PCI Coal Additive: 6-Month Pilot Results from a 3.2 MTPA Blast Furnace

Background

PCI - Pulverised Coal Injection - is a standard technique in modern blast furnace operation. The practical challenge: coal does not combust as efficiently as coke inside the furnace, leading to increased flame temperature variability, higher LOI in flue dust, and in extreme cases, raceway instability.

Trial Design

The trial ran over 6 calendar months, covering approximately 180 heats. PCI coal additive dosing began after a 30-day baseline period. Dosing rate: 0.1% on PCI coal mass, applied via a dedicated dosing pump at the coal injection lance.

Results

• Coke rate reduction: 2.1 kg/thm sustained reduction vs. baseline
• Flue dust LOI: Reduced from 28.4% to 24.1%
• Flame temperature stability: Standard deviation reduced by 18%
• Hot metal quality: No statistically significant change in [Si] or [S] levels
• PCI rate: Sustained at 180 kg/thm throughout the trial period

Commercial Outcome

Based on the validated results, the plant has placed an order for a 6-month commercial supply of ACL's PCI coal additive - the first commercial engagement of its kind in the Indian market.