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TO SIMULATE AND OPTIMIZE

SULFUR RECOVERY UNIT
BAZIL AHMED KHAN
CH-17309

TAIMOOR AHMED KHAN

LODHI
CH-17040
MRS.TUBA SIRAJ
SUPERVISOR
DUAA YOUSUF
CH-17018 2
DR.FAIZAN RAZA
IFFAT SULTANA FAROOQI CO-SUPERVISOR
CH-17310 NED University of Engineering and Technology
TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

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TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT
OPTIMIZATION OF SULFUR
RECOVERY UNIT
 WHY SULFUR RFECOVERY UNIT?
 The Sulfur Recovery Unit (SRU) operating
through Clause process is one of the major
economical desulfurizing and regulatory units
of Oil and Gas sector. The principle objective
of this unit is to recover gaseous hydrogen
sulfide (H2S) from Natural Gas and high sulfur
crude oil. The feedstock of SRU is acid gas and
sour gas produced in the amine treatment unit
and non-phenolic Sour Water Stripping (SWS)
unit.
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TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

MEETING THE AGENDA OF SRU

PRIMARY AGENDA

MEETING EPA
REGULATUON
SECONDARY AGENDA

MAKING OF ELEMENTAL SULFUR

STACK ANLYSIS (H2S<400 PPM)

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PROBLEM STATEMENT
ACID GAS RAIN
• DEPLETION OF OZONE LAYER

DEFORESTATION
• IRRITATION TO EYES,MUCOUS
MEMBRANE,BRONCHITIS

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PRODUCTION RATE OF ELIMENTAL
SULPHUR IN PAKISTAN

NRL PLANT CAPACITY (144 TONNS /DAY)

PARCO PLANT CAPACITY(180000 -20'000 million tons per annum)
Attock refinery capacity(

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SOURCES OF SULFUR
The secondary sources of sulfur is sulfur dioxide originating from
industrial waste and flue gases and hydrogen sulphide produced
from sour natural gas and petroleum refinery products.

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 TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

ELEMENTAL SULFUR
Sulfur recovered from oil and gas processing and sweetening units is termed as Elemental Sulfur. Elemental
Sulphur is the non metallic and the most reactive elemental and occurs in both combine and free state
It is tasteless odorless and insoluble in raw water and occurs in crystalline form. Sulfur naturally exists in three
allotropes namely;
 Monoclinic
 Rhombic
 Triclinic
EXTRACTION OF ELEMENTAL SULFUR:
Elemental sulfur is extracted from following processes namely;
 Clause process
 Split flow process
 Oxidation process



Redox process
Modifies clause process 9
TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

USES OF SULPHUR
Manufacture of Rubber Products Gun Powder, and as fungicide
in plants

UTILIZATION OF SULPHUR IN BATTERIES

Essential plant nutrient

Sulfuric acid production

Process of vulcanization

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 TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT
P R O D U C T IO N (M e t r ic T o n s )

World wide sulfur production data(GLOBALLY)

 IN 2020 CHINA
MORE THAN
8000MILLION OF
METRICTONS OF
SULFURMAKING IT
12,000
WORLDWIDE PRODUCTION DATA WORLD LEADING
10,000 SULFURPRODUCER
8,000

6,000

4,000

2,000

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NAMES OF COUNTRIES
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ORIGIN OF SULFUR:

CRUDE SWEET AND SOUR SOUR GAS AND

PETROLEUM CRUDE OIL ACID GAS

HYDROGEN
SULFUR
SULFIDE

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PAST, PRESENT, AND FUTURE OF RAW MATERIAL AND

IM P O R T S Q U A N T IT Y ( K G ) A N D V A L U E ( U S $ )

PRODUCT

SULFUR IMPORTS FORECAST

7.00E+07

6.00E+07

5.00E+07

4.00E+07

3.00E+07

2.00E+07

1.00E+07

0.00E+00
2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024

YEAR

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VALUE Linear (VALUE) QTY Linear (QTY)
TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

AVAILABLE PROCESSES FOR THE

PRODUCTION OF SULFUR
 OXYGEN-BASED CLAUSS PROCESS
 CLAUS OXYGEN-BASED PROCESS EXPANSION (COPE)
 RICHARDS SULPHUR RECOVERY PROCESS(RSRP):
 SUPER CLAUSS PROCESS
 MODIFIED CLAUS PROCESS
EQUATIONS:
1) H₂S + ½O₂ = H₂O + S
2) 2H₂S + SO₂ = 2H₂O + 3S
3) H₂S + ½O₂ = 2H₂O + S

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 TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT
COMPARATIVE ANALYSIS AMONG THE DIFFERENT PROCESSES
OXYGEN COPE RICHARDS SUPERCLAUS MODIFIED
BASED CLAUS PROCESS SULPHUR PROCESS CLAUS
PROCESS RECOVERY PROCESS
PROCESS

SOURCES FOR Oxygen Combustion air with High pressure By the use of Catalyst and use of
REACTION oxygen catalyst two reactors
TEMPERATURE 2,200⁰F to 3,400⁰F 2,700⁰F to 2900⁰F 700⁰F to 800⁰F 2000⁰F 599⁰F to 626⁰F

METHODS OF HEAT Combustion air Combustion air No heat is required Reaction furnace Burner reactor
INTRODUCTIONFOR in this process burner
REACTION

No catalyst is used No catalyst is used Titanium-based Silica substrate Activated alumina

CATALYST TYPE catalyst supporting iron and catalyst, promoted
chromium oxide or titania catalyst
Alpha- alumina

PRESSURE Negligible pressure Pressure drop is 70 to 300 psi SOLID SULPHUR we Feed=8-11psi
proportional to the get at Atmospheric
 
square of gas flow pressure at 95.5⁰C

CONVERSION It is based on vol%

of oxygen
rate

85% 99% 99% -99.5%

Product=57-65psig

99.8%
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MODIFIED CLAUS PROCESS

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 TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

WHY WE USED MODIFIED CLAUS PROCESS?

 HIGHEST PURITY
 ENVIRONMENTAL FRIENDLY
 LOW OPERATING COST
 HIGH DESIGN CAPACITY
 LOW CAPITAL COST

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PROCESS DESCRIPTION
EQUIPMENTS USED:

• Reaction Furnace
• Burner
• Catalytic Reactors
• Heat Exchangers (Re-heaters)
• Sulfur Condensers

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PROCESS DESCRIPTION
REACTIONS:
 Reaction Furnace
H₂S + 3/2 O₂ → SO₂ + H₂O
2 H₂S + SO₂ → 3/2 S₂ + 2 H₂O

 First and Second Catalytic Reactor

2 H₂S + SO₂ → 3/8 S₈ + 2 H₂O

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PROCESS DESCRIPTION
SULFUR RECOVERY UNIT:

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MATERIAL AND ENERGY BALANCE

  

For steady state accumulation=0

MATERIAL AND ENERGY BALANCE

Reaction 1:
H2S + 1.5 O₂ → SO₂ + H2O
2 H2S + SO₂ → 1.5 S2 + 2 H2O

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TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

ENERGY BALANCE
Inlet Energy – Outlet Energy=Accumulation
At steady state , accumulation = 0
H in + Q= H out

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TO SIMULATE AND OPTIMIZE SULFUR RECOVERY UNIT

FUTURE PLANS
 CASE STUDY
 TECHNO-ECONOMICAL ANALYSIS
 OPTIMIZATION

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