Gypsum, Drywall & Interior Panel Manufacturing worked example

Calcination Energy with calciner connected load of 6 kW: a worked example in gypsum, drywall & interior panel manufacturing

This worked example runs the calcination energy numbers for a tougher week than the baseline: calciner connected load of 6 kW instead of the typical 12 kW. Estimate calcination energy cost per ton of stucco based on calciner connected load, runtime, energy tariff, and stucco throughput.

The inputs for this scenario

  • Calciner connected load: 6 kW (the input this scenario stresses; the baseline uses 12)
  • Calciner runtime: 8 hr (held at the documented default)
  • Energy tariff: 0.12 $ / kWh (held at the documented default)
  • Stucco tons processed: 1,000 tons (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Total calcination energy cost = calciner connected load x runtime x energy tariff.
  • Energy cost works out to 5.76 $ / ton at these inputs, and this is the headline figure for the scenario.
  • Energy used works out to 48 kWh at these inputs.
  • Cost per piece works out to 0.01 $ / piece at these inputs.
  • Hourly cost works out to 0.72 $ / hr at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where calciner connected load sits at 12 kW and the headline result is 11.52 $ / ton, this scenario comes in 50% below the baseline at 5.76 $ / ton.
  • Use it for shift energy tracking, comparing kettle vs. flash calciner efficiency, or quantifying the savings from a tariff change or heat-recovery upgrade. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Energy cost: 5.76 $ / ton (headline result)
  • Energy used: 48 kWh
  • Cost per piece: 0.01 $ / piece
  • Hourly cost: 0.72 $ / hr

Run it with your numbers

  • To rerun this with your own numbers, open the live Calcination Energy calculator, set calciner connected load to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.