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Sasol Limited, commonly referred to as Sasol, is an integrated energy and chemical company based in Sandton, South Africa.

Key Information

The company was formed in 1950 in Sasolburg, South Africa, and built around coal liquefaction processes that German chemists and engineers first developed in the early 1900s. Today, Sasol develops and commercializes technologies, including synthetic fuel technologies, and produces different liquid fuels, chemicals, coal tar, and electricity.[3]

Sasol is listed on the Johannesburg Stock Exchange (JSE: SOL) and the New York Stock Exchange (NYSE: SSL). Major shareholders include the South African Government Employees Pension Fund,[4] Industrial Development Corporation[5] of South Africa Limited (IDC), Allan Gray Investment Counsel,[6] Coronation Fund Managers, Ninety One,[7] and others.[8]

Sasol employs over 27,000 people worldwide[2] and has operations in 33 countries.[9] It is the largest corporate taxpayer in South Africa, and the seventh-largest coal mining company in the world.[10]

History

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The incorporation of Sasol

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The previous Sasol logo

South Africa has large deposits of coal, which had low commercial value due to its high fly ash content. If this coal could be used to produce synthetic oil, petrol, and diesel fuel, it perhaps would have significant benefit to South Africa. In the 1920s, South African scientists started looking at the possibility of using coal as a source of liquid fuels. This work was pioneered by P. N. Lategan, working for the Transvaal Coal Owners Association. He completed his doctoral thesis from the Imperial College of Science in London on The Low-Temperature Carbonisation of South African Coal.

In 1927, a white paper from the government was issued describing various oil-from-coal processes being used overseas and their potential for South Africa. In the 1930s, a young scientist named Etienne Rousseau obtained a Master of Science from the University of Stellenbosch. His thesis was entitled "The Sulfur Content of Coals and Oil Shales." Rousseau became Sasol's first managing director.

After World War II, Anglovaal bought the rights to a method of using the Fischer–Tropsch process patented by M. W. Kellogg Limited, and in 1950, Sasol was formally incorporated as the South African Coal, Oil, and Gas Corporation (from the Afrikaans of which the present name is derived: Suid-Afrikaanse Steenkool-, Olie- en Gas Maatskappy), a state-owned company.

Commissioning of the Sasol 1 site for the production of synfuels started in 1954. Construction of the Sasol 2 site was completed in 1980, with the Sasol 3 site coming on stream in 1982. The Zevenfontein farm house served as Sasol's first offices and is still in existence today.[11][12]

Coal mining

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To support the required economies of scale for coal-to-liquids (CTL) process to be economical and competitive with crude oil, all stages of the operations, from coal mining to the Fischer–Tropsch process and product work up must be run with great efficiency. Due to the complexity of the Lurgi gasifers used, the quality of the coal was paramount. The initial annual output from the Sigma underground mine in Sasolburg was two million tons. Annual coal production from this mine peaked in 1991 at 7.4 million tons.[11]

Today, most of the gasifiers in Sasolburg have been replaced with autothermal reformers that feed natural gas piped from Mozambique. Natural gas generates about 40–60% less carbon dioxide for the same energy produced as coal, thus is significantly more environmentally friendly. Gas-to-liquids technology converts natural gas, predominantly methane to liquid fuels.[11][12]

Today, Sasol mines more than 40 million tons (Mt)[13] of saleable coal a year, mostly gasification feedstock for Sasol Synfuels in Secunda. Sasol Mining also exports some 2.8 Mt of coal a year. This amounts to roughly 22% of all the coal mined in South Africa. Underground mining operations continue in the Secunda area (Bosjesspruit, Brandspruit, Middelbult, Syferfontein, and Twistdraai collieries) and Sigma: Mooikraal colliery near Sasolburg. As some of these mines are nearing the end of their useful lives, a R14bn mine replacement program has been undertaken.

The first of the new mines is the R3.4bn Thubelisha shaft, which will eventually be an operation delivering more than 8M tons/annum (mtpa) of coal over 25 years. The Impumelelo mine, which will replace the Brandspruit operation, is set for first production in 2015. It will be ramped up to produce 8.5 mtpa, and can later be upgraded to supplying some 10.5 mtpa. This coal will be used exclusively by the Sasol Synfuels plant. An underground extension of the Middelbult mine is also on the cards, with the main shaft and incline shaft being replaced by the Shondoni shaft. The first coal from the new complex was expected to be delivered in 2015.[14]

The Secunda collieries form the world's largest underground coal operation.[15]

In conjunction with the continuous improvement in the Fischer–Tropsch process and catalyst, significant developments were also made in mining technology. Coal mining at Sasol from the early days has been characterised by innovation. Sasol Mining mainly uses the room and pillar method of mining with a continuous miner. Sasol successfully used the longwall mining method from 1967 to 1987. Today, Sasol is one of the leaders in coal-mining technology and was the first to develop in-seam drilling from the surface using a directional drilling methodology. This has been developed into an effective exploration tool.[16]

Working with Fifth Dimension, Sasol developed a virtual reality technology to help train continuous miner operators in a 3D environment in which various scenarios can be simulated, including sound, dust and other signs of movement.[17] This has recently been expanded to include shuttle car, roof-bolting, and load-haul dumper simulators.

Fischer–Tropsch reactor technology

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The initial reactors from Kellogg and Lurgi gasifiers were tricky and expensive to operate. The original reactor design in 1955 was a circulating fluidised bed reactor (CFBR) with a capacity of about 1,500 barrels per day. Sasol improved these reactors to eventually yield about 6,500 barrels per day. The CFBR design involves moving the whole catalyst bed around the reactor, which is energy intensive and not efficient as most of the catalyst is not in the reaction zone. Sasol then developed fixed fluidized bed (FFB) reactors in which the catalyst particles were held in a fixed reaction zone.

This resulted in a significant increase in reactor capacities. For example, the first FFB reactors commercialised in 1990 (5 m diameter) had a capacity of about 3,000 barrels per day, while the design in 2000 (10.7 m diameter) had a capacity of 20,000 barrels per day. Further advancements in reactor engineering have resulted on the development and commercialisation of Sasol Slurry Phase Distillate (SSPD) reactors which are the cornerstone of Sasol's first-of-a-kind GTL plant in Qatar.[11][12]

From fuels to chemicals

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The fuel price is directly linked to the oil price, so is subject to potentially large fluctuations. With Sasol only producing fuels, this meant that its profitability was largely governed by external macroeconomic forces over which it had no control. How could Sasol be less susceptible to the oil price? The answer was right in front of them, in the treasure chest of chemicals co-produced in the Fischer–Tropsch process. Chemicals have a higher value per ton of product than fuels.

In the 1960s ammonia, styrene, and butadiene became the first chemical intermediates sold by Sasol. The ammonia was then used to make fertilizers. By 1964, Sasol was a major player in the nitrogenous fertilizer market. This product range was further extended in the 1980s to include both phosphate- and potassium-based fertilizers. Sasol now sells an extensive range of fertilizers and explosives to local and international markets, and is a world leader in its low-density ammonium nitrate technology.[18]

With the extraction of chemicals from its Fischer–Tropsch product slate coupled with downstream functionalization and on-purpose chemical production facilities, Sasol moved from being just a South African fuels company to become an international integrated energy and chemicals company with over 200 chemical products being sold worldwide. Some of the main products produced are diesel, petrol (gasoline), naphtha, kerosene (jet fuel), liquid petroleum gas (LPG), olefins, alcohols, polymers, solvents, surfactants (detergent alcohols and oil-field chemicals), co-monomers, ammonia, methanol, various phenolics, sulphur, illuminating paraffin, bitumen, acrylates, and fuel oil.

These products are used in the production process of numerous everyday products made worldwide and benefit the lives of millions of people around the world. They include hot-melt adhesives, car products, microchip coatings, printing ink, household and industrial paints, mobile phones, circuit boards, transport fuels, compact discs, medical lasers, sun creams, perfumes and plastic bottles.[19]

In South Africa, the chemical businesses are integrated in the Fischer–Tropsch value chain. Outside South Africa, the company operates chemical businesses based on backward integration into feedstock and/or competitive market positions for example in Europe, Asia, and the United States.[19]

Recent developments

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In May 2025, Sasol's CEO spoke about the company's plans to source more renewables and offset the use of coal feedstock. In the same year, Sasol was the world’s top producer of synthetic fuel from coal, and South Africa's -second-largest emitter of greenhouse gases. Sasol maintains a target of reducing emissions by 30% by 2030, and intends to expand its renewable energy target by around two thirds to, 2,000 megawatts in total.[20]

Operations

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A Sasol Garage in Boksburg, close to the company's headquarters in Johannesburg, South Africa

Sasol has exploration, development, production, marketing and sales operations in 31 countries across the world, including Southern Africa, the rest of Africa, the Americas, Europe, the Middle East (West Asia), Russia, Southeast Asia, East Asia, and Oceania.[21]

The Sasol group structure is organised into two upstream business units, three regional operating hubs and four customer-facing strategic business units.[9]

Sasol is a member of the Fuels Industry Association of South Africa (FIASA), and was one of its founding members when the organization launched in 1994.

Operating business units

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Operating Business Units comprise the mining division and exploration and production of oil and gas activities, focused on feedstock supply.[22]

Sasol Mining operates six coal mines that supply feed-stock for Secunda (Sasol Synfuels) and Sasolburg (Sasolburg Operations) complexes in South Africa. While the coal supplied to Sasol Synfuels is mainly used as gasification feedstock, some is used to generate electricity. The coal supplied to the Sasolburg Operations is used to generate electricity and steam. Coal is also exported from the Twistdraai Export Plant to international power generation customers.

Sasol Exploration and Production International (SEPI) develops and manages the group's upstream interests in oil and gas exploration and production in Mozambique, South Africa, Canada, Gabon, and Australia.[23]

Regional operating hubs

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These include operations in Southern Africa, North America and Eurasia.[24]

The Southern African Operations business cluster is responsible for Sasol's entire Southern Africa operations portfolio, which comprises all downstream operations and related infrastructure in the region. This combined operational portfolio has simplified and consolidated responsibilities relating to the company's operating facilities in Secunda, which are divided into a synthetic fuels and chemicals component, Sasolburg, Natref, Sasol's joint-venture inland refinery with TotalEnergies, and Satellite Operations, a consolidation of all Sasol's operating activities outside of Secunda and Sasolburg.[25]

The International Operations business cluster is responsible for Sasol's international operations in Eurasia and North America, which include its US mega-projects in Lake Charles, Louisiana.[26]

Strategic business units

[edit]

Energy business

  • Southern Africa Energy
  • International Energy

The energy business manages the marketing and sales of all oil, gas and electricity products in Southern Africa, which have been consolidated under a single umbrella. In addition, this cluster oversees Sasol's international GTL (gas to liquids) ventures in Qatar, Nigeria and Uzbekistan.[27]

Chemical business

  • Base Chemicals
  • Performance Chemicals

The global chemicals business includes the marketing and sales of all chemical products, both in southern Africa and internationally. The chemicals business is divided into two niche groupings; Base Chemicals, where its fertilisers, polymers and solvents products lie, and performance chemicals, comprising key products which include surfactants, surfactant intermediates, fatty alcohols, linear alkyl benzene (LAB), short-chain linear alpha olefins, ethylene, petrolatum, paraffin waxes, synthetic waxes, cresylic acids as well as high-purity and ultra-high-purity alumina and a speciality gases sub-division.[28]

In South Africa, the chemical businesses are integrated into the Fischer–Tropsch value chain. Outside South Africa, the chemical businesses are operated based on backward integration into feedstock and/or competitive market positions.

Group functions

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Group Technology manages the research and development, technology innovation and management, engineering services and capital project management portfolios. Group Technology includes Research and Technology (R&T), Engineering and Project Services and Capital Projects.[29]

Major projects

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United States

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Sasol has granted final approval for a US$11 billion ethane cracker and derivatives plant near Westlake and the community of Mossville, both across the Calcasieu River from Lake Charles, Louisiana, and is the largest foreign investment in the history of the State of Louisiana. It was stated "Once commissioned, this world-scale petrochemicals complex will roughly triple the company's chemical production capacity in the United States, enabling Sasol to further strengthen its position in a growing global chemicals market.

The U.S. Gulf Coast's robust infrastructure for transporting and storing abundant, low-cost ethane was a key driver in the decision to invest in America." The ethane cracker will also be supported by six chemical manufacturing plants.[30][31][32][33][34]

By January 2015 construction was in full swing. At peak the project will create 5000 construction and 1200 permanent jobs and cost $11 billion to $14 billion.[35]

Qatar

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The Oryx GTL plant in Qatar is a joint venture between Sasol and QatarEnergy, launched in 2007. The more than 32,000 barrels per day (5,100 m3/d) plant produces a combination of GTL diesel, GTL naphtha and liquid petroleum gas.[36][37]

Uzbekistan

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The proposed Uzbekistan GTL project is a partnership between Sasol, Uzbekneftegaz and Petronas.[38][39][40] Sasol reconsidered its involvement in March 2016.

Mozambique

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Sasol is developing a 140 MW gas-fired electricity generation plant in partnership with power utility EDM.[41] This gas project came into operation in 2004, and is a joint venture agreement between Sasol Petroleum International, Empresa Nacional de Hidrocarbonetos (ENH), and the International Finance Corporation.

Technology

[edit]

Natref Refinery

[edit]

Sasol is also involved in conventional oil refinery. Incorporated on 8 December 1967, construction started on the Natref refinery in 1968 and commissioned in Sasolburg in 1971.[42]: 166 [43]: 75  It was built as a joint venture between the Industrial Development Corporation (IDC), National Iranian Oil Company and Compagnie Française des Petroles (Total) with financing by the Rembrandt Group, Volkskas and SA Mutual.[42]: 166 

By 1979, prior to the Iranian Revolution, the refinery was receiving 70 per cent of its oil from Iran, with the National Iranian Oil Company owning 17.5 per cent of the facility.[44] Oil was piped 800 km from Durban via Richards Bay to the refinery.[44]

The refinery is a joint venture between Sasol Ltd and Total South Africa (Pty) Ltd. Sasol has a 63.64 per cent shareholding in Natref, and Total South Africa holds a 36.36 per cent interest.[45] One of few inland refineries in South Africa,[42]: 166  Natref's capacity in 2017, stood at 108,500 barrels per day of crude oil.

The refinery uses medium gravity crude oil for bottoms upgrading, and is capable of producing 70 per cent more white product than coastal refineries that have to rely on heavy fuel oil. Some of the products produced from the refinery are diesel, petroleum, jet fuel, LPG, illuminating paraffin, bitumen and sulfur. Natref has been certified in terms of the ISO 14001 Environmental Management System.[46][47]

Controversies

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In 2009 Sasol agreed to pay an administrative penalty of R188 million as part of a settlement agreement with the Competition Commission of South Africa for alleged price fixing, in which a competitor alleged that Sasol was abusing its dominance in the markets for fertilisers by charging excessive prices for certain products. Sasol won an appeal on the case and will not be paying the settlement anymore.[48]

Sasol also had to pay a €318 million fine to the European Commission (EC) in 2008, which is about R3.7 billion, for participating in a paraffin wax cartel. Despite its indication that it would appeal the fine amount, the full amount had to be paid to the EC within three months of the fine being issued.[49][50]

Sasol has been levied with a R1.2bn tax provision by the Tax Court on 30 June 2017 on the back of its international crude oil purchases between 2005 and 2012. In its 2017 financial results announced on 21 August 2017, the chemical conglomerate agreed upon footing the R1.2bn tax liability. If the court's interpretation is implemented for the following two years – 2013 and 2014 – Sasol Oil's crude purchases could result in a further tax exposure of R11.6bn, thus summing up a total tax figure up to R12.8bn.[51]

A $4 billion cost and schedule overrun at Sasol's Lake Charles project resulted in the resignation of the joint CEOs in October 2019. Adverse weather, poor subsurface conditions, and a "culture of fear" which undermined transparent reporting, were cited as contributing reasons for the over-runs.[52][53][54][55]

Shareholder activists

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Environmental protesters disrupted Sasol’s November 2023 annual general meeting. Old Mutual and Ninety One, two minority institutional investors, voiced concern over the company's emissions-reduction timetable.[56]

Greenhouse gas emissions

[edit]

Due to the stoichiometry of hydrogen production by coal gasification and the Fischer Tropsch reaction, the production of Sasol Secunda's liquid fuels result in some of the highest specific GHG emissions in the world.

Sasol's Secunda CTL plant is, as of 2020, the world's largest point source of greenhouse gas, at 56.5 Mt/a CO2,[57] a status which persists during the 2020s, with the complex producing more carbon dioxide than the country of Portugal at the close of 2023.[56]

Sasol is exploring alternatives such as green hydrogen which is currently being produced by the electrolysers at the Sasolburg plant. These are powered by renewable energy in the form of a 3 MW solar farm.[58]

Air Liquide acquired 16 of Sasol's energy intensive cryogenic air separation trains in 2020 which are capable of producing 42 000 t/d of pure oxygen.[59]

Sasol and Air Liquide plan to purchase 900 MW of renewable electricity as wind and solar power to reduce CO2 emissions as per their stated emissions reduction programmes: 30 per cent reduction in CO2 from the FY17 baseline by 2030.[60][61]

Shareholders and environmentalists doubt that Sasol will meet its goals of 30 per cent fewer emissions by 2030, and net zero by 2050, which may lead to the Secunda complex being shuttered.[56] By 2030, the company aims to lower Secunda coal volume output by 25 per cent in aid of its commitment to decarbonisation.[62]

See also

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References

[edit]
[edit]
Revisions and contributorsEdit on WikipediaRead on Wikipedia
from Grokipedia

Sasol Limited is a multinational integrated energy and chemicals company headquartered in , , specializing in the production of , olefins, polymers, and solvents through proprietary gas-to-liquids and processes based on Fischer-Tropsch synthesis technology.
Established in 1950 as the South African Coal, Oil and Gas Corporation to develop domestic production and reduce reliance on imported oil, Sasol constructed its inaugural facility in , with core operations commencing in 1954 and completing by 1955, marking the first commercial-scale application of globally.
The company expanded significantly during the 1970s and 1980s with Sasol II and III plants in Secunda, which together supplied approximately half of 's liquid fuel requirements using low-temperature Fischer-Tropsch reactors to convert derived from locally mined into hydrocarbons.
Privatized in 1979 and listed on the , Sasol later pursued international growth, including major gas-to-liquids projects in and , while employing over 31,000 people across 32 countries and maintaining dual listings on the .
Notable for pioneering feedstock-flexible synthesis technologies that enable production from , , or , Sasol has faced scrutiny over environmental impacts from -dependent operations but continues to innovate in lower-carbon fuels, including catalysts for sustainable fuels.

History

Incorporation and Early Years

The South African Coal, Oil and Gas Corporation Limited (Sasol) was incorporated on 26 September 1950 as a under South Africa's Companies Act, with the primary objective of producing synthetic liquid fuels from abundant domestic reserves to reduce reliance on imported crude oil. This initiative addressed the nation's strategic vulnerability, as possessed negligible conventional oil resources and faced potential supply disruptions following . The government, recognizing the national importance of , provided substantial initial funding—subscribing to the majority of shares—and maintained effective control, though the entity was not formally a in the traditional sense. The concept originated from a 1927 parliamentary White Paper that explored coal-to-oil conversion, but implementation accelerated in the late 1940s amid global energy constraints and technological feasibility demonstrated by German wartime processes. Site selection for the inaugural facility occurred near Sasolburg in the Orange Free State (now Free State province), leveraging proximity to coal fields; construction commenced shortly after incorporation, with the first administrative offices established in early 1951 at the Zevenfontein farmhouse on the planned township site. By 1955, the Sasolburg coal-to-liquids complex achieved initial production of synthetic fuels and chemicals, employing low-temperature Fischer-Tropsch synthesis licensed from Ruhrchemie AG, marking the commercial debut of the technology outside . Early operations emphasized process refinement and scale-up, producing , diesel, and chemical feedstocks from locally mined via and synthesis, though output remained modest as the plant ramped up amid technical challenges inherent to adapting pilot-scale German methods to industrial volumes. This foundational phase laid the groundwork for Sasol's role in bolstering South Africa's during the 1950s and 1960s.

Technological Foundations and Expansion in South Africa

Sasol's technological foundations were established through the commercialization of coal-to-liquids (CTL) processes, leveraging to produce (syngas) followed by Fischer-Tropsch (FT) synthesis to yield liquid fuels and chemicals. Formed as a state-owned entity in September 1950 to mitigate 's reliance on imported petroleum amid post-World War II shortages, Sasol prioritized low-grade abundant in the region. The core technology drew from German developments in the 1920s but was adapted for commercial scale using Lurgi fixed-bed gasifiers for conversion to and low-temperature FT reactors (operating at 200–240°C with iron catalysts) for hydrocarbon synthesis. The inaugural Sasolburg facility, known as Sasol I, marked the practical implementation of this integrated CTL system. Construction commenced in mid-1952 on a 7,500-hectare site near the , with initial production units operational by 1954 and full output achieved by late 1955, yielding approximately 120,000 barrels per year initially from 3 million tons of annual input. This plant validated the process's efficiency for producing , diesel, and feedstocks like olefins, though early yields were constrained by reactor design limitations and required downstream for product quality. Expansion accelerated in the amid global oil price shocks, prompting a shift to megascale facilities to secure domestic . Sasol II in Secunda, east of , broke ground in 1976 at a cost of R2.3 billion (equivalent to about $1 billion at the time), incorporating 40 Lurgi gasifiers and a mix of fixed-bed and fluidized-bed FT reactors to boost capacity to 50,000 barrels per day upon commissioning in 1980. Sasol III followed, operational by 1982, doubling output and integrating advanced slurry-phase reactors for heavier waxes, with the combined Secunda complex eventually processing 40 million tons of annually to supply up to 40% of South Africa's liquid fuels by the mid-1980s. These developments entrenched Sasol's expertise in syngas purification and FT selectivity, enabling co-production of fuels (60% of output) and chemicals while navigating high —estimated at $30,000–$40,000 per daily barrel of capacity.

Privatization and Shift to Global Operations

In 1979, Sasol underwent privatization, listing its shares on the to raise capital for expansion projects necessitated by the 1973 and 1979 global crises, which heightened the urgency for production in sanction-constrained . This marked the largest stock listing in South African history at the time, transitioning the company from full state ownership—established in 1950 as a parastatal—to a publicly traded entity, while the government retained a significant stake initially. The proceeds primarily funded Sasol III, a massive coal-to-liquids facility at Secunda that doubled production capacity to approximately 150,000 barrels per day by the mid-1980s. Post-privatization, Sasol's operations remained predominantly domestic through the 1980s and early 1990s, centered on securing South Africa's amid international isolation due to apartheid policies. The political transition in and subsequent lifting of sanctions enabled a deliberate shift toward global diversification, reducing reliance on South African feedstocks and accessing international markets for gas-to-liquids (GTL) licensing and chemicals sales. This globalization accelerated in the early , beginning with a 2000 agreement with the Mozambican government to develop Pande-Temane gas fields, securing non-coal feedstocks for export-oriented projects. In 2001, Sasol acquired the Condea Vista chemical business from , gaining foothold in international alpha-olefins and detergents markets across and the . The 2003 listing of American Depositary Receipts on the further supported this strategy by providing access to U.S. capital for overseas investments, coinciding with the start of construction on a GTL plant in 's Ras Laffan industrial zone in partnership with Qatar Petroleum. By 2006–2007, the ORYX GTL facility in —Sasol's first major overseas synthesis plant with 34,000 barrels per day capacity—became operational, demonstrating the scalability of Fischer-Tropsch processes abroad and generating initial products for global export. Complementary moves included opening a chemicals office in to expand in and forming joint ventures, such as a 2008 coal allocation in with and a 2009 GTL pact in with Uzbekneftegaz and . These initiatives diversified revenue streams, with international operations contributing growing shares of earnings—reaching over 40% by the late 2000s—while exposing Sasol to geopolitical risks in regions like the and .

Post-2000 Developments and Challenges

Following its privatization in the 1970s and subsequent global outreach in the 1990s, Sasol pursued aggressive international expansion in the 2000s, leveraging its Fischer-Tropsch expertise to secure gas feedstocks and diversify beyond South Africa. A pivotal development was the 2004 commissioning of the Pande-Temane natural gas project in Mozambique, which supplied gas to Sasol's Secunda operations via a 865-kilometer pipeline, reducing reliance on coal and enabling production of 55,000 barrels per day of synthetic fuels. This initiative, involving partnerships with Mozambique's government and international investors, boosted operational efficiency but highlighted regional cooperation challenges, including geopolitical risks and infrastructure dependencies. In the 2010s, Sasol intensified its global footprint with the Lake Charles Chemicals Project (LCCP) in , , announced in 2014 as a $8.9 billion cracker and derivatives complex to capitalize on cheap U.S. . However, the project ballooned to over $12.9 billion by 2019 due to construction delays, defective materials like forgings, and poor , resulting in $5 billion in impairments and the dismissal of both co-CEOs in 2019. A January 2020 fire at the unit during commissioning exacerbated issues, though no injuries occurred, prompting shutdowns and further investigations. To mitigate losses, Sasol sold a 50% stake in the complex to in 2020 for $2 billion and divested its Gemini HDPE LLC interest in 2021 for $404 million, as part of broader non-core asset sales to reduce debt exceeding $5 billion. Environmental and sustainability pressures emerged as key challenges, particularly from Sasol's coal-dependent Secunda facility, which emits over 80 million tons of CO2 annually, complicating South Africa's decarbonization goals. In response, Sasol adopted a 2030 target to cut greenhouse gas emissions by 30% from 2017 levels and net zero by 2050, alongside strategic shifts under the "Sasol 2.0" framework emphasizing low-carbon technologies and disciplined capital allocation. Financial volatility persisted, with oil price swings and impairments contributing to a 2020 net loss, though fiscal year 2025 results showed recovery, including basic earnings per share of R10.60 versus prior-year losses. These developments underscored risks from over-reliance on megaprojects and commodity cycles, prompting a refocus on core South African assets and feedstock flexibility.

Core Technologies

Fischer-Tropsch Synthesis

The Fischer-Tropsch (FT) synthesis is a catalytic process that converts synthesis gas—a mixture of (CO) and (H₂)—into a range of hydrocarbons, including paraffins, olefins, and oxygenates, through reactions. Sasol has commercialized this technology on a massive scale since the 1950s, initially adapting it for coal-to-liquids (CTL) production in , where it processes from Lurgi dry-bottom gasifiers using iron-based catalysts. The process operates under varying conditions to yield products tailored to market needs, with Sasol's implementations emphasizing high selectivity for fuels and chemicals amid H₂/CO ratios typically around 1.5–2.2 for coal-derived feedstocks. Sasol's high-temperature FT (HTFT) variant, embodied in the Sasol Advanced Synthol (SAS) process, utilizes circulating fluidized-bed reactors at 300–350°C and 20–30 bar with fused iron catalysts promoted by potassium and silica. This configuration favors lighter hydrocarbons, achieving carbon selectivities of about 48% toward gasoline-range products and olefins, with a gasoline-to-diesel ratio of roughly 3:1, alongside byproducts like liquefied petroleum gases and aromatics. At Sasol's Secunda facility, nine SAS reactors process syngas to produce over 150,000 barrels per day of synthetic fuels, demonstrating the process's scalability and operational reliability since its evolution from earlier Synthol designs in the 1980s. In contrast, Sasol's low-temperature FT (LTFT) processes, such as the Slurry Phase Distillate (SPD™) technology, employ - or iron-based catalysts in bubble column reactors at 200–240°C and 20–40 bar, optimizing for heavier distillates and waxes suitable for diesel and after hydrocracking. The SPD process, central to Sasol's gas-to-liquids (GTL) operations, maintains near-isothermal conditions via mixing, enabling high per-pass conversions (up to 90% CO) and wax yields exceeding 80% of hydrocarbons, as deployed in joint ventures like the Oryx GTL plant in , which started production in 2007 with a capacity of 34,000 barrels per day. Sasol also offers proprietary FT catalysts compatible with fixed-bed, fluidized-bed, and micro-channel reactors, supporting third-party integrations while prioritizing attrition resistance and activity stability. These FT technologies underpin Sasol's feedstock-flexible strategy, with HTFT excelling in olefin-rich outputs for chemicals and LTFT in straight-run fuels, though both require downstream upgrading to meet specifications; for instance, HTFT syncrude demands extensive refining to reduce branching and aromatics for clean fuels. Catalyst deactivation by carbon deposition and necessitates regeneration cycles, yet Sasol's designs achieve long-term productivity, as evidenced by Secunda's cumulative output exceeding 1.5 billion barrels of synthetic fuels by 2020.

Feedstock Conversion Processes

Sasol's feedstock conversion processes center on the production of synthesis gas (, a mixture of and ) from and , serving as the intermediate for downstream synthesis. In coal-based operations, primarily at the Secunda Synfuels facility, supplied by Sasol Mining undergoes in Sasol-Lurgi fixed-bed dry-bottom (FBDB) reactors. This process, licensed from Lurgi and refined by Sasol since the , reacts with and oxygen at elevated temperatures exceeding 1000°C and pressures up to 40 bar, yielding raw alongside byproducts like , , and gases. The FBDB technology suits South African s, which have moderate reactivity and ash content, enabling Sasol to operate 97 such units commercially with over 50 years of experience. The sequence begins with drying to remove moisture, followed by ( in a low-oxygen environment) and subsequent zones where exothermic oxidation and endothermic reforming reactions predominate, progressively converting the particle from the top downward. Raw , with a typical H2/CO molar ratio of 1.5–2.0 after initial crude gas formation, requires downstream purification to remove impurities such as , , and particulates via Rectisol or similar absorption processes before adjustment for synthesis applications. Secunda alone gasifies more than 30 million metric tons of annually, supporting the world's largest commercial coal-to-liquids complex. For natural gas feedstocks, Sasol employs autothermal reforming, combining with to generate . (primarily ) reacts with oxygen and in a refractory-lined reactor at high temperatures (around 1200–1500°C) and pressures (30–40 bar), achieving a flexible H2/CO ratio of 1.8–2.2 suitable for Fischer-Tropsch processing. This route was adopted at Sasolburg's Sasol One plant following its 2004 conversion from , reducing compared to coal handling while leveraging abundant gas resources; similar underpins Sasol's gas-to-liquids ventures, such as the former Oryx in . from both feedstocks undergoes water-gas shift adjustment if needed to optimize the H2/CO ratio, emphasizing Sasol's proprietary integration of conversion with purification for high-yield hydrocarbon production.

Innovations in Feedstock-Agnostic and Low-Carbon Applications

Sasol's Fischer-Tropsch (FT) synthesis process, a core technology since the company's inception, exhibits inherent feedstock agnosticism, enabling the conversion of derived from diverse carbon and hydrogen sources—including , , , , or recycled CO₂—into synthetic fuels and chemicals without fundamental process redesign. This flexibility positions FT as adaptable to low-carbon pathways, such as substituting fossil-based with produced via and biogenic or captured carbon, thereby reducing lifecycle emissions while maintaining product quality. Sasol has leveraged this in pilot and demonstration projects, emphasizing power-to-liquid (PtL) routes that integrate to generate e-fuels compatible with existing . Key innovations include advanced cobalt-based FT catalysts optimized for low-temperature operations, which enhance selectivity for high-value liquids like in sustainable aviation fuel (SAF) production from non-fossil feedstocks; these catalysts support carbon-neutral SAF via PtL by efficiently handling from and CO₂. In August 2024, Sasol expanded its gas-to-liquids (GTL) FT wax portfolio, achieving a 35% reduction in through proprietary processes that minimize upstream emissions without altering end-product specifications, targeting adhesives and packaging sectors. For biofuels, Sasol is advancing biomass-derived integration, with facilities designed to process such feedstocks directly; as of February 2025, the company reported active biofuel projects tailored for applications, capitalizing on FT's compatibility to produce drop-in fuels. In e-fuels development, Sasol partnered with in October 2025 for a German demonstration plant employing electrified reactors to convert renewable feedstocks into low-carbon and , yielding primarily with projected emissions reductions via biogenic CO₂ and inputs. This builds on a June 2023 with to construct SAF plants globally, aiming for up to 650,000 tonnes of annual production by integrating FT with carbon and ; a related Danish pilot successfully produced from and CO₂ in 2025. Complementary efforts involve the HyshiFT consortium, launched with partners including Linde and Enertrag, to scale e-kerosene using for SAF. To address residual emissions, Sasol pursues carbon capture, utilization, and storage (CCUS) integration, collaborating with South Africa's Council for Geoscience since October 2023 to evaluate sites and technologies capable of capturing over 85% of CO₂ from coal-to-liquids operations, facilitating its reinjection or use in FT loops for net-low-carbon outputs. These initiatives, while promising for decarbonization, remain largely at demonstration scale as of 2025, with commercial viability hinging on policy incentives and cost reductions in production.

Business Operations

Feedstock Sourcing and Mining

Sasol primarily sources and as feedstocks for its Fischer-Tropsch synthesis processes at the Secunda and facilities in . constitutes the dominant feedstock for Secunda's coal-to-liquids operations, while supports both sites, with volumes piped from offshore-linked fields. The company's vertically integrated model includes direct control over and upstream gas production to ensure supply reliability. Sasol Mining operates six underground mines, five in the Secunda region (Bosjesspruit, Brandspruit, Middelbult, Syferfontein, and Twistdraai) and one near (), producing approximately 40 million tonnes of saleable annually. This output is directed exclusively to Sasol's synfuels complexes, where undergoes in Lurgi fixed-bed reactors to produce . In 2025, Sasol initiated a destoning project at Secunda to improve feedstock quality by removing excess stone, enhancing efficiency and enabling the company to exit the market amid declining profitability. These operations face geological challenges, including variable seam quality, but have sustained production through ongoing capital investments in equipment. Natural gas feedstock is sourced from the Pande and Temane fields in Mozambique's Inhambane province, developed by Sasol Petroleum Temane Limitada (SPT) since acquiring rights in 2004. The fields feed a central processing facility that compresses and cleans gas for transport via an 865-kilometer pipeline to Sasol's South African operations, delivering up to 122 million gigajoules annually. Production enhancements, including reservoir workovers, aim to extend field life, though supplies are projected to decline post-2025, prompting Sasol to restart drilling in September 2025 to avert a "gas cliff." Sasol holds proven reserves of over 36 billion cubic meters in these fields as of early 2025. Emerging efforts include partnerships for alternative feedstocks, such as a 2025 joint development agreement with Anglo American and to produce renewable diesel precursors from mine waste and , though these remain supplementary to fossil-based sources. Sasol's sourcing strategy prioritizes cost-effective, self-supplied inputs to maintain margins amid global energy transitions.

Production Facilities and Synfuels/Chemicals

Sasol's primary production facilities for synfuels and chemicals are located in , with Secunda Synfuels Operations in serving as the core site for production via coal-to-liquids processes. This facility, operational since the , employs over 80 Sasol-Lurgi fixed-bed dry-bottom gasifiers to convert into , which is then processed through Fischer-Tropsch synthesis to yield approximately 150,000 barrels per day of and refined products, including diesel, , , , and . The Secunda complex also generates chemical feedstocks and co-products such as gas, , and , integrating mining inputs from six nearby operations to support an annual output exceeding 40 million tonnes of total products historically. In parallel, Sasolburg Operations in the Free State province focuses on chemicals manufacturing, building on the original 1955 coal-to-liquids complex that has evolved into a hub for commodity and specialty chemicals derived from syngas and Fischer-Tropsch waxes. This site produces base chemicals like ethylene, propylene, and alcohols, alongside advanced materials such as catalysts and carbon products, contributing to an aggregate South African chemicals output of around 4 million tonnes annually across integrated facilities including Secunda and satellite sites in Ekandustria and Durban. Processes at Sasolburg emphasize value-added conversion of synfuels byproducts into solvents, polymers, and surfactants, with downstream refining supported by the Natref joint-venture facility for additional fuel blending. Synfuels production at these facilities relies on proprietary low-temperature Fischer-Tropsch to generate high-quality, low-sulfur fuels from non-petroleum feedstocks, enabling Sasol to supply about 30% of Africa's liquid fuel needs through synthetic equivalents that reduce import dependency. Chemicals output, encompassing both synfuel-derived and gas-based streams, includes olefins, aromatics, and wax-based products marketed globally, with the integrated nature of operations allowing efficient co-production of fuels and over 400 chemical variants to optimize yield and minimize waste. Recent operational data indicate record synfuels volumes at Secunda in fiscal years post-2020, driven by process optimizations despite feedstock variability.

Global Organizational Structure

Sasol Limited maintains its global headquarters at Sasol Place in , , , overseeing operations in 22 countries with sales to 118 nations as of June 30, 2024. The company's structure emphasizes an integrated approach combining energy and chemicals production, leveraging upstream resources like and for downstream fuels and specialty chemicals via Fischer-Tropsch processes. It is organized into three market-focused businesses: Sasol Chemicals, Sasol Energy, and Sasol ecoFT, supported by upstream units including Mining and Synfuels. Sasol Energy encompasses mining, synfuels production, gas operations, and fuels marketing, primarily in Southern Africa, with international gas-to-liquids ventures such as the ORYX GTL plant in and gas fields in . Sasol Mining supplies approximately 32 million tons of saleable annually to the Southern African , targeting 30-32 million tons in 2025. Synfuels operates world-scale coal-to-liquids facilities in Secunda (targeting 7.0-7.2 million tons production in 2025) and . In , these activities are managed through subsidiaries including Sasol Synfuels, Sasol Oil Proprietary Limited, and Sasol Mining Proprietary Limited. Sasol Chemicals is structured around regional operating segments—Africa, Eurasia, and America—with four customer-facing divisions: Base Chemicals, Performance Solutions, Essential Care Chemicals, and . Key international sites include the Lake Charles Chemicals Complex in , USA (regional headquarters in , ), chemical plants in and Brunsbüttel, , and facilities in Augusta and Sarroch, . Sasol ecoFT focuses on sustainable power-to-liquids technologies for low-carbon fuels and chemicals, integrating and captured carbon. Governance is directed by a Board of Directors, chaired by Muriel Dube as of 2024, and executed by the Group Executive Committee, which includes roles for , operations, , and commercial functions. This framework supports a of 25,254 to 26,279 employees, prioritizing , , and alignment with goals like 30% GHG reduction by 2030.

Major Projects

South African Domestic Initiatives

Sasol has pursued several domestic initiatives in South Africa to enhance energy security, integrate renewable sources, and advance decarbonization technologies, primarily supporting its core synfuel operations at Secunda and Sasolburg while aligning with national goals for lower emissions. These efforts include the development of gas-to-power infrastructure and procurement of renewable energy to reduce reliance on coal-fired electricity, amid South Africa's energy constraints and Sasol's commitments to cut scope 1 and 2 greenhouse gas emissions by 30% by 2030 from a 2017 baseline. A key project is the R1.5 billion gas-fired power generation plant in , commissioned as South Africa's first stand-alone gas-to-power facility, which generates 175 MW of electricity using feedstock to supplement grid supply and stabilize operations at Sasol's nearby synfuel complex. This initiative, operational since 2023, leverages Sasol's access to piped from to provide baseload power independent of Eskom's coal-dominated network, reducing exposure to load-shedding risks that have historically disrupted production. In parallel, Sasol has expanded integration through power purchase agreements (PPAs) and direct investments. The Msenge Emoyeni Wind Farm, a 140 MW facility in the , achieved commercial operations in October 2024, delivering Sasol's first large-scale renewable electrons to offset fossil-based power usage at its South African sites. Additional PPAs include the 140 MW Mulilo De Aar 2 Wind Farm and the 120 MW Paarde Valley Solar PV plant, both in the , secured in 2024 to further electrify operations with zero-emission sources. These procurements, totaling over 400 MW, support Sasol's strategy to transition from coal-derived while maintaining chemical and output efficiency. Decarbonization-focused collaborations include a 2025 partnership with to deploy carbon capture and utilization (CCU) technologies for producing sustainable fuels and chemicals, targeting emissions from steelmaking byproducts in the Vaal region and . Sasol also signed a with the government in 2024 for a two-year on a project, aiming to produce low-carbon via powered by regional renewables. Complementing these, a February 2025 agreement with Anglo American and explores generating biogenic feedstock from residues for renewable diesel production, establishing a domestic for biofuels. These initiatives reflect Sasol's empirical pivot toward and CCU amid technological feasibility assessments, though progress depends on infrastructure scalability and cost competitiveness against traditional synfuels. Upgrades to existing assets, such as the 2025 modernization of the Secunda power plant with GE Vernova technology, have introduced low-NOx combustors to cut emissions of oxides, , and usage while extending cycles, directly addressing air quality concerns in the Priority Area. Sasol's programs, detailed in its 2024 In Society Report, co-create solutions for socio-economic challenges around operations, including skills development and local procurement to mitigate impacts from energy transitions.

International Gas-to-Liquids and Expansion Efforts

Sasol's international expansion into gas-to-liquids (GTL) technology began with the development of the Oryx GTL plant in , , marking its first major venture outside . Established as a between Qatar Petroleum (now ) with 51% ownership and Sasol with 49%, the project represented an investment of approximately $950 million and utilized Sasol's proprietary slurry-phase Fischer-Tropsch synthesis process to convert into synthetic fuels. The plant achieved mechanical completion in 2006 and commenced commercial production in 2007, producing high-quality diesel, naphtha, and other liquid hydrocarbons at capacities exceeding its nameplate design of 24,000 barrels per day on a sustained basis. The success of Oryx GTL demonstrated the commercial viability of Sasol's GTL technology for monetizing stranded reserves, prompting further expansion ambitions. Sasol pursued additional GTL opportunities through strategic partnerships, including a 2000 joint venture with Chevron to apply GTL processes to global gas reserves. In , Sasol participated in the Escravos GTL (EGTL) project, establishing an operational presence with offices in , though the facility's development faced delays and scaled-back expectations amid economic challenges. These efforts aimed to replicate the Qatar model by leveraging abundant gas resources in regions like and the , with Sasol positioning itself as a technology licensor and equity partner to diversify from coal-based operations. However, broader international GTL expansion faced significant hurdles due to volatile oil prices and high . Sasol indefinitely suspended a proposed $14 billion GTL facility in Westlake, , in , citing prolonged low crude prices that undermined project economics. Similarly, planned GTL refineries in , targeting up to 96,000 barrels per day from one billion cubic feet of daily gas input, were abandoned as Sasol exited plays and greenfield GTL developments globally. More recently, Sasol contributed technology and expertise to the Uzbekistan GTL , which achieved full performance testing in June 2025, converting 340 million standard cubic feet per day of gas into 37,650 barrels per day of low-sulfur liquids, though Sasol's role was collaborative rather than operational ownership. These outcomes reflect Sasol's strategic pivot toward selective, lower-risk GTL licensing and upstream gas investments over large-scale construction.

Recent and Emerging Ventures

In 2024, Sasol formed a 50/50 with to commercialize synthetic sustainable (SAF) production technologies, leveraging Fischer-Tropsch synthesis for e-fuels derived from and captured CO2. In December 2024, the partnership was selected to develop a demonstration e-SAF plant in , capable of producing 2,500 metric tons per year of e-fuels primarily for , with commissioning targeted for the fourth quarter of 2027; the facility will integrate 's eSAF technology with Sasol's expertise in syngas-to-liquids conversion. This initiative builds on Sasol's participation in the HyshiFT Consortium, a collaborative effort to advance e-kerosene production for decarbonization through power-to-liquid pathways. Sasol established Sasol Ventures, a fund in 2023, to invest in technologies supporting its decarbonization strategy and 2050 net-zero emissions goal, targeting innovations in low-carbon energy and chemicals. In February 2025, Sasol partnered with Anglo American and to pilot renewable diesel production in , utilizing and feedstocks to test scalability for off-road and heavy-duty applications, with initial trials aimed at reducing fleet emissions. Ongoing renewable energy procurement supports these ventures; in July 2025, Sasol and advanced a large-scale project backed by 220 MW of from , initiated in January 2023, to supply for industrial operations in . Sasol committed ZAR 15–25 billion (approximately $850 million–$1.4 billion) for investments from 2025 to 2027 to accelerate transitions, including potential expansions in SAF and hydrogen-derived products, as outlined in its strategic plans. However, some proposed hydrogen-based SAF projects faced setbacks, such as the cancellation in October 2024 of a 200 MW initiative with in due to economic and regulatory challenges.

Economic Contributions

Role in South African Energy Security and GDP

Sasol significantly bolsters South Africa's energy security through its production of synthetic fuels, supplying approximately 30% of the nation's domestic liquid fuel needs via coal-to-liquids and gas-to-liquids processes at its Secunda facility. These synthetic fuels, primarily gasoline and diesel derived from abundant domestic coal and natural gas feedstocks, constitute nearly all of South Africa's liquid fuels output, mitigating dependence on imported crude oil amid global supply disruptions and price fluctuations. This domestic production capability, rooted in Fischer-Tropsch technology operational since the 1950s and scaled up in the 1980s, provides a strategic buffer against oil import vulnerabilities, particularly given South Africa's limited conventional petroleum reserves and exposure to international sanctions or conflicts. In terms of (GDP), Sasol's operations contribute roughly 5% to Africa's national economy when including direct outputs, supplier linkages, and induced effects, with direct contributions estimated at 1.6% to 2.6% based on 2021-2023 data. The company generates substantial fiscal revenues, including R52.6 billion in taxes for the 2022 , while its , , and chemical activities drive exports and industrial clustering. Locally, Sasol anchors economic activity, supporting over 80% of GDP in municipalities like Metsimaholo through , wages, and investments.

Employment, Supply Chain, and Industrial Impacts

Sasol employs approximately 27,107 people globally as of June 30, 2025, reflecting a 2.06% decline from the prior year amid operational optimizations and cost controls. In , where the majority of its workforce is concentrated, Sasol South Africa (SSA) directly supports around 24,000 jobs, primarily in , synfuels production, and chemicals manufacturing at facilities like Secunda and . These direct roles span skilled technical positions, engineering, and operational labor, with a significant portion unionized, influencing labor negotiations and metrics. Through its upstream , SSA sustains 452,683 total jobs in the South African economy, encompassing direct , indirect roles in supplier networks, and induced effects from employee spending. Broader estimates, incorporating downstream and fuels utilization, indicate support for up to 500,000 positions, representing over 3% of national . impacts derive from substantial local , including from integrated mines and services from thousands of vendors, fostering skills transfer and enterprise development in Mpumalanga and Free State provinces. Industrial multipliers amplify Sasol's footprint, with SSA's activities generating indirect and induced GDP contributions equivalent to 5.23% of South Africa's total, driven by linkages to , , and reliant on affordable synfuels and feedstocks. In local municipalities like Metsimaholo, operations underpin over 75% of and 80% of GDP, creating dependencies on sustained production volumes. These effects, quantified via input-output modeling in commissioned economic studies, highlight causal chains from feedstock extraction to product distribution, though vulnerable to global commodity volatility and energy transitions.

Market Performance and Shareholder Value

Sasol Limited's ordinary shares trade on the Johannesburg Stock Exchange (JSE) under the ticker SOL, while its American Depositary Receipts (ADRs) are listed on the (NYSE) under SSL. As of October 24, 2025, the SSL ADR closed at 6.56 USD, reflecting a long-term trajectory of volatility tied to global commodity cycles, with the stock price having declined significantly from peaks above 50 USD in 2018 amid challenges including project impairments and fluctuating oil prices. Over the past five years through April 2025, Sasol's total shareholder return (TSR) decreased by 9.31%, underperforming broader market indices due to factors such as high levels and operational pressures from international expansions. In its fiscal year ended June 30, 2025 (FY2025), Sasol achieved basic (EPS) of R10.60, marking a turnaround from a loss of R69.94 per share in FY2024, driven by improved operational performance and cost disciplines despite a challenging macroeconomic environment. Net stood at $3.7 billion at FY2025 year-end, down from prior levels but still exceeding the company's sustainability threshold, resulting in no final declaration in line with its revised policy prioritizing reduction. Gross was reduced to $5.8 billion, a 10% decrease year-over-year, as part of efforts to enhance strength and support future shareholder returns. Dividend payouts have been curtailed in recent years to preserve capital amid elevated leverage from past investments, with the most recent of $0.0829 per ADR occurring on March 29, 2024, contributing to a trailing twelve-month yield approaching 0% as of mid-2025. Sasol's for the latest reported period was 4.9%, and was 8.94%, indicating modest efficiency in generating value from equity and assets amid sector headwinds. The company's book value to market cap improved to around 1.6x in FY2025 from lower levels in prior years, signaling potential undervaluation relative to assets, though sustained creation remains contingent on price recovery and successful execution of debt reduction strategies.
Key FY2025 MetricsValuePrior Year Comparison
Basic EPSR10.60From loss of R69.94
Net DebtUS$3.7bnAbove dividend threshold
Gross Debt Reduction10% YoYTo US$5.8bn
Final DividendNone declaredPolicy-driven suspension

Environmental and Sustainability Profile

Greenhouse Gas Emissions and Lifecycle Analysis

Sasol's operations, centered on coal-to-liquids (CTL) and gas-to-liquids (GTL) processes, generate substantial (GHG) emissions, with Scope 1 and 2 emissions dominated by production and steam generation at facilities like Secunda Synfuels. In the ended June 2023, Sasol's total GHG emissions reached 64.4 million metric tons of CO2 equivalent, encompassing direct emissions from fuel and processes (Scope 1), indirect emissions from purchased (Scope 2), and value-chain emissions (Scope 3). This volume represented approximately 10% of South Africa's overall GHG output, underscoring the intensity of Sasol's fossil-based synthesis routes. By 2025, emissions had declined to reflect a net 20% reduction from the 2017 baseline, driven partly by lower production volumes yielding about 14% direct cuts, though absolute levels remained elevated due to operational scale. The Secunda complex, Sasol's flagship CTL site, is the single largest of CO2 emissions globally, emitting over 40 million tons annually in recent years and contributing the bulk of the company's footprint. Emissions stem causally from the high-carbon-intensity of , which requires oxygen-blown reactors and produces significant CO2 as a , compounded by inefficiencies in hydrogen-carbon balancing inherent to coal's low hydrogen-to-carbon ratio compared to . Independent analyses confirm Secunda's outsized role, with its emissions exceeding those of many national totals, though Sasol attributes some variability to production adjustments rather than process redesign. Lifecycle assessments (LCAs) of Sasol's products highlight elevated GHG intensities across the full chain—from feedstock extraction and conversion to end-use combustion—relative to conventional petroleum pathways. Coal-based Fischer-Tropsch (FT) liquids, core to Sasol's output, yield lifecycle emissions of 200–250 grams CO2 equivalent per megajoule (g CO2e/MJ), approximately 2–3 times higher than refined gasoline or diesel (around 90 g CO2e/MJ), due to upstream process energy demands and fugitive methane from mining. Sasol's internal LCAs for chemical products, conducted at European sites, quantify carbon footprints incorporating raw material sourcing, manufacturing, and downstream use, revealing similar premiums for synthetic fuels; for instance, value-chain Scope 3 emissions alone approached 20 million tons CO2e in 2023, largely from product combustion. These analyses, aligned with GHG Protocol standards, emphasize that while GTL variants (e.g., at Sasol's facility) mitigate some intensity via methane reforming, overall portfolio emissions persist at premiums reflective of fossil dependency. Empirical comparisons, including South African plastics sector breakdowns, allocate 70–80% of polymer lifecycle GHGs to production stages tied to Sasol-supplied feedstocks, reinforcing causal links to syngas inefficiency.

Efforts Toward Decarbonization and Net-Zero Goals

Sasol announced in 2021 a commitment to reduce its Scope 1 and 2 by 30% by 2030, measured against a 2017 baseline of 116 million tonnes of CO2 equivalent, alongside a net-zero ambition by 2050 envisioning a fossil fuel-free operation reliant on and sources. This strategy emphasizes progressive decarbonization of its high-emission Secunda and synfuels operations in , which account for the majority of its direct emissions. The company's Emission Reduction Roadmap, first detailed in 2021, targeted substitution with from , renewable power integration, and energy efficiency measures to meet the 2030 goal. By 2023, Sasol optimized the roadmap amid faltering Mozambican gas supplies and decisions to extend operations, reducing projected from $7 billion to under $2 billion while asserting the 30% reduction remains achievable through accelerated efficiency gains, increased gas utilization where feasible, and offsets including carbon credits. In May 2025, CEO Simon Baloyi reaffirmed this trajectory during earnings updates, highlighting procurement of carbon credits and investments in production facilities in as complementary measures. Specific initiatives include partnerships for procurement, such as solar and projects to displace coal-fired power, and pilot-scale projects aimed at process heat and feedstock substitution in chemical production. Sasol also set a Scope 3 emissions target of 20% reduction by 2030 from the use of its products, focusing on lower-carbon fuels and product efficiency in downstream applications. Progress reports indicate Scope 1 and 2 emissions fell to approximately 60 million tonnes CO2e in fiscal 2024, though critics including shareholder activists question the optimized roadmap's reliance on offsets and short-term coal extensions, arguing it risks missing targets without verifiable low-carbon alternatives scaling by 2030. Sasol counters that empirical data from ongoing optimizations supports deliverability, with net 2024 payments of R1.7 billion after offsets underscoring fiscal integration of these efforts.

Empirical Trade-Offs Between Energy Production and Emissions

Sasol's coal-to-liquids (CTL) operations at Secunda exhibit high intensity, with 7.77 tons of CO₂e emitted per ton of total production in 2023, reflecting the energy demands of generation and Fischer-Tropsch synthesis from feedstock. This intensity metric, calculated as Scope 1 and 2 emissions divided by production volume, has remained elevated—ranging from 7.33 to 7.79 tons CO₂e per ton between 2021 and 2023—due to the process's reliance on for both carbon and hydrogen inputs, where approximately half of emissions stem from alone at rates of 22 tons CO₂e per ton of H₂. Empirical records indicate that production upticks exacerbate total emissions; for example, a dip in Secunda output from 6,505 kilotons in 2020 to 6,388 kilotons in 2023 coincided with minor intensity stabilization, but overall Scope 1 and 2 emissions hovered near 64 million tons CO₂e annually, underscoring the direct proportionality between fuel output and emissions volume. The inherent causal linkage in CTL—requiring roughly two tons of per ton of synthetic liquid fuels—yields emissions profiles 2–3 times higher per unit than conventional refining, as 's lower hydrogen-to-carbon ratio demands additional processing steps that vent CO₂ during . Gas-to-liquids (GTL) variants offer partial mitigation, with lower per-tonne intensity via feedstock, yet still exceed oil-based benchmarks due to upstream leakage and synthesis inefficiencies; Sasol's shift toward gas in select operations has yielded only modest reductions, constrained by supply plateauing through 2028. Data from show group-wide intensity falling to 3.69 tons CO₂e per tonne of external sales amid higher volumes, but this efficiency gain was offset by absolute emissions rises, highlighting that scaling production to meet demands—such as Secunda's 165,000 barrels per day of synfuels—amplifies total CO₂ output without proportional intensity drops. Efforts to decouple production from emissions, such as integration exceeding 600 MW via power purchase agreements, have curbed Scope 2 portions but falter against Scope 1 process emissions, which dominate at Secunda (84% of total). substitution could slash hydrogen-related emissions by over 90%, yet its deployment trades off against current output, as scalability remains limited by costs exceeding $2 per kg and infrastructure needs, potentially curtailing near-term fuel volumes. Consequently, Sasol's 2030 target of 30% Scope 1 and 2 reduction from a 63.9 million-ton 2017 baseline—aiming for ~44.7 million tons—relies on feedstock swaps and offsets totaling 1.7 million tons CO₂e from 2019–2023, but empirical trends reveal persistent trade-offs: sustained high production preserves supply at the expense of unabated emissions, while aggressive cuts risk economic viability in coal-abundant regions.
FacilityYearProduction (kt)Intensity (t CO₂e/ton)Total Scope 1+2 Emissions (Mt CO₂e, Group)
Secunda20206,5057.3864.8
Secunda2021N/A7.3366.3
Secunda2022N/A7.7963.9
Secunda20236,3887.7764.4

Controversies and Criticisms

Historical Ties to Apartheid-Era Policies

Sasol was founded on September 26, 1950, as a state-owned enterprise by the South African government under the newly elected National Party, which had formalized apartheid policies in 1948, with the explicit aim of producing synthetic fuels from domestic coal reserves to reduce reliance on imported oil. The initiative drew on Fischer-Tropsch synthesis technology originally developed in Nazi Germany during the 1920s and 1930s for wartime self-sufficiency, adapted by Sasol for peacetime energy security amid growing international scrutiny of South Africa's racial policies. The first coal-to-liquids plant at Sasolburg commenced operations in 1955, marking the beginning of a parastatal model heavily subsidized by the apartheid regime, which viewed synthetic fuel production as strategically vital for economic autonomy. Throughout the apartheid era (1948–1994), Sasol received direct financial and infrastructural support from the government, including loans and guarantees totaling billions of rand, to expand operations and counter oil sanctions imposed by the and Western nations starting in the and intensifying in the and . The Secunda complex, operational from 1980 and representing the world's largest coal-to-liquids facility at the time, was state-funded to produce up to 150,000 barrels of per day, enabling to meet approximately 30–40% of its needs domestically by the late despite comprehensive embargoes. This self-reliance mitigated the economic pressure from sanctions, which were explicitly designed to undermine the apartheid system's viability by targeting vulnerabilities like energy imports, thereby extending the regime's endurance. As a parastatal, Sasol operated within the framework of apartheid labor legislation, including the of 1911 (amended under apartheid) and job reservation policies that reserved skilled positions for white workers while confining black employees— who comprised the majority of the unskilled labor force—to lower-wage, hazardous roles in mining and plant operations. Facilities at Sasolburg and Secunda featured segregated hostels and amenities, reflecting broader state-enforced racial hierarchies, though the company employed tens of thousands across racial lines, contributing to industrial development in a sanctioned economy. Critics, including anti-apartheid activists, have characterized Sasol as an "arm of the oppressor" for profiting from these structures and symbolizing Afrikaner , with its expansions coinciding with heightened state repression in the and . However, Sasol's primary function was technological and economic adaptation to isolation rather than direct enforcement of racial policies, as evidenced by its post-1994 and continued operations under democratic governance.

Shareholder Activism and Corporate Governance

Sasol's corporate governance is structured around the King IV Report on Corporate Governance principles, with the board responsible for strategy, oversight of executive performance, and compliance with ethical standards, including regular benchmarking of processes to support decision-making on sustainability and risk. The company's remuneration policy links executive pay to performance metrics such as total shareholder return and operational efficiency, subject to non-binding annual shareholder votes. Shareholder activism at Sasol has intensified since the early , largely driven by environmental groups and institutional investors advocating for accelerated from fossil fuels and stricter emissions targets, often clashing with the company's coal- and gas-to-liquids operations. In November 2023, activists disrupted Sasol's (AGM) in by storming the stage during CEO Fleetwood Grobler's address, forcing cancellation of the in-person event; the meeting was rescheduled virtually to mitigate further interruptions. Similar protests occurred at the 2021 AGM, where activists challenged Sasol's commitments as insufficient for a "just transition" away from carbon-intensive production. Opposition to executive remuneration has been recurrent, reflecting concerns over alignment with shareholder value amid project overruns like the Lake Charles Chemicals Project. At the 2013 AGM, 30.06% of voting shares opposed the remuneration policy, led by the and other investors citing excessive pay relative to performance. More recently, in 2023, Old Mutual recommended voting against the remuneration and climate reports, prompting Sasol to express perplexity at the stance given prior engagements. The 2024 AGM saw the policy approved by 84.67% of voting shareholders, though activist group Just Share voted against it, arguing senior executives were insufficiently penalized for underperformance in emissions reduction and profitability. Governance disputes have centered on Sasol's refusal to table certain shareholder-proposed resolutions, such as enhanced disclosures, which activists like Just Share have criticized as inconsistent with King IV's emphasis on stakeholder inclusivity and transparency; the company has rejected at least six such proposals since 2018, citing legal thresholds for eligibility. support for Sasol's has declined, with 22% voting against the 2023 report compared to 92% approval in 2022, signaling growing pressure from ESG-oriented investors despite the company's targets of 30% GHG reduction by 2030 and net-zero by 2050. These tensions underscore broader conflicts between short-term activist demands for decarbonization and Sasol's reliance on high-emission assets for in .

Lake Charles Chemicals Project Controversy

The Lake Charles Chemicals Project (LCCP), announced by Sasol in 2014 with an initial budget of $8.9 billion for an ethane cracker and derivatives complex in Lake Charles, Louisiana, experienced substantial cost overruns, culminating in expenditures exceeding $12.9 billion by 2019 and resulting in financial impairments surpassing $5 billion. An internal independent review released in October 2019 identified significant control weaknesses and an improper tone at the top, contributing to the dismissal or resignation of senior executives. Safety incidents at the facility included an explosion and fire at the low-density polyethylene unit in January 2020, which caused operational shutdowns but no injuries, and a fire in October 2022 that led to hazardous material releases. In 2020, Sasol sold a 50% stake in the project to LyondellBasell for $2 billion to alleviate debt pressures. The U.S. Environmental Protection Agency settled alleged violations related to the 2022 incident with Sasol in April 2024, imposing a $1.4 million civil penalty for shortcomings in chemical accident prevention programs.

Broad-Based Black Economic Empowerment Controversies

In 2023, Sasol launched Phase 2 of its Khanyisa broad-based black economic empowerment (B-BBEE) scheme, restricting participation to black permanent South African employees defined under B-BBEE codes (African, Coloured, and Indian citizens). Participants were granted rights to approximately 1,240 shares, potentially valued at R400,000–R500,000 upon vesting around 2028, with funding provided by Sasol through vendor financing. White employees and foreign nationals were ineligible, irrespective of tenure or performance. The trade union Solidarity, representing about 6,300 Sasol members primarily in Secunda and Sasolburg, condemned the policy as "blatant discrimination" and "reverse racism". The union argued that it unfairly excluded white employees based solely on race despite their long service, divided workers performing identical jobs by providing unequal benefits, and that B-BBEE compliance did not necessitate such racial exclusions, citing examples of inclusive employee schemes in the mining sector. Solidarity contended that the approach created new inequalities rather than solely redressing historical ones.

Environmental Litigation and Regulatory Pressures

In , Sasol's Secunda operations have faced significant regulatory scrutiny for exceeding national air quality standards, particularly under the Minimum Emission Standards (MES) established by the National Environmental Management: Air Quality Act. In March 2022, the High Court ruled that the government failed to enforce emission limits on Sasol and , ordering measures to reduce and particulate matter pollution in the Priority Area, where Secunda is located, due to breaches of constitutional rights to a healthy environment. Sasol has sought exemptions from MES compliance, applying for alternative load-based limits for emissions from its boilers; in April 2024, Minister Dion George granted an appeal allowing Sasol to operate with emissions potentially 50-130% higher than MES thresholds, a decision criticized by groups like the Legal Agenda Clinic for enabling continued toxic releases. In September 2025, Sasol initiated litigation challenging the Minister of Forestry, Fisheries and the Environment over regulations, arguing aspects of the standards impose undue burdens amid efforts to maintain energy production. Water pollution cases have also imposed pressures, with Sasol facing criminal charges in Secunda Magistrate's Court since October 2022 for discharging contaminated wastewater into the environment over multiple years, violating the National Water Act; the charges targeted executives including operations manager Hannes van Aswegen and alleged negligence in handling hazardous effluents. Related allegations involved unauthorized construction of a plant without environmental authorization, potentially facing fines up to R10 million or 10 years imprisonment. In August 2022, Sasol was summoned to court for linked to polluting the system via Secunda's Benfield operations, though Sasol denied claims. These proceedings, ongoing into 2023, highlight persistent compliance challenges, with charges eventually withdrawn in July 2025 in a related case amid protracted legal delays. Internationally, Sasol encountered U.S. regulatory action when the Environmental Protection Agency settled violations at its Sasol Chemicals facility in Westlake, , imposing a $1.4 million in April 2024 for failures in prevention programs following an 2022 fire that released hazardous materials. Sasol committed to , including enhanced systems. These cases underscore broader pressures from host countries' environmental laws, with Sasol's coal and gas-to-liquids processes amplifying scrutiny over fugitive emissions and wastewater management. Despite self-reported compliance efforts through audits and authorizations, independent assessments have flagged gaps, contributing to operational costs and legal risks.

References

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