F., so that said gypsum material becomes
said removed exhaust gases adjacent to the bottom of said
kettle.
calcined; 9. The method of claim 3 in which said heated media
then, introducing more gypsummaterial into said kettle to comprises one of heated combustion gases or heated oil or
cause the calcined gypsum in said kettle to overflow Steam.
into a recovery means for receiving said calcined 10. The method of claim 3 comprising the further step of
gypsum from said kettle. mixing said gypsum within said kettle during said step of
2. The method of claim 1 in which said step of introducing maintaining the temperature of said gypsum at a temperature
more gypsummaterial into said kettle includes continuously in the range of approximately 290° to 310 F.
introducing new gypsum material at a rate so that at least 45 11. The method of claim 10 in which said mixing step
approximately 18 tons of said calcined gypsum overflows includes actuating a vertically-extending shaft in said kettle
into said recovery means per hour. which shaft is connected to at least a lower mixing blade and
3. Amethod of calcining gypsum comprising the steps of an upper mixing blade, said mixing blades being respec
feeding an initial charge of ground gypsum material into tively positioned proximal to said lower calcining Zone and
a calcining kettle having multiple calcining Zones, 50 said upper calcining Zone.
including at least a lower calcining Zone, and an upper 12. The method of claim 10 in which said mixing step
calcining zone, which said calcining Zones respectively further includes mixing said gypsum by aerating said gyp
include a lower burner tube coil and an upper burner sum within said kettle.
tube coil, said gypsum being feed into the kettle until
said lower burner tube coil is covered; sk sk