Feiring Bruk invests in a new CDE crushing and washing plant
The problem
Natural sand is the most consumed natural resource after water, and in some places this non-renewable resource is already in short supply. At the same time, crushed stone quarries face a recurring problem in that around 20 % of their output consists of low value “waste” materials for which it is difficult to find a use.
Feiring Bruk was looking for a way to maximise the potential of its Bjønndalen quarry by utilising 100 % of what is extracted and recover old residual masses from the crushing operations. Most importantly, the company needed to produce industrial (or manufactured) sand that has the same properties as natural sand to use in concrete production.
The solution
Feiring Bruk invested in a new crushing and washing plant designed and supplied by CDE and their Norwegian partners, Nordic Bulk, to wash by-product materials from crushed stone production and produce high-quality industrial sand.
With a processing capacity of 300 t/h, the plant incorporates an EvoWash™ sand washing system and a full water management system, as well as two high-volume WIMA screens at the top. Thanks to its advanced hydrocyclone technology the EvoWash provides unparalleled control of silt cut points which guarantees in-spec sand straight from the belt. In addition, the combination of an AquaCycle™ thickener for primary stage water management and a filter press for sludge dewatering allows the for efficient water recovery and reuses up to 95 % of the process water in the process. “It costs money to do the right thing. But for those of us who live to improve resource utilisation, we could no longer see these surplus masses lying unused. A surplus product, often considered waste, has been turned into gold,” said Fredrik Brubakken, head of department at Bjønndalen Bruk.
The results
The plant produces 2 sands in 0 – 2 mm and 2 – 4 mm fractions and 4 gravels in sizes 4 – 8 mm, 8 – 11 mm, 11 – 16 mm and 16 – 22 mm. The 0 – 4 mm sand goes mostly into asphalt products, mostly for road gritting in winter while the 0 – 2 mm is in-spec manufactured sand for concrete production.
The new washing facility means that Feiring Bruk will be able to utilise 100 % the extracted material and recover stockpiles of old residues from crushing operations. It makes it possible to produce an industrial sand that has the same or even better properties as natural sand for use in the concrete industry, the biggest user of natural sand. It’s a win-win both in terms of resource use and the emissions associated with transport.
In addition, the CDE washing plant has boosted production on site and improved sand quality, opening up new business opportunities for Feiring Bruk, including a contract with a nearby concrete plant to supply industrial sand and the supply of sand to asphalt producers who would normally have to buy natural sand.
