Conical Kettle System Design
ideas* were commissioned by Boral to complete the design and construction planning for a new conical kettle system in Port Melbourne.
The main purpose of the project was to replace the main kettle (no. 1) with a continuous conical kettle. The kettle converts Gypsum to stucco via a process called calcination.
The kettle and all associated auxiliary equipment will be replaced to upgrade the production from a batch to a continuous process.
The new kettle system design includes new screw conveyors, chutes and a dust collection and control system from the screw conveyor infeed through to the outfeed silos.
The new design will provide significant benefits, including:
- Continuous production rather than a batch process.
- Reduction of manual intervention.
- A system capacity of 20 tph in-feed land plaster, 17 tph out-feed stucco and 35 tph dust collection & return.
NOTE: The CAD model above shows the existing equipment and infrastructure (shaded grey) with the new system (shown in green and yellow).