Conversion Reactors in Sulphur Recovery Units (SRU) Using

Aspen HYSYS Simulation and GPSA Example 22-1

By Tahir Syed
 I am thankful to all the friends on this network who went through my previous
presentation on “Refinery Amine, Sour Water & Sulphur Recovery Unit (SRU) Process
Simulation” and tried the steps successfully to simulate the units.
 It has contributed to our combined learning. The link to the presentation is
https://www.linkedin.com/posts/tahirsyed2_refinery-amine-sws-sru-simulation-123-
activity-6693569720181911552-H6P1.
 The activity started based on a simplified SRU model in the book “Fundamentals of
Petroleum Refining” and is developing into a useful exercise.

 The Conversion Reactors have been used in the presentation

https://www.linkedin.com/posts/tahirsyed2_refinery-amine-sws-sru-simulation-123-
activity-6693569720181911552-H6P1 which gives flexibility to the process engineer to
alter the conversion of a particular reaction and note the impact.
 It is highly useful when we have reactor outlet stream analysis (e.g. from the field). We
can adjust Conversion to verify the field process parameters as approriate.
 However, conversion values should be realistic and verified.
 I looked at the GPSA problem 22-1 regarding SRU and understood that more conversion
reactors can be incorporated.
 I take the opportunity to discuss the application of Conversion reactors in various parts
of an SRU based on GPSA Problem 22-1.

The Conversion Reactors can be used to model the following unit operations and develop a
comprehensive simulation model:
1. Reaction Furnace
2. Waste Heat Boiler Outlet Stream
3. Sulphur Condensers
4. Gas Re-Heaters for Claus Converters feed
5. Claus Converters
6. Incinerator

A brief description of the reaction sets is presented in the following slides:

1. Reaction Furnace
 The main reaction set will be defined as mentioned in my previous presentation:
https://www.linkedin.com/posts/tahirsyed2_refinery-amine-sws-sru-
simulation-123-activity-6693569720181911552-H6P1
 The solution of GPSA problem 22-1 is a handy tool to find both Sulphur
produced in the Furnace (as S2 vapor) and the outlet temperature. Follow GPSA
FIG. 22-27 “Equilibrium Constant for Claus Reaction”, a and b.
 The conversion of various reactions will have to be adjusted in the simulation to
match the sulphur recovery, outlet temperature etc. as calculated above.

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  Please follow GPSA FIG. 22-7 “Potential COS and CS2 Formation in Claus
Furnaces” to adjust the conversion of COS and CS2 forming reactions in the
Reaction Furnace.
 In case we also have Sour Water Stripper gas then more reactions will have to be
added to the reaction set and temperature will be adjusted accordingly.
 Refer to the following theses to add more reactions to the reaction furnace:
 "Kinetic modeling of a Modified Claus Reaction Furnace" thesis by Aaron
Pollock (pdf pages 98, 132, 133).
 “Kinetic modeling of key reactions in the Modified Claus Plant Front End
Furnace” thesis by Kelly Hawboldt (pdf pages 28, 29).
 These theses discuss furnace reactions related to Amine/SWS SRU feeds which
have to be added as Conversion reactions to the Furnace reaction set.
 The link is prism.ucalgary.ca, University of Calgary, Prism Library.

2. Waste Heat Boiler Outlet Stream

The Reaction Furnace produces Sulphur mainly in the “S2 vapor” form. The furnace
outlet stream will be cooled in the Waste Heat Boiler to 370 deg C.

GPSA FIG. 22-21 “Distribution of Sulfur Vapor Species” can be used to estimate the
conversion of S2 to S6 and S8 vapors respectively at 370 deg C or other outlet
temperature as required.

I have prepared a spreadsheet based on GPSA solution to determine the conversion

of S2 to S6 S8 respectively. Email me at hussaintahir123@yahoo.com and I will send
you a copy of the spreadsheet. The following reaction set will be defined:
S2----S6
S2----S8
Some S2 vapor will remain in the feed to Sulphur Condensers. Other sulphur species
have been ignored for simplicity.

3. Sulphur Condensers
 The condenser can be modeled as a conversion reactor where the process gas
will be cooled to 135 deg C.
 The following reactions will be defined to convert S2, S6 and S8 vapor to SLiq
(100% Conversion):
 S2----SLiq
 S6----SLiq
 S8----SLiq
 The vapor stream will be then sent to the Converter.
 This process will apply to other condensers downstream.

4. Gas Re-Heaters for Claus Converters feed

If fuel gas or Acid gas is used as a fuel then a conversion reactor will produce the
effluent to be used in shell & tube exchanger to heat converter inlet stream.

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5. Claus Converters
 In addition to the reaction used in my previous presentation:
https://www.linkedin.com/posts/tahirsyed2_refinery-amine-sws-sru-simulation-
123-activity-6693569720181911552-H6P1.
 Please follow GPSA FIG. 22-7 FIG. 22-10 “Hydrolysis of COS and CS2 with Activated
Alumina Catalyst in Sulfur Converter” to adjust the conversion of COS and CS2 to H2S
in the Catalytic Converter. A separate Reaction set for first Converter can be defined.
 We will add two more reactions for COS and CS2 hydrolysis to the converter reaction
as following:
 COS + H2O - CO2 + H2S
 CS2 + 2H2O - CO2 +2 H2S
 Refer to GPSA FIG. 22-2 “Theoretical Equilibrium Percent Conversion of Hydrogen
Sulfide to Sulfur in Sulfur Converter“

6. Incinerator
 It can also be defined as a Conversion reactor. The reaction set will include
reactions for the 100% oxidation of H2S, COS, CS2, etc.
 A video tutorial (not in English), “#13 Aspen HYSYS - Conversion Reactor _
Combustion of Methane _ Set _ BAHASA INDONESIA” can be followed to develop
the simulation. The youtube link is:
https://www.youtube.com/watch?v=fLrkUd0dTpM

7. Conversion Reactors Tutorial

A video tutorial “Aspen HYSYS Lecture 08 Conversion Reactor”. The youtube link
is: https://youtu.be/3F1b0_Vik1g

As mentioned in the video, add an energy stream to the conversion reactors where
ever fixing of the outlet temperature is required. It will help in fixing outlet
temperature in Converters at 171 degC. It will also help Waste Heat Boiler outlet
stream Sulphur species conversion and condensation at 135 degC, etc. (Step 2/3
above). The temperature will be decrease from 371 degC to 135.1 degC in step 2 and
then from 135.1 degC to 135 degC in step 3.

8. GPSA Reference Figures

 GPSA FIG. 22-2 Theoretical Equilibrium Percent Conversion of Hydrogen Sulfide

to Sulfur (Converters)
 GPSA FIG. 22-7 Potential COS and CS2 Formation in Claus Furnaces”
 GPSA FIG. 22-10 “Hydrolysis of COS and CS2 with Activated Alumina Catalyst in
Sulfur Converter”
 GPSA FIG. 22-27 “Equilibrium Constant for Claus Reaction”, a and b
 GPSA FIG. 22-21 “Distribution of Sulfur Vapor Species”

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