Using Reduced Kinetic Model for the Multi-Objective Optimization of Thermal Section of the Claus Process Leading to a More Cost-Effective and Environmentally Friendly Operation

The Claus process is a sulfur recovery unit wherein hydrogen sulfide is converted into the elemental sulfur. This study aims to model the thermal section of the Claus process, which consists of a reaction furnace and a waste heat boiler, as a configuration of two reactors, and subsequently optimize the entire section. Two different reduced kinetic schemes were provided for both units. Using the validated kinetics, mathematical models were developed. The waste heat boiler was modeled as a plug flow reactor with heat transfer, instead of a heat exchanger. The main objective was to maximize the amount of elemental sulfur at the end of the thermal section. Additionally, maximizing the amount of steam generated in the WHB was considered as a secondary objective, and the multi-objective optimization problem was solved. The sulfur production was improved 14.1% and 30% as a result of single- and multi-objective optimization studies. In addition, as an alternative, the Taguchi method was also used for optimization studies, and optimum values were determined. Using the Taguchi method, we determined that an increase in sulfur production by 24% is possible.