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SunCoke Energy Inc. Coke Oven Plant

Location: Granite City, IL
Completed: 2009
Client: SunCoke Energy
Size: 120 heat recovery ovens and steam distribution system


SunCoke Energy Inc. and Gateway Energy and Coke Co. were confident in relying on Guarantee Electrical to meet the rigorous demands of a revolutionary new $290 million coke oven and steam distribution system to meet the needs of U.S. Steel in Granite City, Ill. That’s because Guarantee had repeatedly provided comprehensive industrial electrical construction services to U.S. Steel for more than 20 years when the ambitious project commenced in 2008.

Gateway Energy, the indirect wholly-owned subsidiary and affiliate of SunCoke Energy Inc., developed the heat recovery coke manufacturing facility to supply metallurgical coke to U.S. Steel. The new plant’s 120 heat recovery ovens have the capacity to produce 650,000 tons of screened blast furnace coke from bituminous coal annually using a very clean process, recognized by the U.S. Environmental Protection Agency (EPA) as the highest standard for coal processing ovens. Prior to this project, the process had been implemented at only three plants worldwide. Engineering services were provided by Industry and Energy Associates, LLC.

The new plant will recover hot gas generated during the coke-making process for transfer to a new cogeneration plant built by U.S. Steel, which will convert the gas into about 500,000 pounds per hour of superheated steam. The steam then will be used to produce electricity for U.S. Steel’s Granite City Works.

Guarantee’s experienced project leaders kept the massive project on schedule, closely coordinating the work of up to 90 Guarantee electricians with up to 900 construction workers overall.

In addition to providing electrical construction services for the distribution system needed to recover and transfer the gas to the cogeneration plant built by U.S. Steel, Guarantee performed extensive electrical work for SunCoke Energy, installing:

  • More than 40,000 lineal feet (in excess of 7.5 miles) of underground conduit
  • 30,000 lineal feet (more than 5.5 miles) of ground wiring
  • A 7.5-MVA, 69KV-4160V double-ended substation and 5KV switchgear
  • Four electrical rooms with 5KV switchgear and 480V motor control centers
  • Coal and coke handling conveyors
  • Six 1,200-psi superheated steam generators
  • Three coke batteries with 120 ovens
  • A flue gas desulfurization plant to reduce emissions and meet EPA guidelines
  • A coke wharf and quench tower
  • A coke screening station
  • Power and instrumentation
  • A high-speed fiber-optic communication system throughout the high-performance plant

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