The dedicated efforts of the employees at Blast Furnace-5 (BF-5) of SAIL, Rourkela Steel Plant (RSP), have significantly boosted production efficiency through strategic modifications to the Pulverized Coal Injection (PCI) system. A newly constructed PCI line, spanning 450 meters in length and 150 mm in diameter, has enhanced the system’s performance by increasing the pressure to 15.5 kgf/cm², enabling a higher PCI injection rate and reducing coke consumption. This has not only stabilized the process, minimized pressure fluctuations, but also generated substantial savings for the company.
The initial PCI injection rate of 150 kg/THM (Tons of Hot Metal) was proved insufficient, as inadequate nitrogen pressure and flow created challenges in sustaining the required injection rates. With the production at Blast Furnace -5 (BF-5) soaring from its designed capacity of 7929 Tons Per Day (TPD) to an impressive 9500 TPD, the existing PCI system faced limitations in meeting the increased demand.
To address this issue, the BF team implemented an innovative solution by constructing a new dedicated PCI line, designed to support the enhanced production requirements. The construction of the line began in mid-December 2024 and was completed within a short timeframe, by the end of the month. Integration of the new line into the existing system was successfully carried out during the scheduled shutdown of BF-5 on 4th January, 2025.
This initiative has not only supported the increased production capacity of BF-5 but also aligned with the plant’s broader goals of operational excellence and cost reduction.
