Engineering Design

Our engineering design philosophy centers on producing an efficiently upgraded plant that meets or exceeds all performance guarantees and warranties. By combining rigorous assessment, innovative design, and advanced technology, TEK7 provides future-proof solutions that optimise productivity, reliability, and sustainability.

Process Engineering

• Process Assessment and Analysis; We begin by thoroughly assessing the existing pelletising process to identify bottlenecks, inefficiencies, and potential improvements. Key Performance Indicators (KPIs) such as production capacity, energy consumption, product quality, and compliance with safety and environmental regulations are carefully evaluated.
• Process Design and Optimisation; Our engineers develop optimised process flow diagrams (PFDs) and conduct detailed heat and material balances. Using advanced process simulations and modelling, we evaluate multiple scenarios to refine process parameters, enhance productivity, and ensure product quality while identifying opportunities for waste reduction and energy recovery.
• Equipment and Technology Selectionn; We review the performance and condition of existing equipment and recommend upgrades or replacements tailored for reliability, throughput, and ease of maintenance. Our design integrates cutting-edge technologies, including improved screening, burners, and pelletising systems, balancing efficiency with environmental impact.
• Process Control and Automation; TEK7 evaluates existing control systems and implements robust control strategies that optimise plant operation and product quality. Our design includes the specification and integration of advanced instrumentation, data acquisition systems, and comprehensive automation to enhance process stability and responsiveness.
• Environmental Considerations; Our designs proactively address environmental impacts by proposing solutions to minimise emissions, water usage, and waste. We optimise dust control, noise reduction, and water treatment systems to ensure compliance with local regulations and promote sustainable operations.

Mechanical Engineering

• Equipment Assessment and Analysis; We conduct detailed evaluations of all mechanical equipment, reviewing their condition, capacity, and maintenance history. This insight allows us to identify performance bottlenecks and recurring issues that could compromise plant reliability.
• Equipment Selection and Upgrades; Based on our assessments, we recommend upgrades or new equipment that improves productivity, reliability, and maintainability. Collaboration with suppliers ensures that selected equipment meets quality standards and integrates seamlessly into existing infrastructure.
• Plant Layout and System Design; TEK7 develops optimised layouts to improve workflow, safety, and accessibility. This includes efficient design of material handling systems such as conveyors and storage facilities to maximisethroughput and operational flexibility.
• Maintenance Accessibility and Reliability; Designs incorporate features to enhance maintenance access and minimise downtime. We recommend predictive maintenance strategies and condition monitoring systems that proactively address equipment health and extend asset life.

Electrical Engineering

• Electrical Systems Assessment; We assess the existing electrical infrastructure, including distribution systems, switchgear, and motor control centers, focusing on capacity, reliability, and safety.
• Electrical Design and Upgrades; TEK7 designs electrical upgrades to support increased power demands while enhancing system reliability through redundancy and fault tolerance. We optimise power distribution to minimise losses and improve energy efficiency.

Instrumentation and Control Engineering

• Assessment of Existing Systems; Our team evaluates the performance and architecture of current instrumentation and control systems, including sensors, transmitters, DCS, and PLCs, to identify improvement areas.
• Control System Upgrades; We design and implement advanced control solutions to improve process control accuracy, data acquisition, and monitoring. Our approach incorporates modern control strategies and automation to boost operational performance and energy efficiency.

Civil and Structural Engineering

• Site Evaluation and Planning; TEK7 assesses existing site layouts and structures, identifying areas suitable for expansion or modification to support upgrade activities.
• Structural Assessment and Design; Our engineers conduct structural evaluations and develop designs or sketches for modifications or new structures necessary for equipment installation and process improvements.

Piping and Utility Engineering

• Utility Analysis and Design; We assess utility requirements such as water, compressed air, steam, and cooling water, designing efficient distribution systems to reliably serve plant needs.
• Piping System Design; In collaboration with process engineers, we design piping networks optimised for flow, pressure, and temperature conditions, selecting materials based on corrosion resistance and process compatibility.

The final outcome of our design work is the preparation of comprehensive, well-structured engineering documentation packages specifically tailored for the upgrading project. These documents serve as the critical reference points for procurement, construction, commissioning, and ongoing operations, ensuring clear communication, effective collaboration, and seamless knowledge transfer among all project stakeholders.

With TEK7’s proven expertise and multidisciplinary engineering design capabilities, your upgrade project will be expertly planned and executed, delivering a safe, reliable, and high-performance pelletising plant fully prepared to meet future demands.