Abstract:
The invention provides a coke oven charging machine including a mobile frame and a coke oven feed device on the mobile frame. The coke oven feed device includes a movable, elongate charging plate having a first end and a second end, retractable side-walls adjacent the charging plate, first and second end walls adjacent the first and second ends of the charging plate and a shuttle section adjacent the first end of the charging plate for spanning an area between the first end of the charging plate and an entrance to the oven. The shuttle section has opposed shuttle side walls and a shuttle end wall. A charging plate moving device is provided for moving the charging plate into and out of the oven. The charging machine apparatus provides a means for quickly charging coking ovens with a compacted coal charge so that lower quality coals may be used to make metallurgical coke.

Description:
FIELD OF THE INVENTION 
     The invention relates to a method and apparatus for making coke from coal and in particular to a method and apparatus for compacting and feeding coal to a non-recovery coking oven. 
     BACKGROUND 
     Coke is a solid carbon fuel and carbon source used to melt and reduce iron ore in the production of steel. During an iron-making process, iron ore, coke, heated air and limestone or other fluxes are fed into a blast furnace. The heated air causes combustion of the coke which provides heat and a source of carbon for reducing iron oxides to iron. Limestone or other fluxes may be added to react with and remove the acidic impurities, called slag, from the molten iron. The limestone-impurities float to the top of the molten iron and are skimmed off. 
     In one process, known as the “Thompson Coking Process,” coke used for refining metal ores is produced by batch feeding pulverized coal to an oven which is sealed and heated to very high temperatures for 24 to 48 hours under closely controlled atmospheric conditions. Coking ovens have been used for many years to covert coal into metallurgical coke. During the coking process, finely crushed coal is heated under controlled temperature conditions to devolatilize the coal and form a fused mass having a predetermined porosity and strength. Because the production of coke is a batch process, multiple coke ovens are operated simultaneously, hereinafter referred to as a “coke oven battery”. 
     At the end of the coking cycle, the finished coke is removed from the oven and quenched with water. The cooled coke may be screened and loaded onto rail cars or trucks for shipment or later use or moved directly to an iron melting furnace. 
     The melting and fusion process undergone by the coal particles during the heating process is the most important part of the coking process. The degree of melting and degree of assimilation of the coal particles into the molten mass determine the characteristics of the coke produced. In order to produce the strongest coke from a particular coal or coal blend, there is an optimum ratio of reactive to inert entities in the coal. The porosity and strength of the coke are important for the ore refining process and are determined by the coal source and/or method of coking. 
     Coal particles or a blend of coal particles are charged into hot ovens on a predetermined schedule, and the coal is heated for a predetermined period of time in the ovens in order to remove volatiles from the resulting coke. The coking process is highly dependent on the oven design, the type of coal and conversion temperature used. Ovens are adjusted during the coking process so that each charge of coal is coked out in approximately the same amount of time. Once the coal is coked out, the coke is removed from the oven and quenched with water to cool it below its ignition temperature. The quenching operation must also be carefully controlled so that the coke does not absorb too much moisture. Once it is quenched, the coke is screened and loaded into rail cars or trucks for shipment. 
     Because coal is fed into hot ovens, much of the coal feeding process is automated. In slot-type ovens, the coal is typically charged through slots or openings in the top of the ovens. Such ovens tend to be tall and narrow. More recently, non-recovery or heat recovery type coking ovens have been used to produce coke. Such ovens are described for example in U.S. Pat. Nos. 3,784,034 and 4,067,462 to Thompson. Conveyors are used to convey the coal particles into the ovens and to level the coal in the ovens. 
     As the source of coal suitable for forming metallurgical coal has decreased, attempts have been made to blend weak or non-coking coals with coking coals to provide a suitable coal charge for the ovens. One attempt is to use compacted coal. The coal may be compacted before or after it is in the oven. While coal conveyors are suitable for charging ovens with particulate coal which is then compacted in the oven, they are generally not suitable for charging ovens with pre-compacted coal. There is a need therefor, for a method and apparatus for charging coking ovens with pre-compacted coal. There is also a need for an apparatus for compacting coal in a short period of time in order to reduce labor and production costs for making metallurgical coke. 
     SUMMARY OF THE INVENTION 
     In accordance with the foregoing need, the invention provides an improved coke oven charging device and method for charging compacted coal to a coking oven, the coking oven having an exhaust-flue heated floor, substantially parallel vertical side-walls, a pusher door adjacent an oven entrance, a coke door adjacent an oven exit and an arched substantially closed roof. According to the method, a coke oven pusher and charging machine is moved adjacent the pusher door of the oven. The coke oven pusher and charging machine includes a movable, elongate charging plate having a first end and a second end, retractable side-walls adjacent the charging plate, a first end wall adjacent the second end of the charging plate, a charging plate moving device for moving the charging plate into and out of the oven and a movably separate coal guide section adjacent the first end of the charging plate for spanning an area between the first end of the charging plate and the oven entrance. The coal guide section includes a bottom wall, opposed fixed side walls attached to the bottom wall and opposed second and third end walls movable with respect to the bottom wall and fixed side walls. 
     Particulate coal is fed to the charging plate between the side walls and second end wall of the coal guide section and to the coal guide section between the second and third end walls to form first and second coal beds. The coal in the first coal bed is compacted between the retractable side walls and first and second end walls. The pusher door is removed from the coking oven entrance and the coke door is removed from the oven exit. Coke is pushed out of the coking oven into a hot car and the coke door is reattached to the oven exit. 
     A portion of the coal guide section is transported into the oven entrance in order to span a distance between the oven entrance and the charging plate. The second and third end walls are retracted from the bottom wall of the coal guide section in order to deposit uncompacted coal in at least a portion of the oven. The retractable side walls are retracted from the compacted coal on the charging plate. The charging plate containing compacted coal is moved into the oven over the coal guide section while pushing uncompacted coal ahead of the compacted coal so that the uncompacted coal forms a layer of substantially uncompacted coal between the heated oven floor and the charging plate. The second and third end walls are repositioned adjacent the charging plate and the charging plate is retracted from the oven while holding the compacted coal in the oven using the third end wall. Finally, the coal guide section is withdrawn from the oven entrance and the pusher door is reattached to the oven. 
     In another aspect the invention provides a coke oven charging machine including a mobile frame and a coke oven feed device on the mobile frame. The coke oven feed device includes a movable, elongate charging plate having a first end and a second end, retractable side-walls adjacent the charging plate, first and second end walls adjacent the first and second ends of the charging plate and a shuttle section adjacent the first end of the charging plate for spanning an area between the first end of the charging plate and an entrance to the oven. The shuttle section has opposed shuttle side walls and a shuttle end wall. A charging plate moving device is provided for moving the charging plate into and out of the oven. 
     In yet another aspect the invention a method for charging coal to a coking oven. The method includes the steps of providing a bed of compacted coal on a first charging plate and a bed of uncompacted coal on a second charging plate. The first charging plate is located outside the oven adjacent an oven entrance and the second charging plate is positioned between the first charging plate and the oven entrance and vertically below the first charging plate so that the first charging plate may be urged to pass over the second charging plate. A portion of the second charging plate is urged into the oven entrance to deposit uncompacted coal adjacent the oven entrance and partially in the oven. The first charging plate is advanced into the oven through the entrance and over the second charging plate to position compacted coal in the oven, whereby portions of the first charging plate and compacted coal contact portions of the uncompacted coal to urge uncompacted coal into the oven ahead of and beneath the first charging plate as the first charging plate is advanced into the oven. The first charging plate is then withdrawn from the oven through the oven entrance and the second charging plate is withdrawn from the oven entrance to yield a resulting coal bed within the oven comprising a compacted coal bed overlying uncompacted coal. 
     The method and apparatus described above provide unique advantages for coking operations including providing insulation between the hot oven floor and the charging plate of the oven charging apparatus so as to reduce warpage of the charging plate caused by heat. The charging plate is shielded by the loose coal layer and compacted coal from radiant heat from the floor and oven walls and does not contact the hot oven floor. Another advantage is that the coal is substantially evenly distributed in the oven without the need for leveling the coal in the oven. Any uneveness of the oven floor will also be compensated for by the loose coal layer. The loose coal layer also reducing sliding friction between the charging plate and oven floor thereby reducing wear on the charging plate and oven floor. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Further advantages of the invention will become apparent by reference to the detailed description of preferred embodiments when considered in conjunction with the drawings, which are not to scale, wherein like reference characters designate like or similar elements throughout the several drawings as follows: 
     FIG. 1 is an overall plan view of a charging machine according to the invention; 
     FIG. 2 is a top plan view of a portion of a charging machine according to the invention; 
     FIG. 3 is an elevational view of a portion of a charging machine according to the invention; 
     FIG. 4 is an end elevational view of a portion of a charging machine according to the invention; and 
     FIGS. 5-11 are schematic representations of a process for charging a coke oven using a charging machine according to the invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference to FIG. 1, there is provided a charging machine  10  for a coke oven. The charging machine includes a compacted coal chamber  12  and an uncompacted coal chamber  14 . Coal is provided to the compacted coal chamber and uncompacted coal chamber by means of a cross conveyor  16  for transferring coal from a coal supply to a charging chute  18  and into a coal charging chamber  20 . The coal charging chamber  20  preferably includes a leveling device such as a chain flight leveling system  22  for distributing coal  24 , preferably uncompacted coal into the coal charging chamber  20 . The coal charging chamber  20  is supported above the compacted coal chamber  12  and uncompacted coal chamber  14  as by support beams  26 . 
     Coal is deposited on a charging plate  28  and in the uncompacted coal chamber  14  by flow through two or more discharge chutes  30 . The discharge chutes  30  are preferably pyramidal-shaped discharge chutes containing flanged exits  32 . Discharge valves  34  which may be selected from rotary valves, slide gate valves, pinch valves and the like are preferably attached to the flanged exits  32  of each of the discharge chutes  30 . It is particularly preferred to provide one or more discharge chutes  30  adjacent the uncompacted coal chamber  14  for depositing coal in chamber  14  separate from coal deposited on the charging plate  28 . 
     A foraminous vibratory plate  36  is movably disposed between the charging chamber  20  and the charging plate  28 . The foraminous plate has a thickness preferably ranging from about 2 to about 4 inches and preferably contains a plurality of holes having a diameter ranging from about 1 inch to about 4 inches. Foraminous plate  36  is preferably suspended so as to be moved toward and away from the charging plate  28  while maintaining a substantially parallel orientation with respect thereto. Accordingly, the foraminous plate  36  is preferably attached to support beams  26  as by chains  38  or other flexible support means and may be raised and lowered as by one or more pulleys  40  or other suitable adjusting structure. A vibrator  42  which may be selected from hydraulic or electro-mechanical rotatable eccentric weight or other suitable vibrating means is preferably attached to the foraminous plate  36 . 
     The compacted coal chamber  12  of the charging machine  10  is defined by a substantially fixed end-wall  44 , intermediate movable wall  46 , movable side walls  48  and movable charging plate  28 . The movable charging plate  28  preferably has a thickness ranging from about 2 to about 3 inches and is preferably made of cast steel. The intermediate movable wall  46  and movable front wall  50  along with stationary side walls  52  and the movable coal guide plate  54  define the uncompacted coal chamber  14 . The intermediate movable wall  46  and movable front wall  50  are attached to a rectangular lifting frame  56  shown in more detail in FIGS. 2 and 3. An actuator  58  is attached to the coal guide plate  54  and is actuated to lift the lifting frame  56  during oven charging once the uncompacted coal chamber  14  is partially inserted into the oven. 
     The movable charging plate  28  is slidably positioned in the oven by moving the charging plate  28  over the coal guide plate  54  by means of a charging plate drive system  60 . The charging plate drive system  60  is preferably a continuous chain drive assembly including a chain and chain drive unit, described in more detail below, attached to one end of the charging plate  28 . 
     The entire coal filling and charging assembly described above is attached to a movable charging car  62  which includes a support frame  64  and wheels  66  defining the charging machine  10 . The charging car  62  rides on rails  68  which are parallel to a battery of coke ovens and perpendicular to the coal charging direction into the oven. The charging car  62  may be a separately movable assembly which is coupled to a coke pusher assembly as described in U.S. Pat. No. 3,784,034 to Thompson, U.S. Pat. No. 3,912,091 to Thompson and U.S. Pat. No. 4,067,462 to Thompson incorporated by reference herein as if fully set forth. 
     Details of the movable coal guide assembly  70  will now be described in detail with reference to FIGS. 2 and 3. The coal guide assembly  70  includes a movable coal guide plate  54  for supporting uncompacted coal  14  and for moving or bridging a gap between the movable charging car  62  (FIG. 1) and the coke oven entrance  72 . The coal guide plate  54  is provided with a plate actuator  92  for moving the coal guide assembly  70  a distance D between the coal charging car  62  and the oven entrance  72 . It is preferred that end  80  the coal guide plate  54  extend into a coke oven  76  a distance ranging from about 0.5 to about 1 foot or more so as to minimize the amount of uncompacted coal  14  which may be lost due to spillage at the oven entrance  72 . Accordingly, the coal guide plate  54  preferably moves a distance ranging from about 15 to about 45 inches. As shown in FIG. 2, an upper surface  78  of the coal guide plate  54  is no more than about 6 to about 12 inches above oven floor surface  82 . 
     The coal guide plate  54  is preferably a cast steel plate having a thickness ranging from about 2 to about 3 inches. The coal guide assembly  70  also includes stiffeners  84  which may include beams or plates fixedly attached to the intermediate wall  46  and front wall  50  to reduce flexing of the front wall  50 . In a preferred embodiment, the stiffeners  84  are plates which form inner side walls of the uncompacted coal chamber  14 . The outer side walls  52  and coal guide plate  54  are attached to one another and move as a unit partially into the oven  76 . The intermediate wall  46  and movable front wall  50  are fixedly attached to lifting frame  56 . The guide plate  54 , side walls  52 , stiffeners  84 , intermediate wall  46  and front wall  50  define the uncompacted coal chamber  14  and move as a unit. Because of the heat generated by an open coke oven during charging, the plate  54  and front wall  50  may be optionally water-cooled such as by a water cooling circulating system. It is preferred that the front wall  50  be refractory-lined or otherwise insulated to reduce warping caused by excessive heat. 
     As seen in FIGS. 2 and 3, the lifting frame  56  is separately supported on the coal guide plate  54  on a slidable support frame  86 . The slidable support frame  86  is slidably disposed on a slide surface  88  attached to the movable coal guide plate  54 . A frame actuator  90  is attached to the slidable support frame  86  to move the support frame  86  along with the uncompacted coal chamber  14  toward the coking oven  76 . A coal guide actuator  92  is attached to the coal guide slide plate  54  to translate the uncompacted coal chamber  14  partially into the oven  76 . As shown in FIG. 2, actuator  58  is attached to the slidable support frame  86 . After the coal guide plate  54  is partially in the oven, actuator  58  is activated to lift and rotate lifting frame  56  about a pivot assembly  94  so that walls  46   a  and  50   a  do not interfere with movement of compacted coal into the oven  76 . The pivot assembly  94  is attached to a vertical pivot support beam  96  which is also attached to the guide plate  54 . 
     After movement of the coal guide assembly  70  partially into the oven  76  and lifting of lifting frame  56  and intermediate wall  46  and front wall  50 , the movable side walls  48  are retracted from the compacted coal  24  in compacted coal chamber  12  so as to reduce sliding friction while moving the compacted coal  24  into the oven  76 . With reference to FIG. 4, the movable side walls  48  may be translated across the charging plate  28  transverse to the movement of compacted coal  24  into the oven or may be tilted away from the compacted coal  24  to provide a sufficient gap between the movable side walls  48  and the compacted coal  24 . In a preferred embodiment, hydraulic actuators  98  are attached to an upper portion  100  of the side walls  48  and to a structural beam  102  attached to the charging car  62  for tiltable movement of the side walls  48  away from the compacted coal  24 . The gap between the compacted coal and the side walls  48  should be sufficient to significantly reduce friction between the side walls  48  and the compacted coal  24 . In this regard, the gap may range from 0.25 inches to about 3 inches or more adjacent the upper portion  100  of the side walls  48 . 
     It is also preferred that a portion of the stationary side walls  52  of the coal guide assembly  70  at least partially overlap the side walls  48  for at least the distance the coal guide assembly is moved into the coke oven  76  as shown in FIG.  3 . Overlapping a portion  104  of the side walls  48  reduces the amount of coal spilled from the coal guide assembly  70  during the charging operation. 
     With reference to FIG. 4 again, the charging plate  28  is preferably supported on slide plates. The slide plates are preferably provided in sections, preferably three sections  106   a ,  106   b  and  106   c  for support of the charging plate  28 . The slide plates  106   a-c  preferably having a thickness ranging from about 2 to about 4 inches and have a relatively smooth finish. Friction reducing coatings may also be applied to the surface of slide plates  106   a-c  between the slide plates  106   a-c  and charging plate  28  to reduce sliding friction. A suitable friction reducing material includes graphite, oil grease and the like. Support beams  116  are attached to the charging car  62  for supporting the slide plates  106   a-c.    
     The charging plate drive system  60  (FIG. 1) includes a chain drive  108 , a drive pin  110  and a drive member  112  attached to an underside  114  of charging plate  28 . The drive pin  110  is disposed in an aperture in drive member  112  and is attached to the drive chain  108  for translational movement of the charging plate  28  into and out of the oven. A chain return guide  118  is provide on the charging car  62  to guide the chain drive  108  during translational movement of the charging plate  28 . 
     As shown in detail in FIG. 4, movable side walls  48  are pivotably connected to a pivot pin  120  on the support frame  64  of the charging car  62 . Upon actuation of hydraulic actuator  98 , movable walls  48  are tilted away from the compacted coal on charging plate  28  as shown by arrow  122  to a position indicated by walls  48   a . After the compacted coal has been moved into the oven, actuators  98  are activated to return movable walls  48  to a substantially vertical orientation so that the walls are substantially perpendicular to a plane defined by charging plate  28 . 
     FIGS. 5-11 provide a schematic representation of a preferred charging sequence for a coke oven using the apparatus of the invention. It will be understood that the sequence of steps may be varied. According to the charging sequence, a charging machine  10  (FIG. 1) is moved adjacent an oven to be charged. The compacted and uncompacted coal chambers  12  and  14  of the charging machine  10  are filled with coal from a coal charging chamber  20  as described above. Coal is supplied to the coal charging chamber  20  from a cross conveyor  16  and charging chute  18  as described above. The coal in the charging chamber is leveled by chain flight leveling system  22  prior to charging the compacted coal chamber  12  and the uncompacted coal chamber  14 . For a coke oven having a width of about 12 feet and a length of about 45 feet and charged to a coal depth of from about 40 to about 50 inches, the coal charging chamber  20  is sized to preferably hold an amount of coal ranging from about 50 to about 80 tons of coal. 
     Uncompacted coal  24  from the charging chamber  20  is provided to uncompacted coal chamber  14  by opening discharge valve  34  on discharge chute  30  directly above the uncompacted coal chamber  14 . The uncompacted coal chamber  14  is sized to hold an amount of uncompacted coal sufficient to provide a layer of uncompacted coal on the oven floor between the charging plate  28  and the oven floor as described in more detail below. The uncompacted coal chamber preferably holds from about 5 to about 20 wt. % of the total coal, preferably from about 5 to about 10 tons of uncompacted coal for the size coking oven described above. Ovens with a width less than about 12 feet and a length less than about 45 feet may require less uncompacted coal to provide the uncompacted coal layer. Likewise, a larger oven requires more coal to provide the uncompacted coal layer. 
     Once the coal is sufficiently leveled in coal chamber  20 , valves  34  are opened on chutes  30  to dispense coal to the compacted and uncompacted coal chambers  12  and  14 . As set forth above, the coal provided to compacted coal chamber  12  is preferably provided by sifting the coal from chutes  30  through foraminous vibratory plate  36 . During the coal dispensing operation, the foraminous plate  36  is suspended by chains  38  above the charging plate  28  of the compacted coal chamber and a low amplitude, high frequency vibratory energy is applied to the plate  36  by means of vibrator  42 . The vibratory energy provided by vibrator  42  preferably has an amplitude of less than about 0.5 inches and a frequency of about 1800/minute, for example. The motion of the plate  36  during the coal dispensing step is effective to enable the coal to form a substantially even level of coal on charging plate  28 , both longitudinally and transversely. 
     Referring to FIG. 5, coal is supplied to the charging plate  28  between fixed wall  44  and intermediate movable wall  46  to provide a compacted coal charge  124 . Uncompacted coal  24  is disposed in uncompacted coal chamber  14  between intermediate movable wall  46  and movable front wall  50 . 
     Once the compacted and uncompacted coal chambers  12  and  14  are fully loaded with coal, the foraminous plate  36  is lowered onto the uncompacted coal in chamber  12 . Vibratory forces are applied to the plate as set forth above and the entire weight of the plate  36  on the coal causes the bulk density of the coal in chamber  12  to increase from about 40 to about 50 pounds per cubic foot to from about 60 to about 80 pounds per cubic foot. Compaction of the coal in chamber  12  may be accomplished in a single compaction step or in multiple compaction steps as the coal is loaded into chamber  12 . Once the coal in chamber  12  is compacted, foraminous plate  36  is raised by means of chains  38  to a position above the compacted coal which does not interfere with movement of the compacted coal into the oven. It is preferred that the coal be compacted in less than about 5 minutes, preferably in from about 1 to about 3 minutes after depositing coal in compaction chamber  12 . 
     Prior to oven charging, the charging machine  10  containing the compacted and uncompacted coal  124  and  24  is positioned adjacent an entrance  72  of a coking oven  76 , which is preferably a non-recovery coking oven. Both the entrance and exit  72  and  126  of the coking oven preferably contain removable oven doors  128  and  130 . Since coking ovens are in substantially continuous operation once initially started, previously finished coke must be removed from the oven  76  prior to charging the oven with compacted coal  124 . Coke is removed from the oven  76  through the exit  126  using a coke pusher as described above inserted through oven entrance  72  after removing oven entrance door  128  to the position indicated in FIG.  6 . 
     Regardless of how and when the finished coke is removed from the oven  76 , once the charging car  62  is provided with coal and the coal compacted, the uncompacted coal chamber  14  is moved part way into the oven entrance  72 . At this point, the movable coal guide plate  54  (FIG. 1) of the uncompacted coal chamber  14  spans the gap  132  between the charging car  62  and the oven  76  (FIGS.  5  and  6 ). Intermediate wall  46  and movable front wall  50  move along with the coal guide plate  54  toward the oven entrance  72  while the compacted coal  124  remains stationary. 
     In the next step of the process, the intermediate wall  46  and front wall  50  are moved upwardly away from the coal guide plate  54 . At this point, the uncompacted coal  24  spreads out into the oven entrance  72  and against the compacted coal  124  as shown in FIG.  7 . 
     As shown in FIG. 8, the charging plate  28  is then moved into the oven  76  by activation of a drive motor attached to drive chains  108 . As the charging plate  28  advances, uncompacted coal  24  is pushed forward of the compacted coal  124  so that a portion of the uncompacted coal  24  forms a layer  134  between the charging plate  28  and the oven floor  136  as the charging plate moves into the oven  76 . The uncompacted coal layer  134  is preferably sufficient to insulate the charging plate  28  from the radiant heat of the oven floor  136  and provides a relatively smooth, level surface for movement of the charging plate  28  into and out of oven  76 . As shown in FIG. 9, the charging plate  28  is moved into the oven  76  until the compacted coal  124  is completely in the oven and the uncompacted coal forms a layer  134  between charging plate  28  and the oven floor  136 . The weight of the compacted coal  124  and charging plate  28  is sufficient to compress the uncompacted coal in layer  134  to increase its density above that of uncompacted coal  24 . 
     Once the oven  76  has been charged with compacted coal, intermediate wall  46  and front wall  50  are lowered to a position adjacent the charging plate  28  so that front wall  50  is adjacent one end  138  of the compacted coal  124  (FIG.  10 ). Front plate  50  is positioned or designed to be moved adjacent end  138  of the compacted coal  124  to hold the compacted coal in the oven  76  while withdrawing the charging plate  28  from the oven  76 . As shown in FIG. 11, the charging plate  28  may be completely withdrawn from the oven  76  to its original position as shown in FIG. 5, while the compacted coal  124  and uncompacted coal layer  134  remain in the oven  76 . As seen in FIG. 11, the intermediate wall  46  and front wall  50  are only lowered part way toward coal guide plate  54  so that the charging plate  28  may move easily between the coal guide plate  54  and walls  46  and  50 . 
     In the final step of the operation, the uncompacted coal chamber  14  is moved away from the oven entrance  72  to its original position and the oven entrance door  128  is lowered and reattached to the oven entrance  72 . At this point, the charging car  62  may be repositioned adjacent the next coke oven to be charged and the process of loading the charge car, compacting the coal and charging the oven is repeated. 
     In the foregoing description, the entire apparatus with the exception of conveyor belts, electrical components and the like may be made of cast or forged steel. Accordingly, robust construction of the apparatus is possible and provides a relatively long lasting apparatus which is suitable for the coke oven environment. 
     The apparatus and methods described above enable use of less costly coal for metallurgical coke production thereby reducing the overall cost of the coke. Depending on the particular coal source and the level of compaction achieved, a compacted coal charge made according to the invention may include up to about 80 wt. % non-coking coal. The amount of coke produced by the apparatus of the invention may also be increased from 35 to 42 tons up to about 50 to about 60 tons as a result of the compaction process. More consistent coal charge physical parameters such as coal charge height, width and depth are also a benefit of the apparatus and methods according to the invention. 
     Having described various aspects and embodiments of the invention and several advantages thereof, it will be recognized by those of ordinary skills that the invention is susceptible to various modifications, substitutions and revisions within the spirit and scope of the appended claims.