Energy Optimization and Efficiency Enhancement in Sulfur Recovery Units Using Aspen HYSYS Simulation

This study investigates the energy consumption and optimization opportunities in the sulfur recovery process, focusing on the thermal reactor and catalytic converters. Simulation results obtained from Aspen HYSYS reveal significant heat generation, with the thermal reactor operating at ۹۹۲.۴°C and generating a heat flow of -۱.۷۷۶ × ۱۰ ⁷ kcal/h, indicating substantial potential for heat recovery. The first catalytic converter operates at ۲۸۴.۸°C, with a heat flow of -۲.۴۲۶ × ۱۰ ⁷ kcal/h, further emphasizing the importance of integrating heat recovery systems. Optimization strategies include enhancing heat recovery systems, utilizing released heat for preheating feed gas, and improving temperature control in heat exchangers. Additionally, process variables such as temperature, pressure, and molar flow ratios significantly influence energy efficiency and sulfur recovery rates. Risk assessments identify operational, environmental, financial, and technical risks associated with proposed optimizations. Effective management strategies are suggested to mitigate these risks. The findings indicate that implementing the proposed optimization measures can lead to energy savings of up to ۱۵%, reduced operational costs, and improved environmental sustainability. Future work should focus on detailed economic analyses and sensitivity assessments to enhance the robustness of the optimization strategies.

کلیدواژه ها:

Hydrogen Sulfide (H ₂S) ، Energy Optimization ، Thermal Efficiency ، Environmental Compliance ، Claus Process