Thermo-kinetic modeling and optimization of the sulfur recovery unit thermal stage

Abstract

In this study, the reaction furnace of Claus process was modeled using the Gibbs free energy minimization method, which involved new parameters in correlations of thermodynamic properties. Using the new parameters, a significant error reduction from 33.50% to 7.86% occurred in the prediction of molar flow rate of components. Subsequently, the waste heat boiler attached to the reaction furnace was modeled using experimental plant data and a new hydrogen sulfide decomposition rate. Utilizing this new rate expression, the capability of the model in H2 molar flow rate prediction was enhanced, and the mean absolute percentage error of the model for H2 and H2S species reached 12.94% and 9.43%, respectively. The combined model including corrected equilibrium model for the reaction furnace and corrected kinetic model for the waste heat boiler could reasonably predict the experimental data so that the mean absolute percentage error reached to 6.50%. An optimization study was carried out to examine the operating condition of the Claus reaction furnace and the waste heat boiler in order to maximize sulfur production and minimize COS emission while maintaining H2S to SO2 flow ratio at constant value of 2.