TEK7 Visualise the unseen. Optimise with confidence.
Computational Fluid Dynamics (CFD)
At TEK7, Computational Fluid Dynamics (CFD) is a cornerstone technology for modernisingand optimising brownfield pelletising plants. Our expert team uses CFD to simulate complex fluid and thermal behaviours within your plant, turning real operating data into clear, actionable insights. By accurately modelling airflow, heat transfer, and process interactions, we reduce risk and support smarter, data-driven decisions that maximiseperformance, efficiency, and reliability throughout your upgrade journey.
— TEK7
At TEK7, Computational Fluid Dynamics (CFD) plays a pivotal role in the modernisation and optimisation of brownfield iron ore pelletising plants. As a leading authority in CFD applications for the pelletising industry, our team leverages this advanced analytical tool to gain deep insights into the complex fluid, thermal, and mass transfer phenomena that drive plant performance. CFD (1D, 2D and 3D) enables us to simulate, visualise, and evaluate real world operating conditions in a virtual environment reducing uncertainty, minimising risk, and supporting data-driven decision-making throughout the project lifecycle.
CFD in Action: TEK7’s Advanced Application
Our CFD methodology begins with the development of a high-fidelity 3D model of the plant, including the entire wet area (or “void” spaces) which are the zones responsible for channeling process gases from fans to exhaust stacks. TEK7 conducts a 1:1 scale simulation of the indurating furnace, incorporating actual plant data and real boundary conditions to ensure precision and relevance.
This detailed CFD study allows us to:
- Diagnose root causes of performance limitations, such as airflow imbalances, localized overheating, or sub-optimal heat recovery.
- Evaluate the effectiveness of existing process fans and identify opportunities to improve pressure uniformity, airflow distribution, and energy efficiency.
- Optimise drying and induration processes by simulating pellet bed behaviour, temperature profiles, gas flow paths, and moisture removal rates across various operating scenarios.
- Model the interaction between combustion chambers, recuperation hoods, wind-boxes, and pellet beds, ensuring optimal thermal efficiency and uniform hardening of pellets.
By synchronising CFD results with real-time plant operating data and on-site measurements, we are able to validate assumptions, improve model accuracy, and propose targeted, implementable improvements that align with the client’s upgrade strategy.
Strategic Benefits of CFD in Pelletising Plant Upgrades
- Process Optimisation; Enables precise control over drying and induration conditions, leading to improved product quality and reduced energy usage.
- Design Validation; Provides assurance that proposed upgrade designs will function as intended before physical implementation.
- Troubleshooting Support; Helps identify and address elusive operational issues that cannot be easily observed through physical inspections alone.
- Long-Term Reliability; Supports predictive maintenance and improved asset lifecycle management.
CFD is more than a simulation tool; it’s a strategic enabler. With TEK7’s deep domain expertise and advanced computational capabilities, clients can confidently modernise their pelletising operations, unlocking new levels of performance, reliability, and efficiency.
