SASOLS ACHIEVEMENTS IN THE 20th CENTURY AS A BUILDING BLOCK

FOR THE 21st

Presentation to the 2000 Gasification Technologies Council

October 8-11, 2000, San Francisco, California, USA

P van Nierop*, HB Erasmus and JW van Zyl, Sasol Technology,

Republic of South Africa

* Corresponding Author:

E-mail pieter.vannierop@sasol.com
P O Box 1
Sasolburg 1947
Republic of South Africa

+27 16 960 3301 (Tel)

+27 16 960 4382 (Fax)
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SASOLS ACHIEVEMENTS IN THE 20 th CENTURY AS A

BUILDING BLOCK FOR THE 21 st

P VAN NIEROP, HB ERASMUS and JW VAN ZYL

SASOL TECHNOLOGY
REPUBLIC OF SOUTH AFRICA

A. SASOL - THE PAST 50 YEARS

1. INTRODUCTION

SASOL was established on 26 September 1950 with the prime objective to

convert low grade coal into petroleum products and chemical feedstocks. Sasol
One was built in Sasolburg and produced its first liquid product in 1955. In 1969
the Natref crude oil refinery was commissioned and in 1980 and 1982 Sasol Two
and Sasol Three respectively began production in Secunda. Today, 50 years after
the initial announcement, Sasol produces the equivalent of 150 000 barrels per
day of fuels and petrochemicals from coal via its indirect liquefaction process.
The process produces in excess of 40% of South Africas liquid fuels
requirements. The company is listed on the Johannesburg Stock Exchange (SOL)
with a market capitalisation of $4,6 billion and on Nasdaq (SASOY). Sasol
manufactures more than 200 fuel and chemical products at its plants in Sasolburg
and Secunda in South Africa as well as at several global locations. Its products
are exported to more than 70 countries around the world.

From the relative humble beginning as an liquid fuels producer Sasol has grown
into a company with a turnover of $3,7 billion from which more than 50% is
generated from chemicals. This is proof of the success of the decision in the mid
1980s to diversify into higher value chemicals from Sasols treasure chest of
intermediate feedstocks.

During the 1990s Sasol has intensified its growth and diversification programme,
primarily focussing on three strategic initiatives:

v The formation of synergistic alliances and joint venture companies;

v The acquisition of strategically beneficial businesses;
v The expansion and improvement of current operations, through a continuous
capital investment program.

The history of Sasol revolves around the Groups impressive track record in
innovating new or improved products and processes. Notable breakthroughs have
been achieved in the fields of geology, mining production systems, coal
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preparation and gasification systems, mining explosives, fertilizers,

biotechnology, environmental engineering and gas to liquids technology.

2. THE SASOL PROCESS

The Sasol process starts with the Gasification plant where coal under pressure and
at high temperature in the presence of steam and oxygen is converted into crude
gas. Condensates from subsequent cooling of the gas yield co-products such as tar
and oils. Other co-products such as nitrogenous compounds, sulfur and phenolic
compounds are recovered as ammonia, sulfur, cresols and phenols respectively.

The purified synthesis feed gas is made available for conversion through the Sasol
Advanced Synthol (SAS) or Sasol Slurry Phase Distillate (SSPD) proprietary
technology to high value products (Figure 1).

FIGURE 1 : THE SASOL PROCESS

Crude
CrudeOil
Oil
Imported crude oil Natref Liquid
refinery fuels
Sasolburg

COAL MINING Synthetic

Syntheticfuels
fuels
- 49 million ton/a
Coal Coal Synthesis Synfuels Liquid
- 6 underground gasification gas production fuels
mines
Secunda
- 2 strip mines Chemical
- 3.1million ton feedstocks
export Chemicals
Chemicals
200
Coal Coal Synthesis Chemicals
gasification gas production chemical
Sasolburg& Secunda products
Sasolburg&
Secunda

2.1 High-temperature Fischer-Tropsch conversion

After purification, synthesis feed gas is sent to the SAS reactors where the
hydrogen and carbon monoxide react under pressure in the presence of a fluidised,
iron-based catalyst at moderate temperature to yield a broad spectrum of
hydrocarbons in the C1 C15 range. This process is primarily used to produce
liquid fuels.
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Oxygenates in the aqueous stream from the SAS process are separated and
purified in the chemical work-up plant to produce alcohols, acetic acid and
ketones including acetone, methyl ethyl ketone (MEK) and methyl iso butyl
ketone (MIBK).

2.2 Low-temperature Fischer-Tropsch conversion

An alternative use for the synthesis feed gas from gasification or reformed natural
gas, is the Sasol Technology developed low-temperature Sasol Slurry Phase
Distillate (SSPD) process. In this process, which Sasol uses at Sasol Chemical
Industries (Sasol One) at Sasolburg, the synthesis feed gas is reacted at a lower
temperature than is the case in the SAS reactors, in a SSPD reactor producing
linear-chained hydrocarbon waxes and paraffins. Apart from hard wax, candle
wax and specialty Fischer Tropsch (FT) waxes, high-quality diesel can also be
produced in this process.

Residual gas from the SSPD process is sold as pipeline gas, while lighter
hydrocarbons are hydro-treated to produce pure kerosene or paraffin fractions.
Ammonia is also produced and is sold as such or is utilized downstream to
produce explosives and fertilizers.

2.3 The Sasol/Lurgi Gasification Process

At both Sasolburg and Secunda, all synthesis gas is produced from coal using the
Sasol/Lurgi fixed bed dry bottom (FBDB) gasifiers. High ash content, high ash
melting point coal is used to produce a high H2 /CO syngas to satisfy the high
demand for hydrogen in Fischer-Tropsch synthesis.

FIGURE 2: MAJOR DIMENSIONS OF GASIFIERS

Scale Up Of Gasifiers At Sasol

Ton Coal \ h
m 3n/h / gasifier 90000
75
Crude Gas Production

65000
54

34000
28

Mark III Mark IV Mark V

13 83 1
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Sasol One was originally equiped with ten Mark III gasifiers with an internal
diameter of 3,66 m. Three gasifiers of similar design were added in 1966. In
1978 three Mark IV gasifiers, scaled up 55% above original design, were installed
and a Mark V (114% scaled up above original) in 1980 (Figure 2).

Sasol currently operates 83 Mark IV gasifiers of which Sasol Two and Three each
have 40 units. These units can truly be seen as the work horses of syngas
production from coal at Sasol, as well as in the world. The demand for synthesis
gas at Sasol, consisting volumetrically of roughly 58% H2 , 29% CO, 11% CH4 ,
1% CO2 and virtually no sulphur, increased steadily over the years, resulting in
continuous pressure to increase production rates of individual units. During the
last 3 financial years (1997, 1998 and 1999), average gas production rates for
these gasifiers have been roughly 20% above design capacity (Table 1).

TABLE 1: AVERAGE SYNGAS PRODUCTION RATE/ GASIFIER

Syngas production % above design

Design syngas load (Secunda) 38 500 m3 n/h -

Actual 1997 45 600 m3 n/h (18%)

Actual 1998 45 600 m3 n/h (18%)

Actual 1999 46 500 m3 n/h (21%)

2.4 Operational Highlights

2.4.1 Reliability

The reliability with which syngas is being produced at Sasol has always been
regarded as one of the corner stones of many of the successes achieved. Some are
illustrated below.

For Sasol West, (Sasol Two), 36 out of 40 gasifiers had at least one run of 100
consecutive days or more on line during the last 30 months. Ten of these gasifiers
achieved more than 200 consecutive days on line, including four gasifiers doing
more than 300 days (two cases of 343 days were recorded).

The longest continuous off-line period for a gasifier is 30 days, which is required
for general overall and sometimes jacket replacement. Average time between two
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of these occurrences (per gasifier) is currently about 3 years and actions are being
taken to increase this to 4 years.

2.4.2 Availability

Continuous improvements of mechanical components, but also to operational and

managerial systems and procedures, resulted in a higher than 90% on-line
availability over the last 30 months. That translates to more than 72 of Secundas
80 gasifiers continuously on-line. This could be achieved in spite of constantly
increasing individual gas loads (Table 1).

Overall plant shut down for maintenance to common systems have been reduced
from the original 560 gasifier days/annum to 400 out of a maximum possible of
29 200 gasifier days, thus a 30 % reduction.

2.4.3 Gasification plants

It is important to note that the significant achievements in reliability and increase

in availability have been achieved while continuously increasing the gasloads.

Each of the Secunda plants has originally been designed to produce 1 100 x
103 m3 n/h syngas with 36 gasifiers. (Four have later been added.) Actual
production rates for the two plants for the last 3 financial years can be seen in
table 2.

TABLE 2: AVERAGE ANNUAL SYNGAS PRODUCTION

Year Syngas Production of m3 n/h

1997 1 520 x 103
1998 1 520 x 103
1999 1 551 x 103

This has been achieved without the addition of major process units only
optimizing and de-bottlenecking of existing systems.

2.5 Gasification Technology Development at Sasol

The conversion of coal to synthesis gas and co-products is a core Sasol

technology. Sasol has over the past fifty years developed the process extensively
by improving on the original facilities commissioned at Sasolburg in the early
1950's and by progressively implementing improvements to the operating plants.

The main processes associated with the conversion of coal to synthesis gas and
co-products covers the following (Figure 3):
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v Coal preparation
v Coal distribution to the top of the gasifiers
v Gasifiers
v Ash removal
v Gas quench and initial cooling
v Tar/oil/condensate cooling and separation
v Gas purification
v Sulfur recovery
v Ammonia Recovery
v Phenols recovery

FIGURE 3: THE SASOL/LURGI GASIFICATION SYSTEM

Coal

Bunker

Feeder
Crude gas to
gas cooling
Coal
lock
Quench
liquor

Steam

Quench Waste heat

cooler boiler

Boiler feed
water
Rotating
grate
Steam &
oxygen

Ash lock
Gas liquor

Ash to sluiceway

These processes are all linked together in an overall process scheme. The most
important achievement of Sasol in this field is that gas from coal is produced on a
mega scale, continuously improving on the output of the plants and achieving
high mechanical availability of equipment. This could only be achieved through
the technical break-throughs in each of the component plants in the overall flow
scheme.

Highlights of the specific achievements in these plants can be summarized as

follows:
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2.5.1 Typical Developmental Highlights

Coal R & D

Enabling the coal preparation plants to produce coal for the gasifiers according to
specific requirements was a steady process stretching over many years. This
entailed implementing projects to minimize coal degradation, improving
homogenization and efficiency in coal screening. The development of an
understanding of the effects of the various properties of the coal on the
gasification process and the quantification of these effects have been an ongoing
activity. Much knowledge has been gained and modifications implemented,
resulting in higher gasifier throughputs, improved carbon utilization and ability of
the process to handle variation in coal properties.

Sasol has gained significant expertise in evaluation of different coal resources for
suitability in the Sasol/Lurgi coal gasification process and have tested and
evaluated numerous coal types from all over the world. Highly specific analytical
laboratory techniques were developed to characterize coals for compatibility with
the gasification process and commercial scale testing of large batches has also
been done on numerous occasions.

During the period 1998 - 2000, renewed efforts were made to characterize the
effects of coal properties on gasifier performance more accurately. A single
gasifier at Secunda was isolated and a separate coal feed system was provided
including additional measurement facilities. The so-called Test gasifier was
extensively used to conduct a number of commercial scale tests.

2.6 Turning co-products into value

In addition to the technical breakthroughs, the economic implications of

gasification by-products optimization has been significant. Some examples are
given below:

2.6.1 Gas Liquor

The aqueous stream, resulting from cooling of crude gas, contains valuable co-
products such as tars, phenols and ammonia. After recovery of these, the
remainder (stripped gas liquor or SGL) can directly be used as cooling water in
the plant. This results in a reduction of raw water intake to the synfuels complex
and also savings on bio-treatment of effluent streams. It is envisaged that this
system will be further optimized to include FT effluents as water make-up.

2.6.2 Tar and Pitch

The Sasol/Lurgi gasification process produces tar in the devolitalization area of

the gasifier as a co-product. The tar is classified as medium temperature tar, as
the temperature of formation is lower than that of coke oven tar. The bulk of the
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tar is converted to liquid fuels in Secunda with the resulting pitch fraction being
processed by Sasol Carbo-Tar.

Sasol Carbo-Tar, a division of Sasol Chemical Industries, was established in 1995

and produces and markets a wide range of carbon and tar products including
calcined anthracite, recarburisers, creosotes and disinfectants. 80% of the
divisions sales are exported to North America, Europe, South East Asia and
Australia.

Currently the feasibility of extracting high value chemicals from the tar distillates
as well as the production of high value binder pitch for use in the aluminum
industry, are being evaluated.

2.6.3 Phenol and Cresol

Phenol is a very highly valued co-product from the FBDB gasifier. Crude phenol
is recovered from the aqueous stream by solvent extraction and refined to very
high purity phenol, cresols, etc. These products are marketed worldwide by
Merisol RSA.

2.6.4 Methane

The relatively high percentage of methane formed in the Sasol/Lurgi gasification

process, (which takes place at a temperature of less than 1 000 C), is fully
utilized. Part of it is used as blend stock to produce hydrogen rich and methane
rich pipeline gas. As there are virtually no natural gas resources within South
Africa, Sasol supplies over 29 million gigajoules of pipeline gas to more than 700
customers via its own pipeline system extending over 1 400 kilometers. The
remainder of the methane is converted to syngas by a steam oxygen-reforming
process.

2.6.5 The Hydrogen Advantage of FBDB

Hydrogen is an essential element required for the production of fuels, chemicals

and ammonium based fertilizers from coal.

For example: hydrogen plays a key role in the mechanism of converting syngas to
hydrocarbon products via FT synthesis. The specifications for a typical FT
syngas requires a hydrogen to carbon monoxide ratio 1.8-2 to 1.

Ammonia synthesis feedgas requires a hydrogen to nitrogen ratio of 3.0 to 1.

Hydrogen is also a key component of Sasols hydrogen rich pipeline gas (48% by
volume).

3 SUMMARY OF THE PAST 50 YEARS

After 50 years, the Sasol/Lurgi FBDB gasification technology is today a reliable

and comparatively risk free process. Sasol believes that further optimization
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potential exists beyond the current levels of maturity and is actively exploiting
these opportunities.

It is the only viable process for the conversion of low-grade high ash content, high
melting point ash coals to high value products. Such coals are abundant in
countries like China and India. As these countries develop, energy demand growth
will require that the low-grade coal resources be exploited. Dedicated operations
development of the process over the past 50 years have enabled Sasol to
potentially become a major contributor in the establishment of such facilities. The
escalating number of inquiries being received by Sasol emphasizes a growing
demand for this expertise.

What does the future hold for gasification technology in general? Is this the end of
a successful era or a solid base for the future? We have attempted to give a
perspective on these questions in the section to follow.

B THE FUTURE

1. INTRODUCTION

The successes achieved over the past 50 years and the continuous development of
Coal to syngas (CTS) technology combined with Sasols proprietary Gas to
Liquids (GTL) technology put Sasol in a unique and strong position for the future
scenarios on syngas production and utilization. Sasols commitment to the future
of CTS technology can be highlighted by our vision to be globally respected and
acknowledged as the leader in the field of the competitive conversion of coal and
related feedstocks to syngas.

It is important to notice that the vision is not restrictive on the type of gasification
technology to be utilised or the feedstock to be converted, but rather on utilizing
Sasols strengths to grow into the future.

2. THE FUTURE OF GASIFICATION TECHNOLOGY

2.1 Introduction

Numerous publications and presentations have recently seen the light on this
subject and it is not our intention to evaluate the pros and cons of each scenario,
but rather to highlight future scenarios where Sasol can contribute through the
application of its experience gained over the last 50 years.
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2.1.1 The Sasol Secunda Factories

The focus in the near future will be on further de-bottlenecking of the current
facilities by implementing results from the Test gasifier. Studies are currently
underway on feed preparation, optimizing process control, modifications on the
internals of the gasifier, pyrolyses and optimization of carbon conversion to
valuable products.

Increasing the current production rate of individual gasifiers may also be

considered if required by the market demand.

2.1.2 Coal to Liquids

Preliminary studies have indicated that there are selected geographical regions in
the world where the economic conversion of coal to liquid fuel and chemicals may
be feasible. In such cases coal should be relatively inexpensive, significant gas
and oil reserves should be absent and markets for the total spectrum of products
should be available. Sasol, with its experience in gasification technology
combined with GTL and other technologies can play a leading role in such
projects.

2.1.3 Petroleum Coke, Refinery bottoms and other unutilized carbonaceous products

The integration of gasification technology combined with GTL technology may in

future provide a solution to the challenge faced by crude oil refiners, namely
processing increasingly lower quality feed stocks. Conversion of the resulting
bottoms to high quality fuel, while complying to more stringent environmental
requirements, may become a future objective.

2.1.4 Fine Coal as feed stock

The impact of discarded fine coal on the environment is another issue becoming
increasingly important in many parts of the world. The application of gasification
technology to solve this issue is currently being investigated. A study, partly
funded by the US DOE evaluates the Texaco gasifier in combination with Sasols
FT conversion technology for a potential coal to liquids plant in Pennsylvania,
USA.

3 THE IMPORTANCE OF BASIC SCIENTIFIC KNOWLEDGE FOR THE

FUTURE OF GASIFICATION

Other potential applications for gasification technology may also arise in the near
future. For development and evaluation of such opportunities Sasol has
developed a strong base of basic scientific knowledge. Some examples are given
below.

Apart from the developments over the past 50 years and the subsequent increase
in knowledge on gasification technology, the modeling capabilities and focus on
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long term R & D are also regarded as particular strengths of Sasol which may in
future contribute to the strengthening of its global competitive position.

3.1 Gasifier Modeling

At present Sasol is in possession of 5 different gasifier models each having a

specific purpose. These models are:

v A thermo-dynamic model;
v A one dimensional pseudo-homogeneous model;
v A one dimensional heterogeneous model;
v A three dimensional pseudo-homogeneous model;
v A stochastic model.

These models each have unique strengths and applicability in the gasification
environment. This paper will not provide the detail of gasifier modeling, but it is
worth mentioning that the Test gasifier has been of significant importance in the
evaluation of various modeled results and subsequent further development of the
various models.

Continuous model development and verification of models utilizing Test gasifier

results enjoy a high priority. Using modeled results as a tool to predict actual
plant performance has led to substantial savings in development resources.

3.2 R&D

The focus of Gasification R & D has shifted from short term optimization to the
development of long term solutions ensuring that the vision of global respect for
the technology is achieved. Research and Development is fully integrated with
the rest of the Coal to Syngas team.

4 TEST GASIFIER

Two years ago Sasol embarked upon a unique project to optimize the performance
of the Sasol/Lurgi fixed bed coal gasification process. It entailed the isolation of
one of the 80 gasifiers in Secunda, and instrumenting it with accurate measuring
equipment to measure all process variables. Provision was also made for a
dedicated coal feeding and coal preparation system. The Test gasifier is described
in detail in the presentation by E L Koper : Perspectives on Long Term Practical
Coal Research for Gasification- GTC 2000 conference.
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5 CONCLUSION

It is the view of the authors that gasification technology has a bright future in the
areas mentioned above and that the role of Sasol in the future of gasification
technology globally is unique. Not only does the company have valuable and
unique operating experience gained over 50 years of successful operations, but
has also been at the forefront of technological breakthroughs in optimizing and
streamlining the technology. Sasol is essentially, however, a company focussing
on the successful operation and optimization of technology and is not primarily
focussing on new technology development. The unique skills of Sasol may
however be complementary to those of other parties who share our view on the
future of gasification and related technologies.