Pulverized Coal Injection Systems

Ironmaking
Pulverized Coal Injection

Coal Preparation and Pulverized Coal Injection

Equipment in Main Structure

STORAGE BIN
BAGFILTERS MAIN
BAGFILTERS

RAW COAL
PULVERIZED STORAGE BIN
COAL STORAGE
BIN

DRYING GAS
GENERATORS

PRESSURIZING
GAS VESSELS
CONVEYING
(INJECTION)
HOPPERS VERTICAL
DRYING GAS
ROLLER MILL
MAIN FANS

2
 MAIN
BAGFILTERS

STORAGE BIN
BAGFILTERS

RAW COAL
STORAGE BIN

PULVERIZED
COAL STORAGE
DRYING GAS BIN
GENERATOR
PRESSURIZING
GAS VESSEL
DRYING GAS
MAIN FAN

VERTICAL
EMERGENCY
ROLLER MILL CONVEYING INERTIZING GAS
(INJECTION) VESSELS
HOPPERS

3
Pulverized Coal Injection

Grinding and Drying of Coal in Inert Conditions

Blast Furnace Gas Based Drying

RAW COAL MAIN BAGFILTER

SUPPLY CONVEYOR
DRYING GAS
MAIN FAN

ROTARY VALVE

RAW COAL SIEVING MACHINE

STORAGE BIN Drying energy supply
based on blast furnace
MILL CHARGING
CONVEYOR gas combustion.

DYNAMIC Inert conditions produced

CLASSIFIER
COMBUSTION by closed loop circulation
AIR FAN
DRYING GAS of waste drying gas as a
GENERATOR
dilution gas for drying gas
HIGH CALORIFIC
POWER GAS
temperature control (self
VERTICAL
inertizing process).
BLAST FURNACE GAS ROLLER MILL

High dew point in drying

gas due to waste drying
gas recirculation.

Blast Furnace Gas Based Drying, Dilution Air

RAW COAL MAIN BAGFILTER

SUPPLY CONVEYOR
DRYING GAS
MAIN FAN

ROTARY VALVE
Drying energy supply
based on blast furnace
RAW COAL SIEVING MACHINE
STORAGE BIN gas combustion.
MILL CHARGING
CONVEYOR Inert conditions produced
by closed loop circulation
DYNAMIC of waste drying gas as a
CLASSIFIER
COMBUSTION dilution gas for drying gas
AIR FAN
DRYING GAS temperature control (self
GENERATOR
inertizing process).
HIGH CALORIFIC
POWER GAS
VERTICAL Dew point in drying gas
BLAST FURNACE GAS ROLLER MILL lowered by means of cold
dilution air injection up to
DILUTION AIR FAN the oxygen limit value for
inert conditions.

4
 Blast Furnace Gas Based Drying, Condenser

RAW COAL MAIN BAGFILTER

SUPPLY CONVEYOR
DRYING GAS
MAIN FAN

ROTARY VALVE
Drying energy supply
RAW COAL SIEVING MACHINE
based on blast furnace STORAGE BIN
gas combustion.
MILL CHARGING
CONVEYOR
Inert conditions produced
SPRAY COOLER FOR
by closed loop circulation WASTE DRYING GAS COOLING DYNAMIC
WATER
of waste drying gas as a
CLASSIFIER
COMBUSTION
dilution gas for drying gas AIR FAN

temperature control (self

HIGH CALORIFIC
inertizing process). POWER GAS
DRYING GAS VERTICAL
Dew point in drying gas BLAST FURNACE GAS GENERATOR ROLLER MILL

lowered by means of
water vapor condensation
in a spray cooler.

Stove Waste Gas Based Drying

RAW COAL MAIN BAGFILTER

SUPPLY CONVEYOR
DRYING GAS
MAIN FAN

Drying energy ROTARY VALVE

supply based RAW COAL SIEVING MACHINE
on inert stove STORAGE BIN
waste gas,
MILL CHARGING
complemen- CONVEYOR
tary on blast
furnace gas DYNAMIC
CLASSIFIER
combustion. COMBUSTION
AIR FAN
DRYING GAS

Low dew HIGH CALORIFIC

GENERATOR
HOT BLAST
point due to POWER GAS
STOVE PLANT

stove waste VERTICAL

gas and little BLAST FURNACE GAS
STOVE WASTE
ROLLER MILL

or no waste GAS FAN

drying gas
recirculation.

5
Pulverized Coal Injection

Unit Operations of Pulverized Coal Injection

PRESSURIZING LOCK AND

GAS VESSEL WEIGHING HOPPER
WT

PC
DISTRIBUTION
HOPPER

WT

INDIVIDUAL
FLOW RATE
CONTROL

FC FY FC FY INJECTION
NITROGEN LINES
FT
COMPRESSED AIR
FT

NITROGEN

FC PRESSURIZED
BAGFILTER

FC FC
DISTRIBUTION
HOPPER
CONVEYING
HOPPERS
WT WT WT
GLOBAL INDIVIDUAL
FLOW RATE FLOW RATE
CLOSED LOOP CLOSED LOOP
CONTROL CONTROL

FC CONTROL FC FY FC FY
EQUIPMENT
CONVEYING FT
FY FT
LINE NITROGEN
PRESSURIZING FT
GAS VESSEL
INJECTION
LINES

NITROGEN

(may be replaced by
INDIVIDUAL FLOW RATE
CLOSED LOOP CONTROL)

GLOBAL PC PC
FLOW RATE
CLOSED LOOP CONVEYING
CONTROL HOPPERS
WT WT
CONVEYING FS
LINE

FC FS

FY FT STATIC PULVERIZED INJECTION

DISTRIBUTOR COAL TUYERES LINES
PRESSURIZING
GAS VESSEL

6
The pulverized coal injection technology is based on
a combination of several unit operations.
Main unit operations include:

Inward Transfer

Hot blast backpressure as well as pressure drops

in pneumatic conveying lines and flow rate control
devices require a pressurizing of pulverized coal
from atmosphere pressure level to overpressure
level.

After pressurizing, pulverized coal is transferred

into a Distribution Device. Transfer may be
• by gravity or
• by pneumatic conveying.

Distribution

Global flow rate to be injected has to be split up

onto the hot blast tuyeres by means of a Distribu-
tion Device. Distribution Device may contain
• a puverized coal buffer volume (Hopper type Dis-
tribution Device) or
• no pulverized coal buffer volume (Splitter type
Distribution Device).

Metering

Global pulverized flow supplied to the Blast Furnace

as well as individual flows supplied to the hot blast
tuyeres shall be controlled. Flow rate control may
be of
• closed loop type or
• static type (only for individual flows).

Pneumatic Conveying

Pneumatic transfer of pulverized coal into the Dis-

tribution Device as well as conveying of individual
flows from the Distribution Device into the hot blast
tuyeres are performed by means of pneumatic con-
veying.

Pneumatic conveying may be of

• the dense phase type or
• the dilute phase type.

7
 Pulverized Coal Injection

Basic Combinaisons of Inward Transfer and Distribution

Transfer without Pressurizing Gas Recovery

Transfer by Gravity Transfer by Pneumatic Conveying

NITROGEN

(MAY BE REPLACED BY
INDIVIDUAL FLOW RATE
CLOSED LOOP CONTROL)

GLOBAL PC PC
FLOW RATE
CLOSED LOOP CONVEYING
CONTROL HOPPERS
WT WT
CONVEYING FS
LINE

FC FS

FY FT STATIC PULVERIZED INJECTION

DISTRIBUTOR COAL TUYERES LINES
PRESSURIZING
GAS VESSEL

Continuous transfer into a Splitter type Distribution Device

NITROGEN
PRESSURIZING LOCK AND
GAS VESSEL WEIGHING HOPPER
WT

FC PRESSURIZED
BAGFILTER

PC
DISTRIBUTION
HOPPER
CONVEYING
PC HOPPER
DISTRIBUTION WT WT
HOPPER INDIVIDUAL
FLOW RATE
CLOSED LOOP
WT CONTROL
INDIVIDUAL CONTROL FC FY FC FY
FLOW RATE EQUIPMENT
CONTROL
CONVEYING FT
FC FY FC FY INJECTION LINE NITROGEN
NITROGEN LINES PRESSURIZING FT
FT GAS VESSEL
COMPRESSED AIR INJECTION
FT LINES

Discontinuous transfer into a Hopper type Distribution Device

NITROGEN

FC PRESSURIZED
BAGFILTER

FC FC
DISTRIBUTION
HOPPER
CONVEYING
HOPPERS
WT WT WT
GLOBAL INDIVIDUAL
FLOW RATE FLOW RATE
CLOSED LOOP CLOSED LOOP
CONTROL CONTROL

FC CONTROL FC FY FC FY
EQUIPMENT
CONVEYING FT
FY FT
LINE NITROGEN
PRESSURIZING FT
GAS VESSEL
INJECTION
LINES

Continuous transfer into a Hopper type Distribution Device

8
 Transfer with Pressurizing Gas Recovery by means of Pressure Equalizing between
parallel Hoppers
Transfer by Gravity Transfer by Pneumatic Conveying
NITROGEN

(MAY BE REPLACED BY
STATIC PULVERIZED
COAL DISTRIBUTION)

PC PC PC
INJECTION
STATIC LINES
CONVEYING
HOPPERS DISTRIBUTOR FC FY
WT WT WT
GLOBAL CONVEYING FT
FLOW RATE LINE
CLOSED LOOP FC FY
CONTROL
FC FT
CONTROL
EQUIPMENT
FY FT CONTROL
EQUIPMENT
PRESSURIZING
GAS VESSEL

Continuous transfer into a Splitter type Distribution Device

NITROGEN
PRESSURIZING PARALLEL LOCK
GAS VESSEL AND WEIGHING
HOPPERS
WT WT

FC PRESSURIZED
BAGFILTER

FC FC
DISTRIBUTION
HOPPER
CONVEYING
PC HOPPERS
DISTRIBUTION WT WT WT
HOPPER INDIVIDUAL
FLOW RATE
CLOSED LOOP
WT CONTROL
INDIVIDUAL CONTROL FC FY FC FY
FLOW RATE EQUIPMENT
CONTROL
CONVEYING FT
FC FY FC FY INJECTION LINE NITROGEN
LINES PRESSURIZING FT
FT GAS VESSEL
INJECTION
NITROGEN
FT LINES

Discontinuous transfer into a Hopper type Distribution Device

NITROGEN

FC PRESSURIZED
BAGFILTER

PC PC PC
DISTRIBUTION
HOPPER
CONVEYING
HOPPERS
WT WT WT WT
GLOBAL INDIVIDUAL
FLOW RATE FLOW RATE
CLOSED LOOP CLOSED LOOP
CONTROL CONTROL

FC CONTROL FC FY FC FY
EQUIPMENT
CONVEYING FT
FY FT
LINE NITROGEN
PRESSURIZING FT
GAS VESSEL
INJECTION
LINES

Continuous transfer into a Hopper type Distribution Device

9
Pulverized Coal Injection

Inward Transfer
Sequences of Parallel Conveying Hoppers
DEPRES- WEIGHING PRESSU-
Sequences of two Con-
SURIZING RIZING
veying Hoppers, operated
CONVEYING PRESSURE
without pressurizing gas
recovery
INJECTION FILLING INJECTION
HOPPER '1' WEIGHT
DEPRES- WEIGHING PRESSU- DEPRES- WEIGHING PRESSU-
SURIZING RIZING SURIZING RIZING

PRESSURE
Sequences linked by
CONVEYING
HOPPER '2' FILLING INJECTION FILLING • continuous transfer of
WEIGHT
pulverized coal to the
TIME Distribution Device

Sequences of three Convey-

DE DEPRES-
SURIZING
WEIGHING PE FP ing Hoppers, operated with
CONVEYING PRESSURE pressurizing gas recovery.
INJECTION FILLING INJECTION
HOPPER '1' WEIGHT
Sequences linked by
PE FP DE DEPRES- WEIGHING PE FP
SURIZING • continuous transfer of
PRESSURE
CONVEYING
INJECTION FILLING pulverized coal to the
HOPPER '2' WEIGHT
Distribution Device
DE DEPRES-
SURIZING
WEIGHING PE FP DE DEPRES-
SURIZING
WEIGHING • pressure balancing
CONVEYING PRESSURE between Conveying Hop-
HOPPER '3’ FILLING INJECTION FILLING
WEIGHT pers for pressurizing gas
recovery.
TIME
DE : DEPRESSURIZING by PRESSURE EQUALIZING
PE : PRESSURIZING by PRESSURE EQUALIZING
FP : FINAL PRESSURIZING

DEPRES- WEIGHING PRESSU- DEPRES- WEIGHING PRESSU-

Sequences of three Con-
SURIZING RIZING SURIZING RIZING
veying Hoppers, operated
PRESSURE
CONVEYING
FILLING FILLING
without pressurizing gas
INJECTION INJECTION
HOPPER '1' WEIGHT recovery.
PRESSU- DEPRES- WEIGHING PRESSU- DEPRES-
RIZING SURIZING RIZING SURIZING

PRESSURE Sequences linked by

CONVEYING
HOPPER '2' INJECTION FILLING INJECTION FILLING • continuous transfer of
WEIGHT
pulverized coal to the
Distribution Device.
DEPRES- WEIGHING PRESSU- DEPRES- WEIGHING PRESSU-
SURIZING RIZING SURIZING RIZING

CONVEYING PRESSURE
FILLING INJECTION FILLING INJECTION
HOPPER '3’ WEIGHT

TIME

10
Gravity Transfer versus Pneumatic Transfer
Transfer by Gravity - Advantages
PRESSURIZING LOCK AND
GAS VESSEL WEIGHING HOPPER • Larger transfer flow rates obtainable.
WT • Lower operating and design pressure levels.
• Less process gas requirement.
• No pneumatic conveying equipment required.

Transfer by Gravity - Disadvantages

PC
DISTRIBUTION
• Transfer flow rate strongly conditioned by
HOPPER flowability of pressurized pulverized coal.
• Larger height of equipment arrangement.
WT
• More equipment installed close to blast fur-
INDIVIDUAL nace.
FLOW RATE
CONTROL

FC FY FC FY INJECTION
NITROGEN LINES
FT
COMPRESSED AIR
FT

NITROGEN

(MAY BE REPLACED BY
INDIVIDUAL FLOW RATE
CLOSED LOOP CONTROL)

GLOBAL PC PC
FLOW RATE
CLOSED LOOP CONVEYING
CONTROL HOPPERS
WT WT
CONVEYING FS
LINE

FC FS

FY FT STATIC PULVERIZED INJECTION

DISTRIBUTOR COAL TUYERES LINES
PRESSURIZING
GAS VESSEL

Transfer by Pneumatic Conveying - Advantages

• Transfer flow rate less conditioned by flowability of pressurized pulverized

coal.
• Direct Global Flow Rate Control possible in case of continuous transfer.
• Lower height of equiment arrangement.
• Less equipment installed close to Blast Furnace.

Transfer by Pneumatic Conveying - Disadvantages

• Transfer flow rates basically smaller.
• Higher operating and design pressure levels.
• Larger process gas requirement.

11
Pulverized Coal Injection

Distribution
Splitter Type Distribution Device

 Distribution Splitter at ArcelorMittal Gijón BF ’A’ & ’B’

Splitter Type Distribution Device - Advan-

tages
• Direct global flow rate control possible in the
upstream Conveying Line.
• Reduced space requirement for equipment.
• Reduced scope of equipment.

Splitter Type Distribution Device - Disadvan-

tages

• Individual flow rate control in downstream individ-

ual Injection Lines less efficient.
• Larger conveying gas input into blast furnace.

 Distribution structure at Cockerill Sambre Seraing BF ‘6’

12
 Hopper Type Distribution Device

 Distribution Hopper at ROGESA Dillingen BF ‘5’

Hopper Type Distribution Device - Advantages

• No mutual disturbing of operation of downstream individual Injec-

tion Lines.
• Maximum accuracy of individual flow rate control in downstream
individual Injection Lines.
• Minimum conveying gas input into blast furnace.

Hopper Type Distribution Device - Disadvantages

• Efficient direct global flow rate control difficult.

• Slightly increased process gas requirement, caused by second
fluidizing of pulverized coal at the inlets of the downstream indi-
vidual Injection Lines.
• Larger space requirement for equipment.
• Larger scope of equipment.

13
Pulverized Coal Injection

Metering
Determining of Pulverized Coal Flow Rate
ABSOLUTE FLOW RATE

PT PT
X

WY WT CONVEYING WY WT
HOPPER ST ET

-T -T
e e DT Int

dW / dt W(t+dt) - W(t) Div

ABSOLUTE FLOW RATE

ABSOLUTE FLOW RATES

PT PT
X X

WY WT DISTRIBUTION WY WT Sum
HOPPER ST ET ST ET

-T -T
e e DT DT Int

dW / dt W(t+dt) - W(t) Div

ABSOLUTE FLOW RATE

By Means of Weighing System of Lock or Distribution

Hopper:

• Indirect flow rate determining based on weight diffe­rences

divided by time interval durations.
• Gives absolute values [kg/s].
• Quicker response reduces accuracy and vice-versa.
• Only gives value of total flow rate supplied by Hopper.

By Means of Correlative Flow Rate Measurement Device

in Coal Conveying Line:

• Direct determining of relative flow rate value in coal conveying

line.
• Gives relative values [mA].
• Requires second level weighing system for turning relative values
[mA] into absolute values [kg/s].
• Quicker response than weighing system based flow rate deter-
mining.
• Gives individual flow rate values in multiple
parallel lines.

14
 Factors Determining Pulverized Coal Flow Rate in Line

VARIABLE VALUE FACTORS CONDITIONING

CONVEYING FLOW RATE

- LINE INLET PRESSURE

- LINE OUTLET PRESSURE
- CONVEYING GAS FLOW RATE
- SINGLE VARIABLE RESISTANCE

PT PT

FIXED VALUE FACTORS CONDITIONING

CONVEYING FLOW RATE

- LENGTH OF LINE
- ROUTING OF LINE
- INNER DIAMETER OF LINE
- SINGLE STATIC RESISTANCE
- CRITICAL EXPANSION TUYERE

Fixed Value Factors, may be used in Static Flow Rate

Control:

• Length, routing of line.

• Inner diameter of line.
• Single static flow resistance
(e.g. orifice, tuyere with sub-critical expansion).
• Critical expansion device
(tuyere with critical expansion).

Variable Value Factors, may be used in Closed Loop Flow

Rate Control:

• Line inlet pressure level.

• (Line outlet pressure level).
• Conveying gas flow rate.
• Single variable flow resistance
(mechanical flow control valve).
• External flow rate determining device
(e.g. variable speed rotary valve).

15
Pulverized Coal Injection

Metering
Static Flow Rate Control
Means of Static Flow Rate Control
FLOW RATE CONTROL DISTRIBUTION PRESSURE LOSS ACCURACY
METHOD PATTERN DUE TO CONTROL

Diameter balanced flow Uniform, fixed none

1 resistances of Lines

increasing
Equalized flow resistance Uniform, fixed none
2 of Lines (length, bends)

Equalized flow resistance Uniform, fixed About 1 - 2 bar

3 plus Subcritical Tuyeres

4%
Critical Expansion Tuyeres Arbitrary, Pin > Pout * 1.65
4 in (arbitrary) Lines may be changed

EQUAL DISTRIBUTION BY DIAMETER BALANCED LINES EQUAL DISTRIBUTION BY LENGTH BALANCED LINES

1 2
DIAMETER INCREASE BALANCED LINE LENGTH

EQUAL DISTRIBUTION BY LENGTH BALANCED LINES AND SUBCRITICAL TUYERES FLOW CONTROL BY CRITICAL EXPANSION TUYERES

3 SUBCRITICAL EXPANSION TUYERE 4

BALANCED LINE LENGTH CRITICAL EXPANSION TUYERE

16
Static Flow Rate Control by Critical Expansion Tuyeres

5 6 7 8 9 10 11 12 [bar a] 7 8 9 10 11 12 13 [kg/nm3]
CRITICAL
EXPANSION
TUYERE
FOR GAS PRESSURE GAS DENSITY
COAL
GAS
Pin / Pmin = 1.65
MIX-
TURE

MEAN VELOCITY
OF MIXTURE

0 10 20 30 40 50 60 70 [m/s]

Acceleration requires gas pressure decrease and causes gas density decrease. Decreases in conver-
gent nozzle are limited to critical values. In critical conditions, flow rate is only determined by pressure
and density upstream of nozzle and by nozzle minimum cross section area.

[bar a]
PRESSURE LEVEL

CONVEYING 20
HOPPER
18

CONVEYING HOPPER
16

CONVEYING
LINE 14 ACTUAL TUYERE INLET

OPTIMUM (variable cross

12
section) TUYERE INLET

10 CRITICAL EXPANSION
STATIC
DISTRIBUTOR
8 LONG LINE TUYERE OUTLET

SHORT LINE TUYERE OUTLET

6
CRITICAL
EXPANSION HOT BLAST TUYERE
TUYERE 4 (maximum pressure level)

2 CRITICAL EXPANSION TUYERE SIZE

INJECTION #1 #2 #3 #4 #5
LINE 0 INJECTION
FLOW RATE [%]
0 10 20 30 40 50 60 70 80 90 100

Pressure drops due to critical expansion are minimized in an “optimum” tuyere, the variable minimum
cross section fitting exactly with any flow rate requested. Actually, flow rate range is split into few
subranges, each having a tuyere exactly fitting with the lowest flow rate in the subrange.

17
Pulverized Coal Injection

Metering
Static Flow Rate Control

Static Flow Rate Control by means of Injection Lines with equalized flow resistance plus
pulverized coal tuyeres with subcritical expansion. Only produces uniform distribution.

Static Flow Rate Control by means of pulverized coal tuyeres with critical expansion installed in Injec-
tion Lines with various line length. May produce uniform distribution as well as arbitrary distribution
patterns.

18
 Closed Loop Flow Rate Control
Means of Closed Loop Flow Rate Control

FLOW RATE CONTROL FLOW RATE PRESSURE LOSS ACCURACY

METHOD DETERMINING DUE TO CONTROL (approximately)

Pressure Variation Weighing System none 2-4%

in Hopper on Hopper
(Global Flow only)

Pressure Variation Flow Rate none 2-4%

in Hopper Measurement
(Global Flow only) Device in Line

Dilution Gas Weighing System none 2-3%

Injection into on Hopper
Conveying Line

Dilution Gas Injection into Flow Rate none 1-2%

Conveying or Measurement
Injection Line Device in Line

Coal Flow Rate Weighing System 1 - 2 bar 2-3%

Control Valve on Hopper
in Conveying Line

Coal Flow Rate Con- Flow Rate 1 - 2 bar 1 - 2 % (Conv.)

trol Valve in Convey- Measurement or
ing or Injection Line Device in Line 0.5 - 1 % (Injec.)

 Depressurizing control valve used in hopper pressure control  Coal Flow Rate Control Valve for Conveying
Line (Global Flow Rate Control)

19
Pulverized Coal Injection

Metering
Closed Loop Flow Rate Control

 Coal Flow Rate Measurement Devices in

Injection Lines, downstream of Coal Flow
Rate Control Valves installed beneath the
Distribution Hopper at ArcelorMittal Gijón
BF ’A’ & ’B’

 Coal Flow Rate Control Valves installed

beneath the Distribution Hopper at Rogesa
Dillingen BF ‘5’

 Coal Flow Rate Control Valves installed

downstream of Splitter type Distribution
Device at ArcelorMittal Gijón BF ’A’ & ’B’

20
 Closed Loop Flow Rate Control

PULVERIZED
COAL STORAGE
BIN

LOCK AND
WEIGHING
HOPPER

PRESSURIZING
GAS VESSELS

DISTRIBUTION
HOPPER

COAL FLOW
RATE MEASUREMENT
COAL FLOW DEVICES
RATE CONTROL
VALVES

INJECTION
LINES

 Injection Structure at Rogesa Dillingen BF ‘5’

21
Pulverized Coal Injection

Pneumatic Conveying
Dense Phase Pneumatic Conveying

Hmax
Ho

Ho
H
NO FLOW

FLUIDIZING GAS FLUIDIZED BED

DISCHARGING
(CONSTANT FLOW RATE)
SOLID MATERIAL SUPPLY
and PRESSURE MAINTAINING
GAS VELOCITY
H(t) MATERIAL HEIGHT

SOLID MATERIAL
DEVIATION VELOCITY

NO FLUIDIZING DEGASSING NO DISCHARGING

FLOW FLOW
t
FLUIDIZING
FLUIDIZING GAS RETEN- TIME
TIME TION TIME

FLUIDIZING GAS INPUT

Pulverized coal has outstanding fluidizability and

gas retaining characteristics. These are the basis
for dense phase pneumatic conveying of pulverized
coal in ­fluidized state.

Fluidizing of pulverized coal is performed in fluid-

izing compartments connected to the coal outlet
nozzles of the Conveying Hoppers or Distribution
Hopper.

Pulverized coal may also be conveyed in conven-

tional dilute phase conveying.

 Fluidizing Compartment below a Conveying Hopper at  Fluidizing Compartments below the Distribution
Cockerill Sambre Seraing BF ‘6’ (upward coal flow) Hopper at Rogesa Dillingen BF ‘5’ (downward coal
flows)

22
 Dilute Phase Conveying versus Dense Phase Conveying
[kg/kg]
DILUTE PHASE CONVEYING SOLID TO GAS RATIO (LOAD)
PULVERIZED COAL PARTICLE GAS MEAN VELOCITY
90

80
VOID
70

60
CONVEYING GAS SOLID MATERIAL
MEAN VELOCITY 50 60 %

DENSE PHASE CONVEYING 40 70 %

PULVERIZED COAL PARTICLE GAS MEAN VELOCITY 30 80 %

20 90 %

10 95 %

0 [bar a]

CONVEYING GAS SOLID MATERIAL 0 2 4 6 8 10 12 14 16 18 20 PRESSURE

MEAN VELOCITY

Load in pneumatic dense phase conveying (ratio of solid flow rate to gas
flow rate) is conditioned by the pressure level existing in the fluidizing
device upstream of the coal conveying line.

 Dense Phase Pneumatic Conveying Line at Sollac Fos-sur-Mer BF ‘2’

23
Pulverized Coal Injection
Pneumatic Conveying
Dilute Phase Conveying versus Dense Phase Conveying
DILUTE PHASE CONVEYING
High solid material velocity, requiring
• abrasion protection in bends.
Low ratio of solid material flow rate to conveying
gas flow rate in coal conveying line, meaning
• higher conveying gas requirement
(conditioned by void).
More pneumatic energy in conveying gas per solid
material unit mass, meaning
• lower pressure drop in coal conveying line
• lower pressure level, less pressurizing gas and
less pressure maintaining gas required in Con-
veying Hopper.
Design criteria: solid material velocity > minimum
velo­city, meaning
• conveying gas flow rate constant when solid
material flow rate is decreasing
• specific conveying gas requirement is increas-
ing with decreasing solid material flow rate
• turn-down ratio of conveying flow rate is unlim-
ited.
Transportability is based on action of gas turbu-
lence on individual solid particle, meaning
• conveying is less conditioned by bulk solid
material properties
• conveying is less sensitive.
24
DENSE PHASE CONVEYING
Low solid material velocity, requiring
• no abrasion protection in bends.
High ratio of solid material flow rate to conveying
gas flow rate in coal conveying line, meaning
• lower conveying gas requirement
(conditioned by line inlet pressure).
Less pneumatic energy in conveying
gas per solid material unit mass, meaning
• higher pressure drop in coal conveying line
• higher pressure level, more pressurizing gas
and more pressure maintaining gas required in
Conveying Hopper.
Design criteria: conveying time duration (travel-
ling time) < maximum possible duration, meaning
• conveying gas flow rate is decreasing with
solid material flow rate
• specific conveying gas requirement is nearly
constant, independently of solid material flow
rate
• conveying distance and turn-down ratio of con-
veying flow rate are limited.
Transportability is based on fluidizing of
bulk solid material, meaning
• conveying is more conditioned by bulk solid
material properties (fluidizability, flowability,
gas retaining capacity)
• conveying is more sensitive.
 Dense Phase Pneumatic Conveying

Main Structure of PCI-System

at Cockerill Sambre Charleroi
BF ‘4’ and BF ‘5’ 

Conveying of pulverized
coal from the PCI-System
Main Structure to Cockerill
Sambre Charleroi BF ‘4’,
total conveying distance
about 1000 m 

25
Pulverized Coal Injection

Preheating of Pulverized Coal

Preheating and Injection Equipment Arrangement
Preheating and Degassing of Pulverized Coal
NITROGEN

HEATING
FLUID
HEAT FC PRESSURIZED
EXCHANGER BAGFILTER

PC PC PC
DISTRIBUTION
HOPPER
CONVEYING
HOPPERS
WT WT WT WT
Pulverized coal is pre-
GLOBAL INDIVIDUAL
FLOW RATE FLOW RATE
CLOSED LOOP CLOSED LOOP
CONTROL
heated in the Conveying
CONTROL
FC CONTROL FC FY FC FY
Line upstream of the
EQUIPMENT
Distribution Hopper.
FT
FY FT
NITROGEN
PRESSURIZING
GAS VESSEL
FT
Residual moisture is
INJECTION separated in the Distri-
LINES
bution Hopper.

Preheating of Pulverized Coal

NITROGEN

PC PC PC
Pulverized coal is pre-
CONVEYING
HEATING
heated in the Conveying
FC FY
Line upstream of the
HOPPERS
WT WT WT FLUID
GLOBAL
FLOW RATE
FT
Splitter type Distribu-
CLOSED LOOP
CONTROL
FC FY tion Device.
HEAT
FC FT
EXCHANGER

CONTROL
INDIVIDUAL Closed loop individual
injection flow rate con-
CONVEYING FY FT FLOW RATE
LINE EQUIPMENT CLOSED LOOP
STATIC
PRESSURIZING
GAS VESSEL
DISTRIBUTOR CONTROL
trol is performed down-
CONTROL
EQUIPMENT
INJECTION
LINES
stream of the Splitter
type Distribution Device.

Preheating of Pulverized Coal

NITROGEN

PC PC PC
Pulverized coal is pre-
CONVEYING
STATIC
PULVERIZED COAL
heated in the Conveying
HEATING
Line upstream of the
HOPPERS
FLUID DISTRIBUTION
WT WT WT
GLOBAL
FLOW RATE
FS
Splitter type Distribu-
CLOSED LOOP tion Device.
CONTROL
HEAT
FC FS
EXCHANGER

CONTROL
Static individual flow
rate control is per-
CONVEYING FY FT PULVERIZED
LINE EQUIPMENT
COAL TUYERES
PRESSURIZING
GAS VESSEL STATIC INJECTION
formed down stream of
DISTRIBUTOR LINES the Splitter type Distri-
bution Device.

26
27
Engineering & Technology worldwide
The Paul Wurth Group is today one of the world leaders in the design and supply of complete
plants, systems and processes as well as specialised mechanical equipment for
 the iron & steel industry:
Blast Furnaces & Auxiliary Plants
Coke Making Plants
Agglomeration Plants
Direct Reduction Plants
Environmental Protection, Recycling & Energy-Saving Technologies
 other industries:
Systems & Equipment for Non-Ferrous Pyrometallurgy, Electrometallurgy & Residue Treatment
Intralogistics Solutions for Heavy Loads
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Feasibility Studies – Conceptual, Basic and Detail Engineering – Project Management – Plant and Components Supply –
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and Remote Operational Assistance – After-sales Services

© Copyright 2006–2015 Paul Wurth S.A. – all rights reserved

Non Contractual Data: Paul Wurth believes that the data contained in this folder are correct and accurate, but cannot guarantee same or better performances for any
specific site without a detailed quote. Patents and Patents pending. — Paul Wurth equipment and processes are protected in many countries by patents.
Paul Wurth and the Paul Wurth Logo are trademarks of Paul Wurth S.A. and may be registered in your jurisdiction.

Paul Wurth S.A. Paul Wurth AMERICAS Paul Wurth India Pvt. Ltd
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L-1122 Luxembourg Moscow, RUSSIA Valparaiso, Indiana, USA Phone: (+91) 124 4523200
Phone: (+352) 4970-1 Phone: (+7) 495 721 1553 Phone: (+1) 219 756 1061 pwindia@paulwurth.com
paulwurth@paulwurth.com pwmoscow@paulwurth.com pwus@paulwurth.com
www.paulwurth.com Paul Wurth International S.A.
IED
S AF E T Y
S
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ISO 9001
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IF

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CERT

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TEM

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BUREAU VERITAS
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(Beijing) Co., Ltd
Beijing, P.R. CHINA
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Tokyo, JAPAN
Phone: (+81) 3 6204 8262
contact@ihi-pw.jp
AFRICA
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South Africa Branch
Johannesburg, SOUTH AFRICA
Phone: (+27) 11 794 1926
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