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Simulation · Minimal Factory · Ruhr area

Hansa coking plant · coal becomes coke

A coking plant as a model you can walk through: charging car, pusher machine, quenching car and quenching tower, plus coal tower, compressor house and coke stockpile, on the real terrain in Dortmund-Huckarde.

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Trailer

Real are location, terrain and buildings (official NRW elevation data, OpenStreetMap). The three further batteries are interpreted; quantities, processes and times are model values. With your data, the model shows your site and your processes.

Hansa coking plant in Dortmund-Huckarde stands as a block model on its real terrain. In the coke oven battery, coal is baked into coke for the ironworks with the air shut out: the charging car runs along the top over the chambers, the pusher machine shoves the glowing coke into the quenching car, and the cloud rises at the quenching tower. The gas goes via the compressor house into the long-distance gas grid.

In the model the real battery is fired up again, three more grow as an expansion on the northern area. Coal trains arrive from the collieries, coke trains leave for the ironworks. Five controls – investment (one to four batteries), workforce, supply, quality and market – show output, stockpile and daily result at once; what is not sold ends up on the coke stockpile.

Real are location, terrain and buildings from official NRW elevation data and OpenStreetMap. New batteries, quantities, processes and times are an interpretation of our own and model values; one working day lasts ten seconds. The page is for museums and exhibitions, schools and universities, industrial heritage and local history.

From raw material to product

  1. 01

    supply – coal trains from the collieries

  2. 02

    batteries – charging car on the battery, cloud at the quench tower

  3. 03

    coke heap – takes in what is not sold

  4. 04

    dispatch – coke trains to the ironworks, gas via the compressor hall into the grid

A site at work

01

A site at work

Hansa coking plant: In the coke oven batteries of Dortmund-Huckarde coal is baked into coke for the ironworks without air; the gas goes into the grid via the compressor hall.

Battery 1 (real)

02

Battery 1 (real)

Battery 1 (real) – A coke oven battery: the charging car runs over the chambers and fills in coal; when the coke is done, the pusher shoves the glowing cake into the quench car, and the cloud rises at the quench tower.

What is shown – why – for whom

What is shown Why For whom
Coke oven battery with charging car, pusher machine and quenching car WhyShows where coal becomes coke. For whommuseum, teaching
Quenching tower with rising cloud WhyShows what happens to the glowing coke. For whommuseum, exhibition
Coal tower and sorting tower WhyShows how the coal is taken in and the coke sorted by size before it goes to the ironworks. For whomteaching, history of technology
Compressor house and gas pipeline WhyShows how the gas was compressed and pushed into the long-distance gas grid. For whomteaching, industrial heritage
Coal trains from the collieries and coke trains to the ironworks WhyShows where the coking plant sits in the chain from colliery to ironworks. For whomteaching, local history
Coke stockpile WhyShows what happens to coke the market does not take. For whomeconomics teaching, exhibition
Five controls with output, stockpile and daily result WhyShows connections in operations, not operating figures. For whomeconomics teaching
Battery 4

03

Battery 4

Battery 4 – the expansion runs along as long as people, materials and market suffice.

Five levers, one works

04

Five levers, one works

Full investment – four batteries: capacity for the boom, but only with enough people and materials.

Films from the model

  • Above Hansa coking plant

    A flight across the whole site: low approach, Battery 1, then across the works to the long shot – everything moving, with the sound of the works.

  • From raw material to product

    The works’ chain in one flight – supply (coal trains from the collieries), batteries, coke heap, dispatch: station by station.

  • A working day in time-lapse

    In time-lapse working days pass in seconds: shifts at the gate, traffic on the supply and dispatch routes, the stockpile (coke heap) changing along.

  • A works grows

    Investment step by step: new batteries appear, the workforce grows with them, then more supply and a boom in the market.

  • Bottleneck – the works respond

    First materials run short and the plant only runs in part, then the market takes too little and the stockpile fills up – in the boom the works recover.

  • Using the software

    With the full interface: open the works, set investment and market, look at stockpile and plant – every lever acts at once.

Facilities and areas in the model

  • Batteries

    A coke oven battery: the charging car runs over the chambers and fills in coal; when the coke is done, the pusher shoves the glowing cake into the quench car, and the cloud rises at the quench tower. In the game: 1 real, 3 as expansion (interpreted).

  • Coke heap

    Whatever is made but not sold ends up here; when it is full the surplus goes at a discount, when the market wants more it is drawn down.

  • Supply

    Coal trains from the collieries. A bigger contract costs more, the store buffers short gaps.

  • Dispatch

    Coke trains to the ironworks, gas via the compressor hall into the grid. The market only takes what it needs.

  • Compressor hall

    Where the gas was compressed and pushed into the long-distance grid; in the model the gas line leads there.

  • Coal tower

    It takes the coal from the trains; the charging car collects it on top for the chambers.

  • Grading tower

    The coke is sorted by size here before it goes onto the trains to the ironworks.

When things get tight

05

When things get tight

Coke heap filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.

Medium long shot

06

Medium long shot

Medium long shot – Battery 1: charging car on the battery, cloud at the quench tower.

Processes in the model

From raw material to product

  1. 01supply – coal trains from the collieries
  2. 02batteries – charging car on the battery, cloud at the quench tower
  3. 03coke heap – takes in what is not sold
  4. 04dispatch – coke trains to the ironworks, gas via the compressor hall into the grid

Expansion

  1. 01raise investment by one step
  2. 02another battery is built on its plot
  3. 03set the workforce to match, otherwise it only runs in part
  4. 04the market decides whether it pays – success in one number at the top

Bottleneck and recovery

  1. 01supply short – the store empties
  2. 02materials missing – the plants only run in part
  3. 03market in a slump – the stockpile grows until the fire sale
  4. 04boom – the stockpile empties, the result rises

What the model can be used for

  • Museum and exhibition

    The battery explains itself on the plant: the charging car fills the chambers, the pusher machine shoves the glowing cake into the quenching car, the cloud rises at the quenching tower. Each step comes with one sentence.

    For whommuseums, visitor centres, exhibitions

  • School and university

    How does coal become coke, and what did the ironworks need it for? Terms like coke oven battery, quenching car and coke oven gas sit where they belong.

    For whomschools, universities, vocational training

  • Industrial heritage and local history

    Coking plant, coal tower and compressor house stand on the real terrain. You see where the coal trains from the collieries and the coke trains to the ironworks ran, and where the gas went.

    For whomindustrial heritage, city marketing, local history societies

  • Understanding operations

    Investment, workforce, supply, quality and market act at once on output, stockpile and result. It becomes visible why a new battery without coal and sales costs money.

    For whomeconomics teaching, further training

Battery 1 at work

07

Battery 1 at work

Battery 1 at work – charging car on the battery, cloud at the quench tower; the machines run with the works’ utilisation.

The whole software

08

The whole software

Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.

What you can change

Controls

  • Investment: Number of batteries (1 to 4): more money builds more, less shuts them down; without more people they only run in part.
  • Workforce: Enough people for all batteries – output rises, and so does success. Too many people cost wages without more output.
  • Supply: More material arrives – the plant no longer has to wait. Levels short, normal and double; supply security costs money.
  • Quality: More quality means less scrap and fewer breakdowns but costs testing and maintenance (levels low, normal, high).
  • Market: Slump, normal or boom. In a slump more is made than sold: the stockpile grows and success drops. In a boom the market takes more: the stockpile empties and success rises.

Disruptions

  • Too few people: Workers are missing, part of the plant stands still.
  • Material missing: Supply is not enough; once the store is empty the plants only run in part (message: “Parts store empty – supply is short”).
  • Too much built: More is made than the market takes: the stockpile grows; when it is full the surplus goes at a 40 % discount (message: “Stockpile full – fire sale at a discount”).
  • Market wants more: Demand is greater than the works can make; once the stockpile is empty orders are lost (message: “Stockpile empty – orders are lost”).

What the model brings

  • 01

    The real terrain as a stage

    Coking plant, tracks and surroundings stand on terrain from official elevation data. You show the site as it lies, not as a diagram.

  • 02

    One battery, step by step

    Charging, pushing, quenching: you see the way from coal to coke before you steer the plant yourself.

  • 03

    Bottlenecks without damage

    Supply runs short, the store empties, the coke stockpile fills up. You see where it gets tight first, and set it back.

  • 04

    For big screens and the browser

    Runs in the browser and on large projections. A working day in fast motion lasts ten seconds.

  • Hansa coking plant: In the coke oven batteries of Dortmund-Huckarde coal is baked into coke for the ironworks without air; the gas goes into the grid via the compressor hall.
    Hansa coking plant: In the coke oven batteries of Dortmund-Huckarde coal is baked into coke for the ironworks without air; the gas goes into the grid via the compressor hall.
  • Hansa coking plant from the other side – the same site in the afternoon sun from the south-west, with long shadows of halls and structures.
    Hansa coking plant from the other side – the same site in the afternoon sun from the south-west, with long shadows of halls and structures.
  • Medium long shot – Battery 1: charging car on the battery, cloud at the quench tower.
    Medium long shot – Battery 1: charging car on the battery, cloud at the quench tower.
  • Far out near Dortmund-Huckarde – terrain, houses and trees come from official elevation data; at the edge the world fades softly into the dark.
    Far out near Dortmund-Huckarde – terrain, houses and trees come from official elevation data; at the edge the world fades softly into the dark.
  • From above – Hansa coking plant as a model of blocks: every cell a block, buildings and terrain from elevation data and OpenStreetMap.
    From above – Hansa coking plant as a model of blocks: every cell a block, buildings and terrain from elevation data and OpenStreetMap.
  • Hansa coking plant from above at an angle – supply, batteries, coke heap and dispatch at a glance.
    Hansa coking plant from above at an angle – supply, batteries, coke heap and dispatch at a glance.
  • All around Dortmund-Huckarde: streets, tracks and water from OpenStreetMap, houses and trees from the elevation data – only the plant in the middle is built specially.
    All around Dortmund-Huckarde: streets, tracks and water from OpenStreetMap, houses and trees from the elevation data – only the plant in the middle is built specially.
  • At eye level – Battery 1, as close as from the fence.
    At eye level – Battery 1, as close as from the fence.
  • Battery 1 (real) – A coke oven battery: the charging car runs over the chambers and fills in coal; when the coke is done, the pusher shoves the glowing cake into the quench car, and the cloud rises at the quench tower.
    Battery 1 (real) – A coke oven battery: the charging car runs over the chambers and fills in coal; when the coke is done, the pusher shoves the glowing cake into the quench car, and the cloud rises at the quench tower.
  • Battery 2 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Battery 2 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Battery 3 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Battery 3 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Battery 4 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Battery 4 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Coke heap – whatever is made but not sold ends up here; when there is no room left, the surplus goes at a discount.
    Coke heap – whatever is made but not sold ends up here; when there is no room left, the surplus goes at a discount.
  • Supply – coal trains from the collieries: a bigger contract costs more, the store buffers short gaps.
    Supply – coal trains from the collieries: a bigger contract costs more, the store buffers short gaps.
  • Compressor hall – where the gas was compressed and pushed into the long-distance grid; in the model the gas line leads there.
    Compressor hall – where the gas was compressed and pushed into the long-distance grid; in the model the gas line leads there.
  • Coal tower – it takes the coal from the trains; the charging car collects it on top for the chambers.
    Coal tower – it takes the coal from the trains; the charging car collects it on top for the chambers.
  • Grading tower – the coke is sorted by size here before it goes onto the trains to the ironworks.
    Grading tower – the coke is sorted by size here before it goes onto the trains to the ironworks.
  • Battery 1 close up – charging car on the battery, cloud at the quench tower.
    Battery 1 close up – charging car on the battery, cloud at the quench tower.
  • Coke heap close up – the material grows into a heap when more is made than collected.
    Coke heap close up – the material grows into a heap when more is made than collected.
  • Supply in full swing – coal trains from the collieries; the bigger the contract, the more is on the move.
    Supply in full swing – coal trains from the collieries; the bigger the contract, the more is on the move.
  • Battery 1 at work – charging car on the battery, cloud at the quench tower; the machines run with the works’ utilisation.
    Battery 1 at work – charging car on the battery, cloud at the quench tower; the machines run with the works’ utilisation.
  • Battery 4 – the expansion runs along as long as people, materials and market suffice.
    Battery 4 – the expansion runs along as long as people, materials and market suffice.
  • Coke heap in day-to-day operation – the material grows into a heap when more is made than collected.
    Coke heap in day-to-day operation – the material grows into a heap when more is made than collected.
  • Dispatch – coke trains to the ironworks, gas via the compressor hall into the grid; in a boom more is on the move, in a slump less.
    Dispatch – coke trains to the ironworks, gas via the compressor hall into the grid; in a boom more is on the move, in a slump less.
  • At the gate – the shifts arrive here, paths lead to the plants, the workshop and the break area.
    At the gate – the shifts arrive here, paths lead to the plants, the workshop and the break area.
  • Full steam – all four batteries running, the market booming: supply and dispatch routes are at their busiest.
    Full steam – all four batteries running, the market booming: supply and dispatch routes are at their busiest.
  • Small investment – only Battery 1 runs, the other plots lie ready as marked foundations.
    Small investment – only Battery 1 runs, the other plots lie ready as marked foundations.
  • Full investment – four batteries: capacity for the boom, but only with enough people and materials.
    Full investment – four batteries: capacity for the boom, but only with enough people and materials.
  • Every facility labelled – battery 1 to 4, coke heap, supplier and market; at the top the working day with the daily output, on the right success in one number.
    Every facility labelled – battery 1 to 4, coke heap, supplier and market; at the top the working day with the daily output, on the right success in one number.
  • Battery 1 labelled – name and number right in the picture.
    Battery 1 labelled – name and number right in the picture.
  • Success in one number – 100 means it cannot get better in this market; below it the result per day, at the top the output per working day.
    Success in one number – 100 means it cannot get better in this market; below it the result per day, at the top the output per working day.
  • Where a lever acts, a ring lights up – here after a change in the market: coke heap.
    Where a lever acts, a ring lights up – here after a change in the market: coke heap.
  • Materials missing – supply is short, the store is empty: the batteries only run in part, the supply route is quiet.
    Materials missing – supply is short, the store is empty: the batteries only run in part, the supply route is quiet.
  • Coke heap filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.
    Coke heap filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.
  • Too few people – the workforce is not enough for all batteries, part of the plant stands still.
    Too few people – the workforce is not enough for all batteries, part of the plant stands still.
  • Boom – the market takes more than is being made: the stockpile empties, the dispatch route is busy.
    Boom – the market takes more than is being made: the stockpile empties, the dispatch route is busy.
  • The whole software – at the top the working day with clock and output, on the right success in one number, below the tiles for works and facilities.
    The whole software – at the top the working day with clock and output, on the right success in one number, below the tiles for works and facilities.
  • Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.
    Running the works – five levers: investment, workforce, supply, quality and market; the chain shows at once what follows.
  • One lever, visible at once – market set to slump: the status line explains the bottleneck, the stockpile grows, the daily result drops.
    One lever, visible at once – market set to slump: the status line explains the bottleneck, the stockpile grows, the daily result drops.
  • Facility card – battery: in operation, workforce and utilisation, plus one sentence on what happens there.
    Facility card – battery: in operation, workforce and utilisation, plus one sentence on what happens there.
  • Stockpile card – coke heap: stock, space used and growth per day.
    Stockpile card – coke heap: stock, space used and growth per day.
  • Supplier card – delivery per day, store and material costs per day.
    Supplier card – delivery per day, store and material costs per day.
  • Market card – demand, sold and turnover per day.
    Market card – demand, sold and turnover per day.
  • Bottleneck in orange – supply is not enough: the line at the top and the works status say in one sentence what is missing.
    Bottleneck in orange – supply is not enough: the line at the top and the works status say in one sentence what is missing.
  • The menu – overview and plant, cutaway, restart, demo, sound and other sites, below the controls for mouse, touch and keyboard.
    The menu – overview and plant, cutaway, restart, demo, sound and other sites, below the controls for mouse, touch and keyboard.
  • Sixteen real sites – blast furnaces, collieries, car plants, harbours and a shipyard, each where it really stands.
    Sixteen real sites – blast furnaces, collieries, car plants, harbours and a shipyard, each where it really stands.

Your site as a model

Would you like to show your plant, your museum or your industrial site like this? Write to us or call. We will send you the password for starting it on request.

Start with password

Request the password if you are interested →

Ask about this

Minimal Factory: Kokerei Hansa · aus Kohle wird Koks

What you enter goes to this site alone and serves only to answer you.

Basis and limits

Real are the location, terrain and buildings in Dortmund-Huckarde (official NRW elevation data and OpenStreetMap). The plant in the middle is our own simplified interpretation: quantities, processes, times and prices are model assumptions; the economy runs in time-lapse (10 seconds are one working day). Not a simulation of real operations and no cooperation with the site.

Public sources the model is based on:

  • Wikipedia (German), article on the site: Kokerei Hansa
  • Geobasis NRW: digital surface and terrain models DOM1/DGM1 (Data licence Germany – Zero – 2.0)
  • OpenStreetMap contributors (ODbL 1.0): streets, tracks, water, land use

More places in the model

← Minimal Factory

Real are location, terrain and buildings (official NRW elevation data, OpenStreetMap). The three further batteries are interpreted; quantities, processes and times are model values. With your data, the model shows your site and your processes.