Sasol achieved substantial cost and schedule savings by the “Next Exact" duplication of Sasol Two in the northeastern highlands (Transvaal) region of South Africa.
The Sasol Three Complex was built adjacent to Sasol Two to optimize the use of construction, workers, community, and facilities. Sasol Three was also based on the commercially proven synthol technology developed at Sasol One and Two.
The two plants include 100 heaters, 2,000 vessels, 2,000 heat exchangers, 3,000 pumps, and miles of piping. The plants consume 1,500 megawatts of electrical power, and each 750-megawatt system includes enough power cable to run from Los Angeles to New York and back to Kansas City.
Sasol negotiated contracts with all previous principal contractors for obvious cost advantages and to meet the compressed construction schedule.
The South Africans were willing to share their 25 years of coal-conversion expertise with the United States. Working with American companies, Sasol processed test batches of Texas lignite and sub-bituminous Wyoming coal through its facility at Sasolburg to determine whether the process was applicable to American coals. Sasol representatives also consulted with American companies to investigate coal conversion technology.