Improved efficiency of blast furnace – Optimizing PCI applications with mass flow measurement
Steel Plant | DensFlow
Customer: Steel Plant
Material: Pulverized coal
Mass flow range: approx. 7%
Installation: Coal injection lances
Function: Control amount of coal injected into blast furnaces


The PCI technology (Pulverized Coal Injection), was designed to dose and control the amount of coal injected into blast furnaces, via the hot blast tuyeres. Modern PCI plant designs use dens phase conveying systems to transport pulverized coal from the storage area to the blast furnace, reducing nitrogen consumption, abrasion and stabilizing coal flow. With optimal coal injection, the last furnace’s burn efficiency is also improved, avoiding downtime and stabilizing iron ore transformation into pig iron. Maintaining burn urn homogeneity is key for stable production.

The best way to control coal injection is by directly measuring the coal mass flow in two potential places, after the pulverized coal storage silos, at the PCI, and on the coal injection lances, underneath the blast furnace. In both points dens phase conveying might be found.


Designed to measure mass flow of bulk solids in dens phase conveying lines, ENVEA’s DensFlow is the perfect fit to complete PCI application’s control loop. The DensFlow delivers continuous coal flow measurement via industry standard communication protocols. The measuring tube is manufactured according to the application point requirements, assembled with flanges on both ends.

The DensFlow installation creates no obstructions in the profile, hence no dead spots in which residue can form. The measurement requires no moving or disposable parts, positioning the DensFlow as the perfect long-term investment as a pulverized coal flow meter.


  • Optimized fuel costs due to continuous coal injection measurement
  • Stable production due to homogeneity in burn urn
  • No operating costs due to maintenance free sensor
  • Easy retrofit since compatible and integrable with already existent PCI plants

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