TEK7 Smart upgrades begin with sharp insight.
Plant Assessment and Feasibility Studies
At TEK7, we believe that meaningful plant improvements can only be achieved through a clear, data-backed understanding of current operations. Our assessment approach is practical, methodical, and focused on uncovering the full potential of your facility. By combining technical expertise with real-world analysis, we lay the groundwork for upgrades that are efficient, reliable, and built to perform.
— TEK7
A successful plant upgrade begins with a comprehensive understanding of the current operating conditions. TEK7’s approach to plant assessment is data-driven, practical, and aligned with international best practices. This phase lays the groundwork for all future engineering, ensuring that proposed modifications are realistic, technically sound, and economically viable.
Engineering Insights and Benefits
Our plant assessment provides a technical foundation for all design and upgrade activities. Key benefits include:
- Improved Decision-Making; Precise field measurements enable tailored engineering solutions.
- Accurate System Design; Precise field measurements enable tailored engineering solutions.
- Risk Reduction; Early detection of bottlenecks and inefficiencies reduces operational and safety risks.
- Cost and Time Optimisation; Efficient planning, accurate scopes, and reduced rework help maintain budget and schedule targets.
- Regulatory Compliance; Site data is reviewed for alignment with applicable environmental and safety standards.
Data Collection and Evaluation
Our team initiates the project by gathering and analysing key data related to material properties, process performance, and system configurations. This includes:
- Chemical and Physical Properties; Detailed analysis of raw materials, green pellets, hearth layer, and fired pellets to establish a complete material profile.
- Operational Parameters; Compilation and review of log sheets, historical process data, and control system screenshots to assess baseline performance.
- Aerodynamic Characteristics; Assessment of fan performance curves (pressure vs. flow, flow vs. power) and evaluation of dust collection systems, including electrostatic precipitators.
- As-Built Documentation; Review of the latest plant drawings, equipment datasheets, and any modifications made to piping, wiring, and structural layouts.
Based on this information, TEK7 prepares a structured site survey plan with clearly defined objectives, measurement points, sampling locations, and a timeline for execution.
Site Survey and On-Site Measurements
TEK7 deploys a specialised engineering team equipped with precision-calibrated instruments to conduct an in-depth plant survey. The survey focuses on key performance indicators and actual field measurements, including:
- Velocity, pressure, and temperature profiling in ducts and process zones
- Gas composition and dust load across the system
- Fan efficiency and power consumption verification
- Pellet property sampling and analysis (green, hearth layer, fired)
- Evaluation of process gas cleaning performance
- Air/gas leak detection and thermal efficiency checks
- Condition assessment of mechanical systems and critical components
- Review and validation of electrical and mechanical documentation
All measurements are performed using TEK7’s proprietary mobile testing equipment, ensuring full control over data quality and test integrity.
