Fertiliser supplier Suiso, founded by Paul Erskine, is taking a decisive step towards sustainability with a R31.5-billion coal-to-fertiliser and methanol project in Kriel, Mpumalanga.

The initiative is not only a response to the critical need for food security in sub-Saharan Africa but also a showcase of how industrial innovation can coexist with ambitious decarbonisation goals, thereby paving the way for a more sustainable future, says Suiso engineering director Gerhard Potgieter.

Suiso’s coal-to-fertiliser process stands out from traditional methods as it uses coal as its feedstock instead of natural gas.

This decision is part of a broader strategy to ensure sustainability in the production of nitrogen-based fertilisers, particularly for the sub-Saharan Africa market.

Potgieter explains that, although both the traditional and Suiso processes produce Syngas, Suiso’s use of coal enables the company to maintain affordability while significantly reducing its carbon footprint.

The Kriel facility is designed to produce 1.5-million tonnes of nitrogen-based fertilisers yearly, including urea, ammonia nitrate and controlled-release variants.

This production volume is a direct response to Africa’s fertiliser shortfall, with the continent, which is home to over one billion people, having only five fertiliser plants.

Further, Suiso’s commitment to sustainability is reinforced by its “cutting-edge” carbon capture and utilisation systems.

The facility will capture carbon emissions and repurpose them to produce gypsum and ammonium carbonate, transforming waste into valuable resources for agriculture and construction, explains Potgieter.

The company is also exploring deep saline aquifer carbon storage to ensure long-term environmental benefits.

The plant’s integrated coal gasification process generates synthetic gas, hydrogen and ammonia, which form the foundation for fertilisers and zero-sulphur methanol.

Suiso is also integrating renewable energy into its operations, and is negotiating a 15-year power purchase agreement with a leading renewable-energy provider, which will feed power into the national grid.

This collaboration aims to reduce reliance on coal-based power and contribute to decarbonisation, reinforcing Suiso’s commitment to sustainable industrial practices, Potgieter adds.

However, to meet international emission standards, Suiso will implement wet flue gas desulphurisation and advanced water recycling systems at its Kriel facility.

These technologies will reduce nitrogen dioxide and sulphur dioxide emissions, addressing air-quality concerns in Mpumalanga – an area historically affected by high levels of industrial pollution.

Suiso will also produce 234 000 t a year of clean, zero-sulphur blue methanol, ensuring compliance with South Africa’s anticipated Fuel Act of 2027.

Additionally, the project’s construction phase is expected to generate 4 000 jobs, which will transition into 981 permanent positions once the facility is operational in 2029.

To ensure a skilled workforce, Suiso is establishing the Gerhard Potgieter Engineering Training College on-site, which will train 400 employees and contribute to sustainable economic development in the area.

This initiative is expected to drive significant economic upliftment and community development in a previously undeveloped area, he says.

Local Commitment

Beyond its focus on emissions control and carbon capture, Suiso is committed to land rehabilitation and biodiversity restoration. Potgieter emphasises that the complex, located on a 900-ha site, will include land rehabilitation projects aimed at restoring local ecosystems.

“These efforts align with South Africa’s just transition framework and global sustainability goals, ensuring that industrial development proceeds with environmental stewardship at its core.”

Potgieter adds that Suiso’s partnerships are pivotal to the success and sustainability of the project.

The company is working with global conglomerate Export Trading Group, which is a significant offtaker, ensuring that its fertilisers reach the most vulnerable farming communities across sub-Saharan Africa.

Collaborations with engineering company Sinopec Ningbo Engineering, technology licensing company Stamicarbon and ammonia synloop licensor KBR will “bring world-class expertise to the project, ensuring compliance with international standards and contributing to operational excellence”, Potgieter concludes.