Question: What’s the difference between natural gypsum and synthetic gypsum (FGD gypsum) and do they produce the same quality of gypsum panels?

Answer:At their core, both natural gypsum and synthetic gypsum (commonly referred to as flue gas desulfurization or FGD gypsum), are the same chemical compound: calcium sulfate dihydrate (CaSO₄·2H₂O). This shared chemistry is the reason gypsum panels manufactured from either source perform equivalently when it comes to fire resistance, durability and strength.

Natural gypsum is a mineral formed from evaporite deposits laid down millions of years ago when shallow seas dried up. Large deposits are mined across North America and globally. Once extracted, the material is crushed, ground, and calcined to produce stucco for wallboard cores. Natural gypsum’s purity can vary from deposit to deposit, sometimes containing trace amounts of clay, silica, carbonates, or salts. While these impurities do not impair the performance of the final product, they may require adjustments in processing conditions, such as controlling firing temperatures or modifying additives, to ensure uniform quality.

Synthetic gypsum (FGD gypsum) is an industrial byproduct produced in coal-fired power plants equipped with flue gas desulfurization systems. These systems use a limestone slurry to capture sulfur dioxide (SO₂) emissions (which can help reduce air pollution), producing calcium sulfite, which is oxidized to form gypsum crystals. The result is a material that is often very pure, frequently above 95% calcium sulfate dihydrate. Synthetic gypsum is typically uniform in composition and particle size, which can make it more predictable and efficient to use in manufacturing. However, one key difference is that FGD gypsum usually contains higher moisture levels than mined gypsum, meaning it often requires additional drying or dewatering before processing.

Performance and Quality Considerations Because both materials are chemically the same, gypsum panels manufactured from natural or synthetic gypsum have no meaningful differences in structural performance, fire resistance, or longevity. Both conform to ASTM C22 Standard Specification for Gypsum. Any minor differences in particle size distribution or trace impurities are addressed during processing and do not affect the performance of the finished panel.

In short, natural gypsum and synthetic gypsum are functionally interchangeable raw materials. The main distinctions lie in where they come from (geological deposits vs. industrial processes) and in small variations in purity, moisture, and handling during manufacturing. Regardless of origin, both provide a reliable foundation for high-quality gypsum panel production.

Wow!! Good to know this!

It’s great to know that Synthetic gypsum is a by product of coal fire plants. The next question is how has the closing of these plants have impacted the gypsum market.