A steel plant was seeking to enhance the efficiency of its blast furnace through continuous monitoring of its Pulverised Coal Injection (PCI) applications. The more accurate the coal injection, the more efficient and stable the burning process, reducing the possibility of system downtime. After implementing the DensFlow system, the plant was able to optimise fuel costs and stabilise its production, leading to maximum efficiency across the plant floor.
PCI technology is a method used to control the amount of coal injected into blast furnaces during dense phase conveying where pulverised coal is transported from storage to the furnace. Designed to cut costs by enabling the use of cheaper coal instead of more expensive fuel sources like coke, it involves injecting pulverised coal directly into the blast furnace through nozzles along with hot air. This injected coal acts as a supplementary fuel, providing additional heat for the smelting process.
The steel plant’s main challenges were ensuring efficient and consistent PCI into blast furnaces while maintaining optimal combustion and reducing costs. Variability in coal flow led to inefficiencies, unstable combustion, and increased operating expenses. To address these issues, precise mass flow measurement was critical for stabilising the injection process, minimising nitrogen use, and reducing abrasion in dense-phase conveying systems.
Our DensFlow solution offered a reliable, maintenance-free way to enhance the plant’s PCI control. Continuously monitoring coal flow with industry-standard communication protocols, the DensFlow solution uses a custom-built measuring tube with flanged ends to prevent obstructions and residue buildup. This design promotes stable production, optimises costs, and ensures easy system integration, making it a highly effective and dependable choice for long-term coal flow management.
Continuous and precise coal injection measurement has allowed the plant to enhance its overall efficiency and sustainability. After installing the DensFlow, the plant was able to lower fuel costs, achieve greater flexibility in coal usage and reduce its emissions.
The maintenance-free sensors eliminated operating costs, while compatibility with existing PCI applications allowed for easy retrofitting and integration––resulting in a seamless upgrade that has transformed the way the plant operates.