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a. PCI (Pulverized Coal Injection) Plant

K I C also installed the Pulverized Coal InjectionPlantwhich led to substantial cost savings, improved operational efficiencies and increased production capabilities thereby positioning the company for continued growth and success. The PCI plant allows the injection of pulverized coal directly into the blast furnace. This technology improved the combustion efficiency, reduced coke consumption, and lowered overall fuel costs.

The main aspect of the competitive iron making is to reduce the cost and increase the performance of blast furnace. This is achieved by replacing part of metallurgical coke by injecting alternative cheap fuels in the blast furnacelike pulverised non coking coal. Pulverised fuel also provides the possibility of substituting larger amount of coke at constant race-way adiabatic flame temperature because of less endothermic cracking.

The Blast Furnace has also been envisaged with modified and efficient cooling & refractory system to support its auxiliary with required blastenrichment.

b. Oxygen Enrichment in Blast Furnace

Overview Oxygen enrichment involves increasing the oxygen content of the air injected into the blast furnace. This is achieved through injecting pure oxygen or enriched air, leading to improved combustion efficiency and higher temperatures within the furnace.

Benefits

1. Increased Production: Enhanced combustion leads to more efficient melting of iron and can increase the rate of pig iron production.
2. Lower Coke Consumption: Higher furnace temperatures allow for reduced reliance on coke, which can lower overall operational costs.
3. Improved Reaction Rates: The higher oxygen levels promote faster reduction reactions, improving the efficiency of iron ore reduction.
4. Enhanced Heat Utilization: With increased temperatures, the heat generated can be utilized more effectively, improving overall thermal efficiency.

• Nitrogen Injection in Blast Furnace

Overview Nitrogen injection involves the introduction of nitrogen gas into the blast furnace. This can be used to control the temperature and improve the overall gas dynamics within the furnace.

Benefits

1. Temperature Control: Nitrogen can help moderate the furnace temperature, preventing overheating and maintaining optimal operational conditions.
2. Reduction of Nitrogen Oxides (NOx): Lowering combustion temperatures can reduce the formation of NOx emissions, contributing to environmental compliance.
3. Gas Composition Management: Adjusting the nitrogen levels can optimize the composition of furnace gases, improving reduction efficiency.

Through our various available facilities, we are committed to producing high-quality pig iron in an environmentally responsible manner, supporting both our business goals and our dedication to sustainable development.