PCI / Injected Coal – Pulverized
Pulverized Coal Injection (PCI) Coal refers to finely ground (pulverized) metallurgical coal that is pneumatically injected directly into the tuyeres (air inlets) of a Blast Furnace. This technique allows for the partial replacement of expensive metallurgical coke, significantly lowering the overall hot metal production cost while maintaining the furnace’s thermal and chemical balance.
The coal must be pulverized to a specific fineness (typically 70% passing a 200 mesh sieve) to ensure rapid, near-complete combustion inside the furnace and proper transport through the injection system.
Main Function and Characteristics
PCI coal provides an essential source of carbon for the reducing reactions and acts as a supplementary fuel to reduce coke consumption.
CHARACTERISTIC — VALUE RANGE — PRIMARY METALLURGICAL FUNCTION
Fixed Carbon — >50% — Source of carbon for the reducing gas (CO).
Volatile Matter — <35% (Low to Medium VM) — Influences coal combustion rate and flame length inside the tuyere zone.
Ash Content — LOW — Minimizes the generation of additional slag, which consumes heat.
CLASSIFICATION — ECONOMIC FOCUS — PRIMARY APPLICATION FOCUS
Supplementary Fuel/Reductant — Cost-effective replacement for metallurgical coke — Blast Furnace Ironmaking (Tuyere injection).
Key Performance Metrics
PROPERTY — TYPICAL PERFORMANCE — MECHANISM OF ADVANTAGE
Combustion Efficiency — HIGH — Fast, complete burning in the raceway is essential for minimizing unburnt char.
Moisture Content — LOW (<1.0%) — High moisture hinders pneumatic transport and consumes excessive heat inside the furnace.
Purity — LOW S and P — Minimizes contamination of the hot metal and slag load.
1. The PCI Mechanism
The main function of metallurgical coke in the blast furnace is twofold: to provide a permeable structure to support the burden (ore and fluxes) and to provide carbon for the heat and reduction reactions. PCI coal can replace the second function:
Combustion: Pulverized coal is injected with hot air (~1000°C) into the raceway zone. The volatile matter in the coal is released and burns quickly, providing immediate heat.
Reduction: The remaining fixed carbon forms a reducing gas, carbon monoxide (CO):
C + O2 → CO2
CO2 + C → 2CO (Crucial gas for reducing Iron Oxide)
Coke Replacement Ratio: The amount of coke replaced by PCI coal (the coke replacement ratio, CRR) is typically around 0.8 to 1.0 kg of coke saved per kg of coal injected.
2. Importance of Volatile Matter (VM)
Low VM Coal (~10–20%): Requires higher blast temperature and oxygen enrichment to ensure complete combustion. Preferred when maximizing the volume of coal injected.
Medium VM Coal (~20–35%): Easier to ignite and combust rapidly, reducing the risk of unburnt char. Often used when the PCI rate is lower.
3. Technical Guidance
Infrastructure: PCI requires significant capital investment for the drying, crushing, pulverizing, storage, and injection systems.
Unburnt Char: Incomplete combustion leaves unburnt carbon (char) that can pass into the hearth, affecting metal quality and furnace operations. Monitoring the fineness and volatile matter content is essential to maximize combustion efficiency.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
