Rocktec designed and built a heavy-duty belt feeder for Downer EDI Engineering Power Pty Ltd, supporting OneSteel Manufacturing’s Iron Baron LGO Beneficiation project in Whyalla, South Australia. Engineered for consistent iron ore handling, this feeder offers durability, efficiency, and minimal maintenance in demanding mining environments.
Project Overview: 12.75m Belt Feeder for Iron Baron
- Client: Downer EDI Engineering Power Pty Ltd
- Location: Whyalla, South Australia
- Industry: Mining / Iron Ore Processing
- Scope: Design, manufacture, and delivery of a belt feeder with 200 tph capacity and heavy-duty scrapers
The Challenge: Consistent Feeding Under Harsh Mining Conditions
The Iron Baron project needed a belt feeder capable of reliably handling iron ore up to 40mm in size. It had to maintain a minimum feed rate of 200 tonnes per hour while withstanding abrasive material flow and coastal environmental exposure.
Rocktec’s Solution: Custom Heavy-Duty Belt Feeder Design
Rocktec engineered a tailored system built for high reliability and reduced downtime, featuring:
- 12.75m length and 1800mm wide belt for smooth material handling
- Installed 15kW drive motor to maintain consistent belt speeds under heavy loads
- ESS Primary and Secondary Belt Scrapers for efficient belt cleaning
- Return belt vee plough preventing carryback and improving housekeeping
- Rugged structural frame designed for long service life in harsh mining environments
The system provides reliable feeding performance while keeping maintenance easy and operating costs low.
Installation and Commissioning
- Design Phase: Rocktec collaborated with Downer EDI and OneSteel to finalise feeder specifications and layout integration.
- Fabrication: The belt feeder was built at Rocktec’s Matamata facility with strict quality controls.
- Installation: The unit was installed onsite and connected seamlessly to existing iron ore processing systems.
- Commissioning: Final testing confirmed the feeder achieved throughput targets and belt tracking efficiency immediately.
Results and Benefits
- High Throughput: Reliable material flow at 200 tph with minimal stoppages.
- Reduced Downtime: Scraper systems and vee plough minimise material buildup and wear.
- Durable Construction: Heavy-duty materials ensure a long service life, even in abrasive conditions.
- Efficient Operation: Integrated cleaning systems help lower maintenance intervals and operational costs.
Conclusion: Rugged Belt Feeder Built for Iron Ore Handling
This belt feeder project demonstrates Rocktec’s expertise in designing robust, efficient solutions for heavy mining applications. At Iron Baron, the new feeder ensures reliable material flow, improved housekeeping, and long-term operating reliability.
Want to Learn More?
To explore more about belt feeder systems or heavy-duty material handling solutions, visit the QuarryNZ website.
If you’re planning a feeder installation or upgrade, contact Rocktec to discuss your project.