Rocktec partnered with Thiess Pty Ltd to supply two purpose-built filter cake belt feeders for the Onesteel Project Magnet in Whyalla, South Australia. Designed for performance and durability, these belt feeders play a vital role in the safe, efficient handling of filter cake material under high-load conditions.
Project Overview: Filter Cake Belt Feeders for Project Magnet
- Client: Thiess Pty Ltd
- End User: Onesteel (Project Magnet)
- Location: Whyalla, South Australia
- Industry: Mining & Materials Handling
- Scope: Supply of two filter cake belt feeders
- Timeline: Less than 4 months from design to build
The Challenge: Efficient Filter Cake Handling in Harsh Conditions
Thiess required a belt feeder system capable of handling dense, heavy filter cake material with precision and reliability. Moreover, the solution had to operate in a harsh, high-dust environment while minimising downtime and wear. The feeders needed to ensure continuous flow and withstand the challenges of load surges and moisture variation—common in mineral processing.
Rocktec’s Solution: High-Capacity Filter Cake Belt Feeder System
Rocktec delivered two filter cake belt feeders engineered for strength, precision, and reliability. Each unit featured:
- 2.1m wide by 15.5m long belt system
- Nominal feed rate of 140 tph, with a maximum capacity of 200 tph
- 11kW drive for consistent, controlled throughput
- Impact rollers to support load carrying and resist shock
- Stainless steel hopper chute for corrosion resistance
- Ceramic lagged head drums to reduce slippage and wear
- Automated pneumatic belt tracker for continuous alignment
Additionally, the feeder frames were constructed from mild steel to provide strength and stability, while critical contact areas were upgraded with stainless steel for improved hygiene and durability.
Implementation Timeline: Built Fast, Built Right
- Engineering: Rocktec worked closely with Thiess to finalise technical specs for throughput, flow control, and material compatibility.
- Fabrication: All components were manufactured at Rocktec’s New Zealand facility under strict quality control.
- Delivery: Despite tight deadlines, both units were built and delivered within four months—ready for rapid installation and commissioning.
Results and Benefits
- Throughput: Delivered consistent 140–200 tph filter cake feed to downstream processing equipment.
- Durability: Withstood abrasive conditions with minimal maintenance requirements.
- Precision: Automated belt tracking system reduced misalignment and wear over time.
- Fast Turnaround: Project delivered in under four months—helping the client stay on schedule.
Conclusion: Built for Demanding Mineral Environments
This project demonstrates Rocktec’s ability to deliver customised belt feeder systems on time and to spec. By combining advanced materials, automation, and practical design, the solution enabled Thiess and Onesteel to optimise material flow while minimising downtime at their Whyalla operation.
Want to Learn More?
To explore belt feeder design strategies and best practices, visit Australian Bulk Handling Review.
If you need a high-capacity belt feeder or customised materials handling solution, contact Rocktec to discuss your requirements.