Abtract

The Fischer–Tropsch (FT) process has experienced fluctuating interest over the past century, often driven by strategic and geopolitical factors. Sasol has been at the forefront of FT implementation with well over 250 000 b/d of fuels and chemicals produced from our own facilities and licenced technology. Today, the resurgence in FT is fuelled by the urgent need for sustainable solutions, with the technology offering feedstock flexibility that supports the integration of renewable sources such as green hydrogen, unavoidable CO₂, biomass, and waste-derived syngas. This adaptability positions FT as a key enabler for emissions reduction and decarbonization, especially in hard-to-abate sectors like aviation [1]. 

However, the use of these often-costly renewable feedstocks presents several challenges, among them being the development of FT catalysts with high conversion efficiency and enhanced selectivity toward desired products. Commercially deployed iron and cobalt catalysts show significant potential for sustainable aviation fuel production via both “direct” and “indirect” FT pathways-each of which will be examined. 

To support the development of more sustainable catalyst and process technologies, a range of complementary approaches will be explored. These include collaborative partnerships aimed at evaluating catalyst behaviour under realistic conditions (operando) [2], the application of theoretical methods [3], as well as artificial intelligence and machine learning to accelerate discovery and optimization. Techno-economic assessments, life cycle analysis, and product carbon footprinting are also increasingly used tools for guiding catalyst and process design. Finally, the critical role of a risk-mitigated, stepwise scale-up strategy [4] will be emphasized as a cornerstone for successful industrial implementation. 

[1] Moodley, D., Botha, T., Crous, R., Potgieter, J., Visagie, J., Walmsley, R. and Dwyer, C., 2024. Catalysis for a Sustainable Environment: Reactions, Processes and Applied Technologies (Wiley), 2024, 1, 73-116. 

[2] https://care-o-sene.com 

[3] Moodley, D., Potgieter, J., Moodley, P., Crous, R., van Helden, P., van Zyl, L., Cunningham, R., Gauche, J., Visagie, K., Botha, T. and Claeys, M., 2025. Catalysis Today, 454, p.115282. 

[4] Potgieter, J.H., Moodley, D., Botha, T., Visagie, J., Manong, T., Frank, M., Claeys, M., van Steen, E., Böltken, T. and Pfeifer, P., 2024. Catalysis Today, 432, p.114554. 

Biograhy

Dr. Denzil Moodley is a Senior Scientist at Sasol Research and Technology and an Industrial Research Fellow at Helmholtz-Zentrum Berlin (HZB), with over 25 years of experience in catalysis, process chemistry, and industrial R&D. With expertise in Fischer-Tropsch catalysis, he has driven scientific innovation in catalyst development, regeneration, and scale-up for GTL and CTL technologies. 

Denzil has led multiple high-impact projects, bridging fundamental science and industrial application. He is a steering committee member and work package lead in the CARE-O-SENE project, advancing catalysts for sustainable aviation fuel. He holds a Ph.D. in Chemistry from Eindhoven University of Technology in the Netherlands.