NuGyp™ ROI Examples

Plant Situation Descriptions

  1. Small older plant , rock, few additives, low gas price, breaking even
  2. Small renovated plant , rock, additives to run faster, average gas cost, breaking even
  3. Small renovated plant , DSG, some additives to run faster, average gas cost, breaking even
  4. Large new plant, rock, flash calciners, few additives, low gas price, marginally profitable
  5. Large new plant , DSG, additives to run faster, average gas cost, marginally profitable
  6. Large new plant , DSG, flash calciners, some additives to run faster, average gas cost, marginally profitable

Easy Target

Represents the savings and additional revenue that should be available with minimal changes to current operations.

Stretch Target

Represents the savings and additional revenue that should be available if the plant is able to take advantage of the newly available very low water demand stucco through improved evaporation, plant efficiency and production capacity.

Plant Situation - Imperial Units
  1 2 3 4 5 6
Line Speed (ft/min) 240 280 260 475 525 500
Board Weight (lb/msf) 1625 1625 1625 1625 1600 1615
Evaporation (lb/msf) 850 770 800 820 750 790
Gypsum Cost ($/ton) 20.00 20.00 7.00 20.00 7.00 7.00
Dispersant Cost ($/msf) 0.50 2.50 1.50 0.50 2.00 1.00
Dryer Efficiency
(Btu/lb of water evaporated)
1750 1650 1650 1500 1500 1500
Gas (Energy) Price ($/MMBtu) 5.00 9.00 9.00 5.00 9.00 9.00
Soluble Anhydrite % 8 8 20 20 20 20
Current Overhead Cost
(unit cost 1/2" basis, $/msf)
10.00 12.00 10.00 12.00 12.00 12.00
Current before tax profit
(unit cost 1/2" basis, $/msf) )
- - - 10.00 10.00 10.00
Plant Situation - Metric Units
  1 2 3 4 5 6
Line Speed (m/min) 73 85 79 145 160 152
Board Weight (kg/m2) 7.93 7.93 7.93 7.93 7.81 7.89
Evaporation (kg/m2) 4.15 3.76 3.91 4.00 3.66 3.86
Gypsum Cost ($/tonne) 22.05 22.05 7.72 22.05 7.72 7.72
Dispersant Cost ($/m2) 0.005 0.027 0.016 0.005 0.022 0.011
Dryer Efficiency
(kJ/kg of water evaporated)
4070 3838 3838 3489 3489 3489
Gas (Energy) Price ($/GJ) 4.74 8.53 8.53 4.74 8.53 8.53
Soluble Anhydrite % 8 8 20 20 20 20
Current Overhead Cost
(unit cost 12.7mm basis, $/m2)
0.11 0.13 0.11 0.13 0.13 0.13
Current Before Tax Profit
(unit cost 12.7mm basis, $/m2)
- - - 0.11 0.11 0.11
Plant Profit Improvement at full plant utilization in million dollars per year.
Improvement Easy Target ($US) 0.69 1.24 0.92 1.11 1.53 1.34
Improvement Stretch Target ($US) 3.89 5.24 4.36 9.11 9.54 9.74