Sulsim Sulfur Recovery in Aspen HYSYS

3-Stage Modified-Claus Process with Incinerator

Background
This example file was developed using Sulsim Sulfur Recovery in Aspen HYSYS.
The file utilizes the "Sulsim (Sulfur Recovery)" property package and Sulsim Sub-Flowsheet environment.
The process removes elemental sulfur from an acid gas feed with 75% H2S content.
The process contains 1 thermal stage and 3 catalytic stages before sending vapor effluent to the incinerator/flare.

Set Up
To use the model, enable Aspen Simulation Workbook (ASW) in Excel. If the ASW tab is not visible, use the COM "add-ins" feat
Ensure ASW is enabled (button is available on the "Aspen Simulation Workbook" tab.
Connect to the embedded HYSYS case using the ribbon functionality, or the button available on the "Operations Dashboard" w

Simulation & Optimization

All "blue" values/text on the "Operations Dashboard" are editibale inputs to the HYSYS case file.
Change the "blue" values to simulate a what-if scenario, and evaluate the impacts on sulfur removal, process efficiency, and co
Graphs and results should update immediately upon the HYSYS Solver converging.
Please use the status bar provided on the "Operations Dashboard" or the ASW logs to troubleshoot convergence issues.
KPIs and select results use conditional formating based on the values entered in the "targets" section.
cinerator/flare.

use the COM "add-ins" feature in Excel options to enable.

e "Operations Dashboard" worksheet.

al, process efficiency, and component breakthrough. Slider bars can also be used to change some variables.

t convergence issues.
 Solver: Ready
Operational Inputs
Optimization Options Feed
Acid Gas (Wet) 100 By Mole Fraction
Flow Rate kgmol/h
Air Demand 2 H2S
H2S:SO2 Ratio @ "Conv 3 Out" CO2
Outlet Dew Point 10 CH4
Margin °C on "Conv #3" C2H6
Converter #1 270 C3H8
Temperature °C via WHE bypass
O2 mol frac at 0.02
Incinerator Out mol fraction
 % Sulfur Conversion &
by Stage
100
96
95
90
88.5
85
80
75
70
65
60
56.4
55
50

2
ce

#
na

er

er
r

rt

rt
Fu

ve

ve
n

n
Co

Co

Co
nal Inputs S Conversion (%)
Feed Temperature Inputs S Cumulative Conv. (%)
By Mole Fraction WHE Bypass 600 °C Recovery after Cond (%)
WHE Vapor Out 300 °C S Cumulative Rec. (%)
0.75 Condenser #1 (Furnace) 135 °C S Recovered (kg/hr)
0.242 Converter #1 270 °C COS+CS2+H2S (ppmmol)
0.005 Condenser #2 135 °C S Dewpoint Margin (°C)
0.002 Converter #2 210 °C Target
0.001 Condenser #3 135 °C S Cumulative Conv. (%)
1.00 Converter #3 182 °C S Recovered (kg/hr)
Incinerator Exit 600 °C COS+CS2+H2S at Outlet
S Dewpoint Margin (°C)
 Simulation Results
ulfur Conversion & Recovery COS, CS2, and H2S by Stage
tage 100 60000
COS
98.4
96.7 90 Hydrolysi
s (%)
50,370 50000
80 CS2
88.5 Hydrolysi
70 s (%)
COS+CS2+ 40000
Cumulative 60 H2S at
Conversion Outlet
(%) 50 (ppmmol) 30000
Cumulative
Recovery (%) 40 22,304
20000
30
20
10000
10 6,346
2,816
0 0124
1

or

3
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#

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t

rt

rt

rt

rt

rt
Fu
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in

in
ve

ve

ve

ve

ve
c

c
n
n

In

n
n

In
Co

Co

Co

Co

Co

Simulation Results vs. Targets

Furnace WHE Conv 1 Conv 2 Conv 3 Incinerator Total
70.3 64.1 72.1 55.9
ve Conv. (%) 70.3 68.6 88.7 96.9 98.6 98.6
fter Cond (%) 56.4 73.7 70.9 52.3
56.4 88.5 96.7 98.4 98.4
1597 469 189 41 2297
H2S (ppmmol) 50370 22304 6346 2816 124
Margin (°C) 74 21 10
Targets H2S at Outlet (ppmmol) 29.4
ve Conv. (%) 98.5 H2S, Outlet (ppm) 30 CS2 at Outlet (ppmmol) 54.1
2280 CS2, Outlet (ppm) 50 COS at Outlet (ppmmol) 40.2
H2S at Outlet 120 COS, Outlet (ppm) 40 H2 at Outlet (ppmmol) 5340
Margin (°C) 15 CO at Outlet (ppmmol) 4878
 ASW Table

Object
SRU-1.Acid Gas (Wet)
SRU-1.Acid Gas (Dry)
SRU-1.Acid Gas (Dry)
SRU-1.Acid Gas (Dry)
SRU-1.Acid Gas (Dry)
SRU-1.Acid Gas (Dry)
SRU-1.Acid Gas (Dry)
SRU-1.Acid Gas (Dry)
SRU-1.Air (Wet)
SRU-1.Air Demand Analyzer
SRU-1.WHE Bypass
SRU-1.WHE Vapor Out
SRU-1.Reaction Furnace
SRU-1.Reaction Furnace
SRU-1.Reaction Furnace
SRU-1.Cond #1 Vapor Out
SRU-1.Condenser #1
SRU-1.Waste Heat Exchanger
SRU-1.Waste Heat Exchanger
SRU-1.Target Converter Temp by Chang
SRU-1.Catalytic Converter #1
SRU-1.Catalytic Converter #1
SRU-1.Catalytic Converter #1
SRU-1.Cond #2 Vapor Out
SRU-1.Condenser #2
SRU-1.Converter #2 Inlet
SRU-1.Catalytic Converter #2
SRU-1.Catalytic Converter #2
SRU-1.Catalytic Converter #2
SRU-1.Cond #3 Vapor Out
SRU-1.Converter #3 Inlet
SRU-1.Catalytic Converter #3
SRU-1.Catalytic Converter #3
SRU-1.Catalytic Converter #3
SRU-1.Achieve +10C Above Sulfur Dewp
SRU-1.Tail Gas
SRU-1.INC-100
SRU-1.INC-100
SRU-1.INC-100
SRU-1.INC-100
SRU-1.INC-100
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
SRU-1
Main
SRU-1.Catalytic Converter #1
SRU-1.INC-100
SRU-1.INC-100
SRU-1.INC-100
SRU-1.INC-100
SRU-1.INC-100
 ASW Table

Variable Value Units

Phase - Molar Flow (Overall) 100 kgmole/h Specified
Phase - Temperature (Overall) 34.999993896 C Specified
Phase - Pressure (Overall) 170.27499296 kPa Specified
Overall and Phase Comp Mole Frac (Overall-CO2) 0.242 Specified
Overall and Phase Comp Mole Frac (Overall-H2S) 0.75 Specified
Overall and Phase Comp Mole Frac (Overall-Methane) 0.005 Specified
Overall and Phase Comp Mole Frac (Overall-Ethane) 0.002 Specified
Overall and Phase Comp Mole Frac (Overall-Propane) 0.001 Specified
Phase - Molar Flow (Overall) 171.78614662 kgmole/h Specified
Target Value 2 Specified
Temperature 600 C Specified
Temperature 300 C Specified
Air Demand -3.5129642782 % Calculated
Sulfur Conversion Efficiency 70.327044173 % Calculated
COS+CS2+H2S at Outlet 50369.62257 ppmmol Calculated
Temperature 135 C Specified
Sulfur Recovery Efficiency 99.742564325 % Calculated
Split Fraction: Bypass 0.1759602478 Calculated
Split Fraction: Process Stream 0.8240397522 Calculated
Target Value 270 C Specified
Sulfur Conversion Efficiency 64.116769563 % Calculated
Inlet Sulfur Dewpoint Margin 44.381409632 C Calculated
COS + CS2 + H2S at Outlet 22303.868086 ppmmol Calculated
Temperature 134.9999939 C Specified
Sulfur Recovery Efficiency 99.443715806 % Calculated
Temperature 210 C Specified
Sulfur Conversion Efficiency 72.120300279 % Calculated
Outlet Sulfur Dewpoint Margin 21.356200241 C Calculated
COS + CS2 + H2S at Outlet 6345.5116926 ppmmol Calculated
Temperature 135 C Specified
Temperature 181.82502623 C Specified
Sulfur Conversion Efficiency 55.919482098 % Calculated
Outlet Sulfur Dewpoint Margin 9.9868064102 C Calculated
COS + CS2 + H2S at Outlet 2816.2998585 ppmmol Calculated
Target Value 10 C Specified
Temperature 135 C Specified
Kinetic Value 8 Specified
Target Incinerator Exit Temperature 600 C Specified
Target Outlet O2 Mole Fraction 0.02 Default
COS + CS2 + H2S at Exit 123.59069214 ppmmol Calculated
S Emission as S1 1.1555019425 kgmole/h Calculated
Variables.Performance Summary.Conversion (Cumulative).Train Reac1597.3358755 kg/h Calculated
Variables.Performance Summary.Conversion (Cumulative).Train React2066.8218187 kg/h Calculated
Variables.Performance Summary.Conversion (Cumulative).Train React2256.3178102 kg/h Calculated
Variables.Performance Summary.Conversion (Cumulative).Train React2297.2809969 kg/h Calculated
Variables.Performance Summary.Recovery (Cumulative).Train React 1312.8794049 kg/h Calculated
Variables.Performance Summary.Recovery (Cumulative).Train Reactio2062.6279998 kg/h Calculated
Variables.Performance Summary.Recovery (Cumulative).Train Reactio2251.8914971 kg/h Calculated
Variables.Performance Summary.Recovery (Cumulative).Train Reactio2292.5253008 kg/h Calculated
Variables.Performance Summary.COS Hydrolysis.Train Reaction Furnace.Thermal: R % Missing
Variables.Performance Summary.COS Hydrolysis.Train Reaction Furnac 90.285183328 % Calculated
Variables.Performance Summary.COS Hydrolysis.Train Reaction Furnac 35.574286981 % Calculated
Variables.Performance Summary.COS Hydrolysis.Train Reaction Furnac 11.762513978 % Calculated
Variables.Performance Summary.CS2 Hydrolysis.Train Reaction Furnace.Thermal: Re% Missing
Variables.Performance Summary.CS2 Hydrolysis.Train Reaction Furnac71.78240147 % Calculated
Variables.Performance Summary.CS2 Hydrolysis.Train Reaction Furnac9.412472425 % Calculated
Variables.Performance Summary.CS2 Hydrolysis.Train Reaction Furnac2.044784276 % Calculated
Variables.Performance Summary.Overall Recovery Efficiency.Train Re98.410026734 % Calculated
Variables.Performance Summary.Recovery Efficiency (Cumulative).T 56.357283076 % Calculated
Variables.Performance Summary.Recovery Efficiency (Cumulative).Tra88.54134632 % Calculated
Variables.Performance Summary.Recovery Efficiency (Cumulative).Tra96.665760836 % Calculated
Variables.Performance Summary.Recovery Efficiency (Cumulative).Tra98.410026734 % Calculated
Variables.Performance Summary.Conversion Efficiency (Cumulative) 68.567996244 % Calculated
Variables.Performance Summary.Conversion Efficiency (Cumulative).T88.721372174 % Calculated
Variables.Performance Summary.Conversion Efficiency (Cumulative).T96.855766848 % Calculated
Variables.Performance Summary.Conversion Efficiency (Cumulative).T98.614171995 % Calculated
UnitOps.SRU-1 OK
Workbook.Description of Highest Status Condition OK Specified
Variables.Attached Unit Operations.Catalytic Converter #1.Outlet S 74.382249348 C Calculated
Variables.Attached Unit Operations.INC-100.Exit H2S Concentraion 29.365859267 ppmmol Calculated
Variables.Attached Unit Operations.INC-100.Exit COS Concentraion 40.151746516 ppmmol Calculated
Variables.Attached Unit Operations.INC-100.Exit CS2 Concentraion 54.07308636 ppmmol Calculated
Variables.Attached Unit Operations.INC-100.Exit H2 Concentraion 5340.1454516 ppmmol Calculated
Variables.Attached Unit Operations.INC-100.Exit CO Concentraion 4878.0880017 ppmmol Calculated
 Cumulative Cumulative COS Hydrolysis CS2 Hydrolysis
Conversion (%) Recovery (%) (%) (%)
Furnace 68.5679962439 56.3572830759 Furnace
Converter 88.7213721738 88.54134632 Converter #1 90.2851833275 71.7824014699
Converter 96.855766848 96.6657608357 Converter #2 35.5742869814 9.41247242501
Converter 98.6141719955 98.4100267345 Converter #3 11.7625139784 2.04478427596
Incinerator Incinerator

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COS+CS2+H2S
at Outlet
(ppmmol)
50369.6225699
22303.8680856
6345.51169265
2816.2998585
123.590692143