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Simulation · Minimal Factory · Ruhr area

Zollverein · coal washery

A coal washery as a model: belts, screens and water, the loading bunker above the track, plus Shaft XII and the coking plant on the real terrain in Essen.

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Trailer

Real are location, terrain and structures (official NRW elevation data, OpenStreetMap). The throughput has not been handed down, further washeries are interpreted; quantities, processes and times are model values. With your data, the model shows your site and your processes.

Shaft XII and the large coal washery in Essen stand as a block model on their real terrain. Belts carry the raw coal up, screens separate it by grain size, water washes the rock out; the clean coal drops into the loading bunker above the track. Raw coal trains arrive, coal trains leave for the coking plant and for dispatch.

In the model the real washery runs again, more washeries grow in the park to the north of it. Five controls – investment (one to four washeries), workforce, supply, quality and market – show output, stockpile and daily result at once. The coal stockpile grows when more is washed than is taken.

Real are location, terrain and structures from official NRW elevation data and OpenStreetMap. The washery's throughput has not been handed down; new washeries, quantities, processes and times are an interpretation of our own and model values, and 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 – raw coal trains

  2. 02

    washeries – belts carry the raw coal up, water washes out the rock

  3. 03

    coal heap – takes in what is not sold

  4. 04

    dispatch – coal trains to the coking plant and dispatch

A site at work

01

A site at work

Zollverein: Shaft XII and the big coal washery in Essen: belts, screens and water sort the raw coal by size, further washeries grow in the park to the north.

Washery 1 (real)

02

Washery 1 (real)

Washery 1 (real) – A coal washery: belts carry the raw coal up, screens sort it by size, water washes out the rock; the clean coal drops into the loading bunker above the track.

What is shown – why – for whom

What is shown Why For whom
Coal washery with belts, screens and water WhyShows how raw coal is separated by grain size and freed of rock. For whommuseum, teaching
Loading bunker above the track WhyShows where the clean coal is loaded onto trains. For whommuseum, exhibition
Shaft XII with double-headframe winding tower WhyShows the central winding plant right next to the coal washery. For whomhistory of technology, exhibition
Coking plant with a long row of coke ovens WhyShows where part of the coal travels on. For whomteaching, industrial heritage
Raw coal trains and coal trains to the coking plant and dispatch WhyShows what is delivered to the washery and what leaves it. For whomteaching, local history
Coal stockpile WhyShows what happens to coal 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
Washery 4

03

Washery 4

Washery 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 washeries: capacity for the boom, but only with enough people and materials.

Films from the model

  • Above Zollverein

    A flight across the whole site: low approach, Washery 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 (raw coal trains), washeries, coal 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 (coal heap) changing along.

  • A works grows

    Investment step by step: new washeries 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

  • Washeries

    A coal washery: belts carry the raw coal up, screens sort it by size, water washes out the rock; the clean coal drops into the loading bunker above the track. In the game: 1 real, 3 as expansion (interpreted).

  • Coal 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

    Raw coal trains. A bigger contract costs more, the store buffers short gaps.

  • Dispatch

    Coal trains to the coking plant and dispatch. The market only takes what it needs.

  • Shaft XII

    The central hoisting plant with its twin-trestle headframe, right next to the coal washery.

  • Zollverein coking plant

    The long row of coke ovens, in the model from the elevation data.

When things get tight

05

When things get tight

Coal 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 – Washery 1: belts carry the raw coal up, water washes out the rock.

Processes in the model

From raw material to product

  1. 01supply – raw coal trains
  2. 02washeries – belts carry the raw coal up, water washes out the rock
  3. 03coal heap – takes in what is not sold
  4. 04dispatch – coal trains to the coking plant and dispatch

Expansion

  1. 01raise investment by one step
  2. 02another washery 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 washery explains itself on the plant: belts carry the raw coal up, screens sort by grain size, water washes out the rock, the clean coal drops into the loading bunker.

    For whommuseums, visitor centres, exhibitions

  • School and university

    How was coal washed and sorted by size? Terms like raw coal, grain size, screen and loading bunker sit where they belong.

    For whomschools, universities, vocational training

  • Industrial heritage and World Heritage

    Why is Zollverein a World Heritage site? Shaft XII with its double-headframe winding tower, the coal washery and the long row of coke ovens stand side by side on the real terrain.

    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 further washery without raw coal and sales costs money.

    For whomeconomics teaching, further training

Washery 1 at work

07

Washery 1 at work

Washery 1 at work – belts carry the raw coal up, water washes out the rock; 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 washeries (1 to 4): more money builds more, less shuts them down; without more people they only run in part.
  • Workforce: Enough people for all washeries – 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

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

  • 02

    From raw coal to clean coal

    Belts, screens, water, loading bunker: you see the path of the raw coal before you steer the washery yourself.

  • 03

    Bottlenecks without damage

    The raw coal fails to arrive, the store empties, the coal 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.

  • Zollverein: Shaft XII and the big coal washery in Essen: belts, screens and water sort the raw coal by size, further washeries grow in the park to the north.
    Zollverein: Shaft XII and the big coal washery in Essen: belts, screens and water sort the raw coal by size, further washeries grow in the park to the north.
  • Zollverein from the other side – the same site in the afternoon sun from the south-west, with long shadows of halls and structures.
    Zollverein 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 – Washery 1: belts carry the raw coal up, water washes out the rock.
    Medium long shot – Washery 1: belts carry the raw coal up, water washes out the rock.
  • Far out near Essen – terrain, houses and trees come from official elevation data; at the edge the world fades softly into the dark.
    Far out near Essen – terrain, houses and trees come from official elevation data; at the edge the world fades softly into the dark.
  • From above – Zollverein as a model of blocks: every cell a block, buildings and terrain from elevation data and OpenStreetMap.
    From above – Zollverein as a model of blocks: every cell a block, buildings and terrain from elevation data and OpenStreetMap.
  • Zollverein from above at an angle – supply, washeries, coal heap and dispatch at a glance.
    Zollverein from above at an angle – supply, washeries, coal heap and dispatch at a glance.
  • All around Essen: streets, tracks and water from OpenStreetMap, houses and trees from the elevation data – only the plant in the middle is built specially.
    All around Essen: streets, tracks and water from OpenStreetMap, houses and trees from the elevation data – only the plant in the middle is built specially.
  • Washery 1 (real) – A coal washery: belts carry the raw coal up, screens sort it by size, water washes out the rock; the clean coal drops into the loading bunker above the track.
    Washery 1 (real) – A coal washery: belts carry the raw coal up, screens sort it by size, water washes out the rock; the clean coal drops into the loading bunker above the track.
  • Washery 2 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Washery 2 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Washery 3 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Washery 3 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Washery 4 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
    Washery 4 (expansion, interpreted) – only appears with more investment and runs only with enough people and materials.
  • Coal heap – whatever is made but not sold ends up here; when there is no room left, the surplus goes at a discount.
    Coal heap – whatever is made but not sold ends up here; when there is no room left, the surplus goes at a discount.
  • Supply – raw coal trains: a bigger contract costs more, the store buffers short gaps.
    Supply – raw coal trains: a bigger contract costs more, the store buffers short gaps.
  • Shaft XII – the central hoisting plant with its twin-trestle headframe, right next to the coal washery.
    Shaft XII – the central hoisting plant with its twin-trestle headframe, right next to the coal washery.
  • Zollverein coking plant – the long row of coke ovens, in the model from the elevation data.
    Zollverein coking plant – the long row of coke ovens, in the model from the elevation data.
  • Coal heap close up – the material grows into a heap when more is made than collected.
    Coal heap close up – the material grows into a heap when more is made than collected.
  • Supply in full swing – raw coal trains; the bigger the contract, the more is on the move.
    Supply in full swing – raw coal trains; the bigger the contract, the more is on the move.
  • Washery 1 at work – belts carry the raw coal up, water washes out the rock; the machines run with the works’ utilisation.
    Washery 1 at work – belts carry the raw coal up, water washes out the rock; the machines run with the works’ utilisation.
  • Washery 4 – the expansion runs along as long as people, materials and market suffice.
    Washery 4 – the expansion runs along as long as people, materials and market suffice.
  • Coal heap in day-to-day operation – the material grows into a heap when more is made than collected.
    Coal heap in day-to-day operation – the material grows into a heap when more is made than collected.
  • Dispatch – coal trains to the coking plant and dispatch; in a boom more is on the move, in a slump less.
    Dispatch – coal trains to the coking plant and dispatch; 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 washeries running, the market booming: supply and dispatch routes are at their busiest.
    Full steam – all four washeries running, the market booming: supply and dispatch routes are at their busiest.
  • Small investment – only Washery 1 runs, the other plots lie ready as marked foundations.
    Small investment – only Washery 1 runs, the other plots lie ready as marked foundations.
  • Full investment – four washeries: capacity for the boom, but only with enough people and materials.
    Full investment – four washeries: capacity for the boom, but only with enough people and materials.
  • Every facility labelled – washery 1 to 4, coal heap, supplier and market; at the top the working day with the daily output, on the right success in one number.
    Every facility labelled – washery 1 to 4, coal heap, supplier and market; at the top the working day with the daily output, on the right success in one number.
  • Washery 1 labelled – name and number right in the picture.
    Washery 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: coal heap.
    Where a lever acts, a ring lights up – here after a change in the market: coal heap.
  • Materials missing – supply is short, the store is empty: the washeries only run in part, the supply route is quiet.
    Materials missing – supply is short, the store is empty: the washeries only run in part, the supply route is quiet.
  • Coal heap filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.
    Coal heap filling up – more is made than sold; when there is no room left the surplus goes at a 40 % discount.
  • 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 – washery: in operation, workforce and utilisation, plus one sentence on what happens there.
    Facility card – washery: in operation, workforce and utilisation, plus one sentence on what happens there.
  • Stockpile card – coal heap: stock, space used and growth per day.
    Stockpile card – coal 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: Zollverein · Kohlenwäsche

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 Essen (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: Zeche Zollverein
  • Website of the site
  • 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 structures (official NRW elevation data, OpenStreetMap). The throughput has not been handed down, further washeries are interpreted; quantities, processes and times are model values. With your data, the model shows your site and your processes.