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Feiring Bruk, Norway

Case study

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CDE wet processing plant reduces fines by 88% for Norwegian aggregates producer Feiring Bruk.

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A common problem for sand and aggregate processors is finding an outlet for the large volumes of 0-20 produced. Feiring Bruk, a leading Nordic aggregates producer, found the solution through the introduction of a CDE wet processing plant at their quarry in Lørenskog, Norway.

Feiring Bruk is a family owned business operating primarily in eastern Norway where it has 10 sites extracting and producing crushed stone, gravel, and asphalt. The company also works across Norway for clients using their mobile crushing and screening plants. The modular and mobile nature of the CDE equipment was, therefore, appealing to Feiring Bruk allowing flexibility should they wish to transport the plant to another site.

Why Wet Processing?

Using their previous system Feiring Bruk were unable to successfully process or sell the fines and had built up stockpiles of several hundreds of thousands of tonnes at Lørenskog alone. Trygve Ollendorff, CEO explains, “We had a massive warehouse filled with material we had been unable to exploit and which previously would have been deposited. With the new facility, we get washed out particles of zero size and can recover a range of new products.”

Tormod Wæhle, Technical Manager at Feiring Bruk

We are processing 0–20 left over from previous production. Many plants struggle with the finest fraction, 0–4, and it is often difficult to do anything with it. Using the washing plant, we are able to make use of a very large proportion of the excess product. We struggled to sell fraction 4–16 as drainage gravel because customers are wary of there being fines within it. But here we are able to wash fraction 4–16, which gives a completely different and attractive product.

The CDE Wet Processing Plant

CDE Gravel Wash Plant in Norway - Feiring Bruk - CDE Projects

The washing plant was designed specifically to Feiring Bruk’s requirements using the CDE co-creation approach which sees engineers work closely with the customer throughout the design and commissioning process. The plant comprises an M2500 E5X mobile washing plant with integrated hopperfeed conveyor and P3-75 Infinity screen and EvoWash sand washing plant.

For water processing, there is an AquaCycle thickener with automatic dosing station, AquaStore water storage tank and a secure control station.  The M2500 E5X is the latest model in the M-Series which can produce up to five different products and includes CDE patented Infinity screening technology.

The Feiring Bruk machine has the extra significance of being on display on the CDE Stand at Bauma 2016. After the event, the plant was transported to Norway for installation and began production at the start of August 2016. With the current material, the plant is processing 150 tonnes per hour and with optimum feed material this will be as high as 200 tonnes per hour.  Laboratory tests carried out by Feiring Bruk have provided compelling support for the success of the project. 

“After a series of analysis, we have determined that our system washes out 88% of the fines. Before washing the material contains 65kg of fines per tonne, whereas the washed product has just 8kg of fines per tonne. In fraction 0–20, they have measured 6.5% fines before washing. After washing, the fines content is reduced to 0.75%.” reports Petter Hamborg, Laboratory Technician at Feiring Bruk.  

Products In Demand

There are several areas of application for the washed material. For example, washed fine sand can be used for asphalt and concrete production, cable sand or paving stones. Many contractors use fraction 2–4 under paving stones, but fraction 0–2, which is almost free of fines, can serve as a good and cheaper alternative. The products have attracted the attention of many new potential customers, one being a cable provider who needed a product which was accurately graded with the ability to transport away heat. 

“Most of our customers want drainage gravel in fraction 8–16 to avoid fines. Now we can supply excellent drainage gravel in fraction 4–16 that has been washed and is free of fines. We are thus making better use of the raw materials” says Co-Owner Knut Harald Ollendorff.

The washing plant has been operating since August 2016 and Feiring Bruk continue to enjoy the benefits as the system is allowing them to operate more efficiently and enter new markets. Over the long term, the plant will also ensure the company is a leader in environmental best practice. “The plant is both innovative and productive while opening new revenue areas. We are clearly enthusiastic” concludes Trygve Ollendorff, General Manager. 

Saving Water

Water Treatment System - CDE Global

Photo by Håkon Hoseth

CDE systems are designed to recirculate up to 90% of water used, helping to reduce the volume of fresh top-up water required. In addition to the water conserved within the system, the Feiring Bruk plant has been placed on a sloped asphalted surface which allows water to flow into the water basin which has been created to act as a reservoir, creating almost a closed system. 

The plant obtains water resources from its own borehole and water is recirculated so that water loss is minimal. Trygve Ollendorff describes the process, “Through several steps sifted different factions of the masses, until we are left with a mass similar to thin yogurt. This mass contains fines (<0,063mm) is filtered out and the water is recycled.” 

Feiring Bruk has also considered their long-term environmental strategy when investing in the new plant. “It allows us to make better use of our resources. It’s good for us, and for society and the environment” says Knut Harald Ollendorff, co-owner of Feiring Bruk.

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