A continuous process has been designed by Dr. Richard Wolfe and proven in two multi-million dollar pilot plants and one commercial demonstration plant over the past 20 years to convert coal (Bituminous, Sub-bituminous, Lignite, and other carbon materials) into a new clean carbon product called “Carbonite™” char and foundry coke that is mercury free. The commercial demonstration plant was designed by the Wolfe’s (Dr. Wolfe and Eric Wolfe) in 2010, built in 2011-2012 and began start up operations in 2012 in Norton, Virginia. This plant was designed for a maximum output of about 50,000 tons of Foundry Coke per year.