Rocktec, a reputable industry leader in New Zealand for over 20 years, expanded operations into Australia by setting up a facility near Brisbane in 2009 to provide contract maintenance support in major aggregate processing plants.
Since then, it has evolved its operation to provide a complete design and build capability. It has recently overseen a major plant extension for Southern Quarries in South Australia and has almost completed a turnkey crushing and screening plant for Boral in Victoria.
Rocktec?s philosophy includes a thorough evaluation of process and development of flow. It uses the best independent simulation programme, in conjunction with ongoing client input, to ensure that the concept proposed is 100 per cent suited to the required duty and will meet the client?s required performance parameters.
The plant design is executed with 3D modelling by a team of trained, experienced engineers who use their expertise to design out maintenance and wear. A 15 per cent or more reduction in maintenance can be achieved by attention to, for example, transfer points and chutes, where trajectory points and velocity are analysed in order to prevent wear by repositioning conveyors, introduction of rockboxes/dead pockets, and the use of the optimum type of liner to resist abrasion, impact, or a combination thereof. Reduction of maintenance is reflected by a significant increase of availability and is complemented by the provision of ample and free access for maintenance, etc, all of which increase operational profit.
Careful selection of manufacturing sources internationally enables Rocktec to provide significant cost reductions of cost per tonne, with no consideration of any compromise on weight or quality. All manufacturing is carried out under Rocktec supervision and to its own onerous standards, surpassing those imposed for Australia and New Zealand.
The design of the conveyor system, often regarded as ancillary to the process, is carefully sized and designed. All components are selected to be reliable/durable in operation.
Rocktec believes that operational efficiencies achieved by adhering to the supply of quality components will yield ongoing, long term economies in the form of reduced running costs, long into the future. Another example is that all Rocktec conveyor drives are adequately sized to enable, at a minimum, full load starts at any time. Rocktec?s policy on structural steel and selective sourcing enables it to maintain competitive prices yet supply the high standards demanded by its clients.
STRATEGIC PARTNERSHIPS
Further to the above measures, Rocktec has entered into strategic partnerships with reputable equipment suppliers of diverse types and locations to complement the existing design and build capabilities with the finest, most comprehensive range of process equipment available.
An example is ERAL SA, a Spanish family-owned company with a pedigree of over 30 years in the design and supply of tailored technical solutions for the treatment of clays and silts, mineral and sand treatment, waste minimisation and handling of difficult waste materials.
This association provides a unique talent and strength for the Australasian quarrying industry. As well as the wealth of application and technical support, ERAL?s products include washing drums, modularised hydrocyclones, sieve bends, clarifiers and thickeners, and filter presses. The ERAL range fits in with Rocktec?s own Flowmax system, which offers efficient, high-volume and environmentally friendly treatment of sludges, silts and other fines.
Rocktec can supply a wide selection of feeders and screens ? including horizontal, inclined, multi-deck and dewatering feeders and screens ? to handle all duties from primary run of quarry handling to fine sands and minerals separation. The range, manufactured by International Combustion (India) Ltd, includes the high energy Omniscreen, capable of up to 7g in acceleration under normal operations. Like all Rocktec equipment, maintenance is reduced, as the design incorporates an adjustable vibrating mechanism, all mounted outside the screen frame to eliminate the possibility of wear from impact or abrasion.
Rocktec?s selection of crushers – eg jaws, rolls, cones, HSIs, VSIs – are also of innovative design and constructed to the highest standards to afford many years of reliable and efficient operation.
ADVANCED CONTROL SYSTEMS
No strategy for high quality plant and simplified operation is complete without a reliable, advanced control system. Rocktec incorporates well recognised control and switchgear into its plant control panels, which are based on the PC/PLC Scada control system of the whole plant. This includes the full technical integration of all quarry plant and associated equipment, as agreed with clients.
Rocktec is now equipped to provide complete plant solutions to all quarrying applications, incorporating optimised process equipment, computer-assisted design and manufacture, robust and well designed and built machines, and state of the art controls.
Source: Rocktec