Sasol opens destoning plant to boost coal quality and strengthen Secunda operations

Energy and chemicals group Sasol has officially opened its new destoning plant in Mpumalanga, marking an important step in improving coal quality and enhancing operational performance at its Secunda operations.

The facility, which achieved beneficial operation in December 2025, forms part of Sasol’s broader strategy to strengthen, grow and transform its business while supporting more efficient coal processing.

Minister of Mineral and Petroleum Resources Gwede Mantashe said in a keynote address that the investment demonstrates confidence in South Africa’s mining sector and its long-term potential.

“Investments of this nature and magnitude give us confidence that, with commitment and dedication, we can indeed transform the South African mining sector into an industry that we can all be proud of,” he said.

Sasol explained that the facility was developed through the conversion of the Twistdraai Export Plant and is designed to remove high-density stone from run-of-mine coal sourced from the Thubelisha and Bosjesspruit mines.

“Developed through the conversion of the Twistdraai Export Plant, the facility removes high-density stone from the run-of-mine coal sourced from the Thubelisha and Bosjesspruit mines.”

By reducing ash and sink material before coal enters the gasification process, the plant improves the quality of syngas used in Sasol’s synthetic fuels and chemicals value chain.

“Since commissioning, the plant has contributed to a reduction in average sinks for Q1 FY26 to below 14%, supporting improved coal quality availability to Secunda Operations and helping to lift overall production for the quarter,” the company said.

Simon Baloyi, President and CEO of Sasol, said the facility delivers on a commitment made during the company’s Capital Markets Day in 2025.

“This facility is a key commitment we made at Capital Markets Day in 2025, and it plays an important role in enhancing operational performance at Secunda Operations by enabling the processing of higher-quality, destoned coal.”

Mantashe said the project demonstrates how investment in beneficiation and industrial capacity can support economic growth and job creation in South Africa.

“This is significant because it speaks directly to our long-standing mission of adding value to the minerals mined on our shores, closer to the point of production. Sasol’s decision to upgrade an export plant into a modern destoning facility demonstrates that you are serious about transforming your business in a way that delivers sustainable value for both Sasol and South Africa as a whole.”

The Minister also reflected on the historical challenges associated with mining, noting that the industry has long been described using the “five Ds”: dirty, difficult, dangerous, diseased and deadly.

“It has also been characterised by holes left in the ground while much of the mineral wealth was exported for beneficiation elsewhere, thus exporting jobs and profits that should have benefited the people of South Africa.”

According to Mantashe, the country has been working to change that legacy since the introduction of the Mineral and Petroleum Resources Development Act, though further transformation remains necessary.

“Whereas we have made notable progress in addressing this historical injustice since the enactment of the Mineral and Petroleum Resources Development Act (MPRDA), much more still needs to be done to transform the industry.”

He added that coal continues to play a critical role in the country’s economy despite increasing global pressure to move away from fossil fuels.

“Our country has been actively engaged in coal mining since the late 1860s. Over the decades, coal has played a central role in meeting the country’s energy needs, including supporting steel production, petrochemicals, cement manufacturing, and brick production.”

Coal also remains central to electricity generation through the power stations operated by Eskom, providing the baseload energy needed to support industrial development.

“Today, South Africa produces the largest amount of coal in Africa and ranks among the top 10 coal-producing countries in the world,” Mantashe said.

He added that the government’s Critical Minerals Strategy recognises coal’s ongoing role in supporting employment, economic activity and energy security.

“It also makes a significant contribution to the national economy through both domestic use and exports. We therefore continue to invest in the future of cleaner coal utilisation in South Africa, including initiatives such as Carbon Capture, Utilisation and Storage (CCUS).”

Mantashe concluded that global geopolitical tensions are a reminder of the importance of energy security and diversified feedstocks.

“The ongoing tensions in the Middle East serve as a powerful reminder of the importance of energy independence and diversified feedstocks in the production of petrochemicals. Projects such as this destoning plant demonstrate that industrialisation, beneficiation, and responsible resource utilisation remain central to South Africa’s economic future.”