Pulverized Coal Injection (PCI) is a process that involves blowing large volumes of fine coal granules into the BF. This provides a supplemental carbon source to speed up the production of metallic iron, reducing the need for coke production.  As a result energy use and emissions can be reduced.   However, as coke provides physical support and gas permeability in the BF, its complete substitutions is not possible. The amount of coal that can be injected will depend on the coal and coke quality, furnace geometry, and operational practices.  The maximum level of coal that can be injected at the tuyére is around 0.27 t/t-Hot Metal(HM). The use of oxy-coal enables around 20% increase in coal injection and help reduce coke quantities accordingly (Worrell et al., 2010).

With 170 - 200 kg/t-HM pulverized coal injection, coke consumptions as low as 286 - 320 kg/t-HM has been achieved in modern blast furnaces.  However, global average for PCI remained at 125 kg/t-HM in 2005 (IEA, 2007. p. 117). Although PCI increases the costs for extra oxygen supply, BF maintenance, and coal grinding, these are offset by reduce coke production/purchase costs making providing an overall reduction in operation and maintenance costs.  Cost of PCI plant largely depends of the size of blast furnace and the layout of the plant. The layout of the plant can make it difficult to install PCI accessories with some alternative arrangements which would ultimately increase the installations costs.

   While this technology is regarded to have a high potential for application in China and India, in the case of US, injectin of natural gas may be a more cost effective measure.