Simultaneous Optimization of Sulfur Recovery Efficiency and Thermal Energy Generation in the Catalytic Section of the Sulfur Recovery Unit Simulated Based on Reaction Kinetics.

The Claus process is widely used in refineries for sulfur recovery, significantly reducing sulfur dioxide emissions. In line with this, the current study presents the simulation and multiobjective optimization of the Claus sulfur recovery process catalytic section. The catalytic reactors were modeled by using Aspen HYSYS software and then validated with industrial data from the South Pars refinery in Iran. The work was based on critical parameters that influence the efficiency of sulfur recovery and energy generation with added value to the balance between environmental and operational outcomes. Sensitivity analysis of the catalytic bed depth and cross-sectional area in combination with the inlet temperature on the performance of the reactors was performed by evaluating H₂S conversion, COS, and CS₂ hydrolysis as well as sulfur yield. The optimization was carried out using the response surface methodology to achieve maximum sulfur recovery, efficient energy utilization, and optimal H₂S/SO₂ ratios. From the obtained results, it is evident that the enhancements of recovery effectiveness were very pronounced; hence, the potential of the kinetic modeling and optimization strategies had been proven true. Most essentially, this overall approach lays the foundation for insights into improving the operational efficiency of sulfur recovery units with a minimum environmental impact.