Sasol Secunda Synfuels Complex
The world's largest coal-to-liquids plant — South Africa's strategic fuel independence engine.
The Sasol Secunda complex in Mpumalanga Province is the world's largest commercial coal-to-liquids (CTL) facility, converting coal into synthetic fuels and chemicals using proprietary Fischer-Tropsch technology. With a production capacity of approximately 160,000 barrels per day of synthetic fuels and chemicals, Secunda supplies approximately 28% of South Africa's liquid fuel requirements. The complex also produces a wide range of chemical products including ethylene, propylene, ammonia, solvents, and waxes. Built during the apartheid era to ensure fuel self-sufficiency, Secunda remains one of the most complex industrial operations in the world and is Sasol's primary production asset.
- 01Produce approximately 160,000 barrels per day of synthetic fuels and chemicals from coal feedstock
- 02Supply approximately 28% of South Africa's total liquid fuel demand from domestic coal resources
- 03Manufacture a broad range of commodity and speciality chemicals for domestic and export markets
- 04Maintain South Africa's strategic fuel production capability from indigenous energy resources
- 05Reduce the carbon intensity of operations through the Future Sasol programme and energy transition initiatives
- 06Sustain Secunda's role as the economic anchor of the Mpumalanga Highveld region
1980 · completed
Sasol Two Commissioned
The first of the two Secunda synfuels plants (Sasol Two) is commissioned, built at massive scale and speed in response to the global oil crisis and apartheid-era sanctions.
1982 · completed
Sasol Three Commissioned
The second plant (Sasol Three) comes online, doubling the complex's capacity. Combined, the two plants make Secunda the world's largest synthetic fuels facility.
2005 · completed
Reactor Upgrade Programme
Sasol completes its Sasol Advanced Synthol (SAS) reactor upgrade programme, replacing the older Synthol reactors with more efficient circulating fluidised bed technology.
2015 · completed
Growth in Chemicals Portfolio
Secunda expands its chemicals production portfolio, increasingly shifting value towards higher-margin chemical products alongside fuel production.
2021 · completed
Future Sasol Decarbonisation Plan
Sasol launches its Future Sasol roadmap targeting a 30% reduction in greenhouse gas emissions by 2030 from its 2017 baseline, including plans for renewable energy and green hydrogen.
2025 · in progress
Energy Transition Investments
Sasol progresses green hydrogen pilot projects and solar/wind power procurement to reduce coal dependency at Secunda over the long term.
Raw Material
Coal Supply
Approximately 40 million tonnes per year of coal from Sasol Mining's captive collieries and external suppliers on the Mpumalanga Highveld.
Processing Equipment
Gasifiers
Over 80 Lurgi gasifiers converting coal into synthesis gas using steam and oxygen at high temperature and pressure.
Processing Equipment
Fischer-Tropsch Reactors
Multiple Sasol Advanced Synthol (SAS) reactors converting syngas into synthetic crude and chemical intermediates.
Utility
Air Separation Units
Multiple large-scale air separation units producing industrial quantities of oxygen for coal gasification.
Utility
Water Infrastructure
Large water allocation from the Vaal River system, extensive recycling and treatment facilities to minimise freshwater consumption.
- Sasol proprietary Fischer-Tropsch synthesis converting syngas into liquid hydrocarbons
- Lurgi fixed-bed dry-bottom gasification technology converting coal to synthesis gas (syngas)
- Over 80 Sasol Advanced Synthol (SAS) circulating fluidised bed reactors for FT synthesis
- Extensive downstream refining and chemical separation trains for product purification
- Oxygen production via multiple air separation units (ASUs) — among the largest globally
- Water treatment and recycling systems processing millions of litres daily
What it means for the community
Secunda is the largest single-site employer in Mpumalanga Province, directly employing over 8,000 Sasol staff and approximately 15,000 contractors. The complex generates tens of billions of rand in annual revenue and contributes significantly to South Africa's GDP. It provides strategic fuel security by producing approximately 7.3 billion litres of fuel annually from domestic coal, reducing reliance on imported crude oil. However, Secunda is also one of the world's largest single-point sources of greenhouse gas emissions, making its decarbonisation a critical challenge for South Africa's climate commitments.
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