Prepared By:

Tahir Syed
Process Engineer
Introduction
 The Conversion Reactors provide flexibility to the process
engineer to alter the conversion of a particular reaction and
note the impact on the outlet conditions.
 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 appropriate. However, conversion
values should be realistic and verified.
 GPSA problem 22-1/HYSYS Sulsim templates can help in
estimating the outlet temperature and stream composition
while adding reactions to the Front End Furnace.
 Furthermore, Conversion reactors can be applied in other
parts of an SRU.
SRU Flow Diagram
SRU Flow Diagram
SRU Process Description-Brief
 An acid gas containing 20-55% Hydrogen Sulphide (H2S) as well as
other components is fed to thermal stage (combustion reactor) of a
once-through Claus Process Sulphur Recovery Unit (SRU) at 40 oC
and 179 kPa. The air feed to the SRU is at 118 oC and 179 kPa. The
product stream from Furnace is fed to the waste heat boiler to be
cooled to 370 degC, flashed in a vessel and vapor stream is fed to
sulphur condenser to condense Sulphur at 135 oC. The remaining
vapor product enters the catalytic step made of three reactors as
shown in the PFD. Each reactor operates at 240 oC; therefore, a
heater is placed before each reactor. The gas stream from the final
condenser is sent to the incinerator.
 Note: Plant capacity and operating conditions vary from one
application to another.
Conversion Reactors in SRU
The Conversion Reactors can be used to model the
following units to develop a comprehensive SRU HYSYS
simulation model:

 Reaction Furnace
 Waste Heat Boiler Outlet Stream
 Sulphur Condensers
 Gas Re-Heaters for Claus Converters feed
 Claus Converters
 Incinerator

A brief description of the reaction sets applicable to each of

the above is presented in the following slides.
Reaction Furnace
The following are the two main reactions:
 2H2S + O2 2S + 2H2O
 2H2S + O2 2SO2 + 2H2O

 Refer to the following theses which discuss furnace reactions related

to Amine/SWS SRU feeds which have to be added as Conversion
reactions to the Furnace reaction set:

 "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).

 The link is prism.ucalgary.ca, University of Calgary, Prism Library.

Reaction Furnace
 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.
 Also, 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 to approx. 1250 degC.
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. Add an energy
stream to this conversion reactor.
 I have prepared a spreadsheet based on GPSA solution to determine
the conversion of S2 to S6 and 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 for this
conversion reactor:
 S2 S6 (100% Conversion)
 S2 S8 (100% Conversion)
 Some S2 vapor will remain in the feed to Sulphur Condensers.
 Other sulphur species have been ignored for simplicity.
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 Catalytic Converter.
 This process will apply to other condensers downstream using
considering sulphur species existing at that temperature.
 An energy stream will be added to this conversion reactor also
and the outlet temperature of 135 degC will be specified.
Gas Re-Heaters
 If fuel gas or Acid gas is used as a fuel to pre-heat
Claus Converters feed then a conversion reactor
will produce the effluent to be used in shell & tube
exchanger.
Claus Converters
The main reaction is:
 2H2S + SO2 3S + 2H2O

 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 1st converter reaction set 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“
Incinerator
 It can also be defined as a Conversion reactor. The reaction set
will include reactions for the 100% oxidation of H2S, COS, CS2,
Hydrocarbons, etc.
 Reaction sets used for Front End Furnace can be defined here as
well.
 An estimate of incinerator inlet and outlet stream compositions
can be made by using Sulsim. The conversion values can be
adjusted accordingly for this conversion reactor.
 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
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., as
mentioned above). The temperature will be decreased from
371 degC to 135.1 degC then from 135.1 degC to 135 degC in
next conversion reactor.
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., as
mentioned above). The temperature will be decreased from
371 degC to 135.1 degC then from 135.1 degC to 135 degC in
next conversion reactor.
Comments
 As soon as I found an Example E-15.11 in the Book
"Fundamentals of Petroleum Refining", I put together
proposed HYSYS simulation steps and posted on
LinkedIn while some friends tried them out using
HYSYS and provided their feedback. The problem E-
15.11 was also solved by using GPSA Example 22-1 and
SULSIM template. The reaction furnace outlet
temperature and stream composition obtained from E-
15.11 was different. Specially, approx. 1000 kgmoles/h
Sulphur was produced as compared to 200 kgmoles
recovered in E-15.11).
Comments
 The Example 15.11 uses two reactions for furnace and
one reaction for catalytic converters which is an
excellent approach to get started. However, more
reactions were added to Furnace reaction set as per
referenced resources in this presentation. HYSYS
Example 22-1 as well as SULSIM template conditions
were successfully met which resulted in increased
Sulphur recovery from the 1st Sulphur condenser. Few
useful applications of Conversion reactors in SRU
simulation are discussed in this presentation. Hope it
will be an interesting exercise for those who want to
have more insight into the chemistry of Claus Process.
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”
Reference Presentations
 1. https://lnkd.in/d6ySF5B Video Presentation
Sulphur Recovery Unit (SRU) UNISIM/HYSYS
Simulation
2. https://lnkd.in/dSWdG-s Sulphur Recovery On
Aspen HYSYS - A YouTube tutorial on above
presentation.
3 https://lnkd.in/dB_6isZ Refinery Amine, Sour
Water and Sulphur Recovery Unit Simulation
4. https://lnkd.in/e_-f_QK Develop your own
template for Amine, SWS & SRU Unit
Reference Presentations
Disclaimer
 This presentation is intended for personal learning
only. A thorough review with technology suppliers on
case by case basis is recommended for practical
applications.
Thank You