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Which of the following can be used as an alternative for the blast furnace in the steel manufacturing industry for energy saving?
Heat recovery from hot sinter
Programmed coke heating
Pulverised coal injection
Dry quenching
Pulverised coal injection
Pulverized Coal Injection (PCI) is an energy-saving technique where fine coal is injected directly into the tuyeres of a blast furnace, replacing a significant portion of expensive metallurgical coke. This substitution reduces the dependence on the energy-intensive coke-making process and optimizes the fuel-to-ore ratio within the furnace.
Pulverized Coal Injection (PCI) is an energy-saving technique where fine coal is injected directly into the tuyeres of a blast furnace, replacing a significant portion of expensive metallurgical coke. This substitution reduces the dependence on the energy-intensive coke-making process and optimizes the fuel-to-ore ratio within the furnace.
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Coal powder is dried and ground to a fine size (typically <1┬аmm) and then transported pneumatically into the raceway of the blast furnace. Upon entry, the coal combusts rapidly, releasing heat and generating reducing gases like CO and H2тАЛ, which facilitate the reduction of iron ore. This process reduces the thermal load and coke requirement at the top of the furnace, thereby lowering overall energy consumption per tonne of hot metal produced.
PCI significantly lowers the coke rate in blast furnaces.
It helps in bypassing the coal carbonization (coke oven) stage.
Improves furnace productivity by allowing higher oxygen enrichment.
Allows usage of non-coking coal as a replacement for high-grade metallurgical coke.
Reduced coke consumption
Lower operational costs
Improved control over furnace heat
Environmentally friendly compared to traditional coke ovens
Requires high-quality coal preparation infrastructure
Risk of unburnt char affecting permeability
Requires oxygen enrichment for high injection rates
Integrated steel plants
Blast furnace ironmaking optimization
Capacity expansion of aging blast furnaces
Option A (Heat recovery from hot sinter) and D (Dry quenching) are heat recovery systems, not direct alternatives to the blast furnace process itself.
Option B (Programmed coke heating) refers to process control improvements, not a replacement of the furnace energy source.
PCI typically replaces 100 to 200┬аkg of coke per tonne of hot metal.
C is correct тАФ Pulverised coal injection is the primary technique used to substitute expensive metallurgical coke with coal, significantly reducing energy costs in the blast furnace.
In competitive exams, remember that PCI is a metallurgical process efficiency tool, whereas 'dry quenching' is a heat recovery technique associated with coke ovens.
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