Rådal, Norway

Fana stein & gjenvinning AS was established in 1954 and supplies crushed stone and gravel products, as well as recycling and landfill services, to the building and construction industry in Norway. They were seeking a solution to reuse materials while also extending the lifespan of the landfill at Stendafjellet.

Fana stein og gjenvinning has built a new washing plant in Rådal in collaboration with Nordic Bulk. The plant opened in November 2024 and is expected to produce 100 000 tons of recycled materials per year. These are planned to be sold to the market in Bergen and the surrounding area.

The Challenge

FSG extracts stone products for the construction industry from Stendafjellet outside Bergen. After these products have been extracted from the mountain halls, the halls are used as a landfill for contaminated masses/products.

This has been a good solution for FSG, but the landfill has increased considerably over time. Therefore, the new washing plant supplied by Nordic Bulk in collaboration with CDE will make it possible to wash the contaminated masses and reuse 80% of them. This eases the pressure on the landfill in Stendafjellet and extends its lifespan, while at the same time creating a good circular economy for FSG in that contaminated masses that previously went to landfill can be converted into fresh products for sale.

The solution

Compact design

According to project manager Steen Sanddahl, one of the biggest challenges in the project was related to the installation of the plant. A plant of this size requires a certain amount of space for installation and operation, but limited space at the site made the task more complicated. One example of this was the challenge of installing the filter press, which is located in an existing building. Nordic Bulk was thorough in their planning and maintained a good dialogue with the customer, which ensured a good installation process and a good result despite the limited space in the area.

The washing process

Washing begins with the contaminated masses being fed onto a conveyor belt where they are washed and sorted into different fractions. High-pressure water sprays the product, while the masses are scrubbed against each other to remove any adhesion and floating waste (wood, plastic, etc.).

Water and fines from the washing process are led to a separator (Aqua Cycle). In the separator, flocculant is added to sediment out as many particles as possible before the sludge is pumped to a sludge tank. The particle phase from the separator will be pumped to a sludge tank and then on to a filter press. In the filter press, additional water is removed so that the waste becomes dry sludge (filter cake). Contaminated sludge (filter cake) is transported to the landfill in Stendafjellet.

The plant is equipped with a CFCU and two EvoWash units, which ensure efficient washing of 0-2 fractions. Using this technology, the material is washed to a high standard, ensuring that the end product is of a consistently high quality. This means that the end product can be used for e.g. concrete, where the quality of the material is crucial in order to be sold on.

The plant produces aggregates with the fractions 0-2, 0-8, 2-4, 2-8, 4-8, 8-16, 16-32 and 32-80.

Purification and reuse of water

The water in the washing plant for contaminated product is reused. A water treatment plant has been installed to help further remove contaminants in the process water. The water passes through the treatment plant before being pumped back to the process water tank.

The roof water from the building above the washing plant is collected and can be used when needed, or discharged as clean water to the municipal water network.

The results

Reduced load on landfill and increased service life

The new facility allows FSG to reduce the amount of waste/contaminated materials that previously went to landfill. This extends the life of the landfill considerably.

Efficient circular economy

The washing plant also enables the reuse of up to 80% of the contaminated masses, providing an alternative to the extraction of new resources and contributing to a more sustainable construction industry. This is good for both the environment and the economy.

Steen Sanddahl, project manager for the new washing plant from Nordic Bulk, says: “It has been fantastic to be involved in this project from planning, to installation and start-up of the plant. Despite the limited space, we have developed a compact and space-efficient solution that delivers high-quality recycled materials.”

Steen adds, “We are convinced that this washing plant will help strengthen FSG as a leading player in crushed stone and gravel products, as well as services in landfill and recycling of masses in the region.”

Joar Hovda, Environmental Manager at FSG said: “We are very pleased with the solution Nordic Bulk has delivered. The new facility meets our needs for efficient reuse of contaminated soil and rock masses, which previously went to our landfill. FSG is proud to have put in place a modern, environmentally and economically sustainable solution for the long term.”

Advantages

  • Reduced load on landfill.
  • Better for the environment.
  • Improved circular economy.
  • New revenue stream from the sale of what was previously considered waste materials.