TEK7 SERVICES
Combustion Technology
Solutions
Custom Burner Design and Development
TEK7 specialises in the design and development of custom industrial burners engineered to meet the specific requirements of each client’s process. Our burners are developed with careful consideration of factors such as fuel composition, heat input demand, flame shape and stability, emissions performance, and system integration.
We begin with a detailed evaluation of process conditions, including operating temperature ranges, chamber geometry, flow dynamics, and load variability. Based on these inputs, our engineering team develops burner concepts that are optimised for efficient combustion, high thermal transfer, and safe, stable flame characteristics.
Our burner development process includes Computational Fluid Dynamics (CFD) modelling to simulate combustion behaviour, optimise flame geometry, and predict temperature profiles and pollutant formation. This is followed by prototype fabrication and performance testing under controlled and representative conditions to validate functionality and refine the design.
TEK7’s custom burners are designed for high turndown ratios, uniform heat distribution, and compatibility with various fuels including natural gas, hydrogen blends, and alternative or process-derived fuels. Special attention is given to materials selection and cooling strategies to ensure longevity under high thermal loads.
All burner designs are developed with ease of maintenance, mechanical robustness, and compliance with relevant safety and environmental regulations in mind. Our custom solutions support both new installations and retrofit applications, helping clients achieve operational efficiency, emissions reduction, and long-term reliability.
Combustion System Integration and Upgrades
TEK7 provides complete solutions for the integration and retrofit of combustion systems into both new and existing industrial furnaces, kilns, dryers, and thermal processing units. Our services cover the entire lifecycle of combustion system implementation, from concept design through to commissioning and optimisation.
For new systems, we work closely with process, mechanical, and control teams to ensure that the combustion system is seamlessly integrated into the plant’s architecture and process flow. This includes defining burner placement, air and fuel supply routing, heat recovery considerations, and safety system interfaces.
In retrofit applications, we assess the existing system’s performance, constraints, and structural limitations. Our team develops engineered upgrade strategies that improve combustion efficiency, reduce fuel consumption, and meet stricter emissions standards, all while minimising disruption to plant operations.
We apply advanced simulation tools such as CFD and thermal analysis to evaluate heat distribution, flame behaviour, and flue gas flow. These insights inform the selection of appropriate burner technology and control strategies, ensuring stable operation and optimised performance under real-world conditions.
TEK7’s integration and retrofit solutions are tailored to each facility’s specific needs, with a focus on improving reliability, enhancing safety, and extending the operational life of the plant’s combustion infrastructure.
CFD-Based Combustion Modelling and Optimisation
TEK7 applies advanced Computational Fluid Dynamics (CFD) to analyse and optimise combustion systems with a high level of precision. CFD simulations provide detailed insight into flame behaviour, heat transfer, fluid flow, and pollutant formation under a range of operating conditions.
Our modelling process begins with the development of accurate 3D geometries representing the combustion chamber, burner layout, and associated components. We simulate key parameters such as velocity fields, temperature gradients, pressure zones, and gas composition to understand how the combustion process behaves in real time.
These simulations allow us to evaluate flame stability, burner interaction, fuel-air mixing quality, and thermal loading across critical surfaces. By visualising these dynamics, we can identify inefficiencies, hotspots, dead zones, or incomplete combustion regions, and provide data-driven recommendations for design improvements.
CFD modelling is particularly valuable in troubleshooting existing issues, validating design modifications, and supporting retrofit and upgrade projects. It also supports regulatory compliance by enabling accurate prediction of NOₓ and CO emissions.
By integrating CFD into the combustion system development process, TEK7 ensures efficient, low-emission, and high-reliability solutions tailored to the unique requirements of each plant.
Combustion Control and Automation Solutions
TEK7 designs and implements advanced combustion control and automation systems to maintain stable, efficient, and safe operation under varying process conditions. Our control solutions are tailored to the specific characteristics of each burner system and are fully integrated with plant-wide automation architecture.
We apply a combination of proven control strategies such as PID loops, ratio control, excess air trimming, and feedback from process sensors to regulate fuel-air mixing, flame stability, and thermal output. Where required, we incorporate model-based or adaptive control logic to respond dynamically to changing loads or process demands.
Our systems support multiple modes of operation, including automatic, manual, and remote supervision, providing operators with flexibility, control, and real-time visibility of key parameters. Integrated safety interlocks and burner management systems (BMS) are included to ensure compliance with international safety standards and to protect both equipment and personnel.
TEK7’s automation team also provides configuration of local control panels, PLCs, and distributed control systems (DCS), along with human-machine interface (HMI) design for operator-friendly monitoring and control.
By delivering fully engineered and tested control systems, we help clients improve combustion efficiency, reduce emissions, extend equipment life, and ensure consistent process performance.
Low-Emission Solutions and Compliance Support
TEK7 provides engineering solutions focused on reducing emissions from industrial combustion systems while ensuring compliance with local and international environmental regulations. Our approach combines process optimisation, advanced burner technology, and emissions control strategies tailored to each application.
We begin by assessing the combustion system’s current performance, identifying the sources of emissions such as nitrogen oxides (NOₓ), carbon monoxide (CO), unburned hydrocarbons, and particulate matter. Based on this analysis, we develop targeted solutions that may include low-NOₓ burner designs, flue gas recirculation, staged combustion, or oxygen enrichment strategies.
Our team uses advanced modelling tools to predict emissions under a range of conditions and validate proposed solutions before implementation. We also support the integration of emissions monitoring systems, enabling clients to track performance and demonstrate regulatory compliance in real time.
Whether applied in new projects or retrofit upgrades, TEK7’s low-emission solutions help clients reduce environmental impact, improve energy efficiency, and future-proof their operations against tightening emissions standards.
Performance Monitoring and Lifecycle Services
TEK7 offers comprehensive performance monitoring and lifecycle support services to ensure long-term reliability, efficiency, and safety of combustion systems. Our approach focuses on proactive diagnostics, continuous performance assessment, and timely maintenance planning.
We provide customised monitoring solutions that collect and analyse key operational data such as fuel consumption, flame stability, temperature distribution, and emissions levels. This real-time information helps operators detect early signs of performance degradation, allowing corrective actions to be taken before critical issues develop.
Our team also conducts routine performance audits and combustion system health checks, providing detailed reports and actionable recommendations. These assessments assist clients in maintaining optimal system performance, improving energy efficiency, and extending equipment life.
Lifecycle support includes assistance with spare parts planning, system upgrades, and integration of new technologies as operational needs evolve. Whether through remote diagnostics or on-site support, TEK7 remains engaged with clients to deliver consistent technical value throughout the system’s operational life.