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The SunCoke Energy oven operates on a regenerative principle that separates coal into carbon in solid state and transforms volatile matter into gases. These toxic gases are then thermally destroyed. A horizontal bed of coal approximately 1m deep, 4m wide and 14m long is charged into the side of a hot oven using a leveling conveyor. Immediately after charging, the coal absorbs heat from the surrounding refractory. Volatile matter in the coal is driven from the bed and burned, transferring heat from combustion back into the refractory. Partial combustion of volatiles occurs in the oven crown above the bed. Gases are then drawn into sole flues beneath the oven floor where more air is introduced to complete combustion and provide underfiring to the process. This permits carbonization from the top and bottom at equal rates. Heat is neither gained nor lost by the refractory over a normal coking cycle. This feature allows the SunCoke Energy oven to be a self-sustaining operation without any requirement for auxiliary fuel.
SunCoke Energy uses large batch coal charges and 48-hour coking cycles. This combination minimizes machine usage, frequency of door removal, and thermal cycling in the ovens. The result is prolonged life of the plant and reduced operating and maintenance costs. Additionally, the oven's large thermal reservoir stabilizes the process, requiring only one combustion air rate adjustment in an eight-hour shift.
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