Coke utilisation highlights operational improvements

Cost savings and production benefits with employee-driven initiative

A major improvement in metallurgical coke utilisation is one of several benefits emerging from the stabilisation of operations at the Whyalla Steelworks during administration.

Since the Whyalla coke ovens were shut down in 2023, the OneSteel Manufacturing Pty Ltd (Administrators Appointed) (OneSteel) steelworks has sourced coke both domestically and internationally in shipments of 30,000 to 40,000 tonnes.

During last year’s unplanned blast furnace shutdowns and production disruptions, the site experienced up to thirty per cent degradation of coking coal. In practical terms, for every 100 tonnes purchased, only about 70 tonnes were suitable for use in the blast furnace.

With a stable steelworks, this is another example of different crews across the operation being able to collaborate and come up with processes that save us even more time and money

Hayley Perkins

OneSteel General Manager Supply Chain, Hayley Perkins said that while several factors can contribute to degradation, repeated handling is known to be a primary driver of yield loss.

“If the blast furnace is constantly stopping, it results in the coke being discharged from the ship onto a conveyor to storage, picked up, trucked back to the wharf, dumped on a pad, re-picked up, and eventually consumed in the hopper,” Hayley said.

“The more you touch coke, the more it breaks down.’”

The furnace’s improved stability, supported by funding from the South Australian and Federal governments’ Whyalla operations rescue package, now enables far more efficient planning.

With operations running steadily, the team can feed the furnace directly from the pad, significantly reducing movement and handling of the coke. This streamlined process has also shortened vessel unloading times with the latest shipment completed in just two and a half days, compared with five or more days last year.

These improvements can save up to A$25,000 per day in ship demurrage. With an approximate 10% increase in coke usability, this can also generate savings of up to A$500,000 per shipment through reduced product loss.

Hayley congratulated all involved in the coordinated planning and strong collaboration between the Transport and Logistics team, Blast Furnace personnel, Port Operations, and Qube, the site’s third-party stevedores.

“With a stable steelworks, this is another example of different crews across the operation being able to collaborate and come up with processes that save us even more time and money,” Hayley said.

“We are unloading shipments of coke on-time and providing it in-time for the blast furnace which further contributes to the stability and sustainability of our steelworks.”

Main picture and above: OneSteel’s Michael Jonker, Barry Jackson from contractors Qube and James Brown (OneSteel)