Syngas production from South African coal sources using Sasol-Lurgi gasifiers

Sasol has been operating the Sasol-Lurgi fixed bed coal gasification process for more than fifty years, and with ninety seven units in operation still remains the world's largest commercial application of this technology. The combined operational and engineering expertise vested in Sasol represents a formidable capability in the field of coal and gasification science. Coal is a crucial feedstock for South Africa's unique synfuels and petrochemicals industry, and is used by Sasol as a feedstock to produce synthesis gas (CO and H-2) via the Sasol-Lurgi fixed bed dry bottom gasification process. South Africa, as well as many other countries in the world, will for many years to come rely on its abundant coal resources for energy and specifically for the production of petrochemical products. Synthesis gas production through gasification is growing at a rate of approximately 10% per annum [Office of Fossil Energy, National Energy Technology Laboratory and the Gasification Technologies Council, 2000. Gasification: Worldwide use and acceptance. Contract DE-AMO1-98FE65271], indicating that gasification is definitely not a dying technology. The Sasol plants located in Secunda and Sasolburg (South Africa) gasify > 30 million tons per annum of bituminous coal to synthesis gas, which is converted to fuels and chemicals via the Fischer-Tropsch process. The production of chemicals is currently the dominant application for synthesis gas, followed by power generation, Fischer-Tropsch synthesis and gaseous fuels. Sasol-Lurgi gasifiers are extremely robust devices, and coal from sources with widely varying properties (e.g. ash content < 10% to as high as 35% or brown coal with moisture content of approximately 30%) can be gasified provided that certain operational changes are implemented. Other properties, like high caking propensity for example, require blending to acceptable levels and /or mechanical modifications. Interpretation of coal characterization data gives an indication of expected gasifier performance and the suitability of a specific coal source for Sasol-Lurgi Fixed Bed Gasification process. It is therefore critically important to gain an accurate and fundamental understanding of the properties and expected behavior of the targeted coal feedstock in order to (1) prepare a suitable conceptual flow scheme and (2) to maximize the eventual probability of success in any proposed gasification venture and (3) to optimize the operation and profitability of existing plants and (4) effectively address the environmental aspects. It is the view of the authors that fixed bed gasification technology has a bright future in the areas mentioned above and that Sasol has a unique role in the future application and commercialization of gasification technology globally. The unique skills of Sasol could however be complementary to those of other parties who share our view on the future of gasification and related technologies. (c) 2005 Elsevier B.V. All rights reserved.