An energy efficient method for making a gypsum cellulose fiberboard
comprising adding a first portion of cellulose fiber to gypsum before the
gypsum and cellulose fiber are co-calcined in a reactor, adding a second
portion of cellulose fiber to the slurry after it leaves the reactor to
form a second slurry, depositing the slurry to form a mat dewatering the
mat, rehydrating the mat and then finishing the mat to form a final
gypsum cellulose fiberboard. A reduction of up to about 40% to 50% of
steam energy used can be achieved when the second portion of added
cellulose fiber is 50% or more of the total cellulose fiber used in the
final board compared to gypsum cellulose board made with the same
ingredients but when all of the fiber is added to the gypsum prior to the
reactor.