Iron Ore

Iron Ore

Our TEK7 team has hands-on experience in the iron ore industry including with pelletising, direct reduced iron (DRI) and agglomeration processes. We can also improve heat-flows schemes of furnaces—whether indurating or sintering.

TEK7 engineers have been involved in the process, fuel handling, automation and combustion systems of many recent plants built over the last decade.

Our mining and minerals expertise specifically in iron ore covers a full range of services, including:

  • Feasibility studies
  • Strategic planning
  • Front-end engineering design
  • Basic design & heat & mass balance calculations
  • Detailed design & simulation
  • Project procurement & management
  • Combustion services
  • Commissioning & operations support


In DRI, TEK7 Global is actively collaborating with Köppern.For instance the utilization advanced technology of roller presses in briquetting and other compaction processes such as Köppern high pressure grinding rolls (HPGR). These technological advances have resulted in a significant drop in machine time-outs caused by wear and repairs as well as energy consumption at the same time more efficiency and productivity simultaneously.

Today, the Köppern Group is a modern, high-tech German group of companies at the forefront of plant and machinery manufacturing for various processes related to the fertilizer, cement, minerals and metalworking industries.

Köppern’s business is built on three different, but interrelated, process technologies:

  • Briquetting – cold and hot briquetting predominantly for metallurgical applications
  • Compaction – for the production of fertilizers
  • Comminution – high-pressure grinding for the cement industry including air classifiers especially developed for roller press applications as well as high-pressure grinding for size reduction in the ores and minerals industries.

Partnership with TOREX

In 2019, TEK7 and TOREX formed a strategic alliance to further improve straight-grate pelletising and DRI technology by combining each company’s scientific expertise and vast operation, simulation and design experiences.

By uniting TOREX’s history of process design and operation optimisation with the advanced simulation and engineering techniques of TEK7 (such as CFD, FEA, AI and deep learning), we have been able to achieve desirable performance outcomes.

These positive outcomes are supported by existing data from the NextGen (Rev 1.0) pelletising plant commissioned in Russia that has been producing premium quality pellets since 2015.

Outstanding results from NextGen have given us the confidence to guarantee production rates (per hour and per induration machine unit area), as well as fuel, water and electrical consumption rates of 7% to 16% improved compared to industry standards.


NPVP TOREX Ltd, a research-and-development enterprise (Yekaterinburg, Russia), was founded in August 1989. Main activities are process engineering and revamping of mining, beneficiation, metallurgical plants, including sintering and pelletising plants, blast furnaces, direct reduction units and metallurgical furnaces.

TOREX renders engineering services in processes elaboration, auditing, retrofitting, grinding, adjusting of thermal metallurgical equipment and in classifying of equipment—and does so for mining, metallurgical, machine-building and construction industries. TOREX also provides consulting, supervision, training, commissioning and process adjustment services.

TOREX experts possess 40 years of experience in studying iron ore agglomeration (sintering and pelletising), development and elaboration of agglomeration processes, and upgrading of the heat-flows schemes of indurating and sintering straight-grate furnaces.

One of the latest achievements of the TOREX team was the upgrade of the Mikhailovsky GOK plant in Russia using NextGen technology which resulted in significant heat, power and water consumption reduction while production rates of consistently high-quality pellets were increased. These outstanding results were complemented by reducing harmful environmental pollutions well below industry averages.