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HOW THE ILLAWARRA COKE COMPANY
produces metallurgical and foundry coke

>> coal shed delivery from local mines

Coal is received by truck from local Illawarra coal mines and deposited on site.
The coal is blended and ground into a fine even consistency, then travels by conveyor from the grinding plant to the fine coal bins ready to be put into the ovens - a process known as charging.

>> charging the ovens is a sealed, automated process

Charge Cars travel along the top of each oven battery to deliver a measured quantity of fine coal into each oven. The Charge Car lifts steel lids on the oven tops, deposits its load of coal into the oven then puts the lids back on the charge holes. The oven has then been charged.

>> the `Ram' levels the coke bed before the oven door is closed

Following charging, a machine called a Ram which travels alongside the oven battery is used to level the coke bed as the coking process is much more efficient with an even or level coke bed. The coal ignites spontaneously due to the heat in the oven. The coal is left in the oven for three days (during the week) or four days (over the weekend), by which time the volatile matter in the coal is released and burnt off.

>> the hot coke is pushed from the oven into the coke car

This is non-recovery cokemaking technology as none of the volatiles are recovered, instead they are burnt to provide the heat needed to coke the coal. When the coke is ready it is pushed out of the oven. The Ram uses a large blade to push the solid red mass of hot coke horizontally into the coke car on the other side of the oven to prevent it breaking up.

>> a clay mixture `daub' prevents air from getting into the oven

Once the coke has been pushed out of the oven, the oven doors are closed and workmen seal the doors with a clay mixture to prevent air from getting into the oven. The oven is now ready to be charged again.

>> the coke car runs on rails to the quench tower

The coke car containing the hot coke pushed from the oven travels along a track to the quench tower.

>> the hot coke is cooled at the quench tower

At the quench tower treated water is sprayed over the hot coke to cool it as quickly as possible.

>> steam from the quench goes up the quench stacks

When this water contacts the hot coke a large volume of white steam (water vapour) is created which comes out the top of the quench stacks and dissipates into the atmosphere.

>> water sprays cool the hot coke

Water sprays continue to cool the coke as it travels onto the conveyor. All water used in coke operations is recycled.

>> conveyors take the coke to the screens to be sized & sorted

Once cooled the coke travels on conveyors to the screens to be sized or sorted into different size fractions.

>> coke is loaded onto trucks for transporting

After screening the coke travels by conveyor to the coke bins to be loaded onto trucks for transporting to domestic customers or the Port Kembla Coal Terminal for loading onto ships for export to world markets.

>> export coke is loaded onto ships to be taken to world markets

Coke for export is loaded onto ships at Port Kembla Coal Terminal a few kilometres by road from Coacliff and Corrimal Cokeworks.

For more information on non-recovery cokemaking technology please refer to ICC's information sheet 'Producing coke from coal'