MATERIAL BALANCE OF THE SULFUR RECOVERY UNIT (SRU)
3.1 Introduction The material balance across the proposed sulfur recovery unit (SRU) is done by the conservation equation of mass, as is done conventionally. A system must be defined to account for the streams entering and leaving. In our case the obvious selection is the sulfur recovery unit (SRU) itself, while all the other premises are considered surroundings. Some preliminary bases are to be specified for the sake of convenience in the calculations. Following specifications are taken to meet the above mentioned situation:
Sulfur production: 80 tons per day Time of operation: 1 hr
Now the material balance calculations are made first along the whole unit and then across individual equipments. It is to be noted that whether the calculations are made across the whole unit or the individual equipments, the basic law of conservation of mass equation remains the same and is given as:
3.2 Overall Material Balance
The chemical reactions taking place are:
Main Reactions: 1- H 2 S + 3/2O 2 SO 2 + H 2 O (3.2) 2- SO 2 + 2H 2 S 3/8S 8 + 2H 2 O (3.3) Fig 3.1: Overall material balance across SRU.
NOTE: In all the diagrams the compositions are mentioned in mole fraction basis Sulfur production target (S 8 ) = 80 ton/day
Flow Rate = ? H 2 S = 0.523 CO 2 = 0.376 CH 4 = 0.004 H 2 O = 0.010 C 2 H 6 = 0.0008 C 3 H 8 = 0.0001 Flow Rate = ? O 2 =
0.999 H 2 O = 0.001 Flow Rate = 13 kgmol/hr
S8 = 0.999
H2O = 0.001
Side Reactions: 3- CH 4 + 2O 2 CO 2 + 2H 2 O (3.4) 4- C 2 H 6 + 7/2O 2 2CO 2 + 2H 2 O (3.5) 5- C 3 H 8 + 5O 2 3CO 2 + 4H 2 O (3.6)
80 Tons 1 Day 100 Kg 1 Kgmol Day 24 Hrs 1 Tone 256.5 Kg
=13.0kgmol/hr
H 2 S required by S 8 = 16x13.0kgmol (from equ. 3.3) = 69.30kgmol
H 2 S supply for S 8 (on account for 99.9% conversion from the Claus process) = 0.999 x 69.30kgmol =69.37kgmol
SO 2 required by S 8 = 3 13.0 kgmol (from equ. 3.2)
=34.65 kgmol H 2 S consumed for SO 2 = 34.65 kgmol (from equ. 3.2) Total H2S supplied = 69.37 kgmol + 34.65 kgmol = 198.82 kgmol Total Acid gas feed supply = 104.30 kgmol / 0.523 = 198.80 kgmol Now the Streem-01 composition is as follows :
Component Mole fraction Flow rate-F 01 (kgmol/hr) H 2 S 03523 104.03 CO 2 0.375 74.83 CH 4 0.004 0.95 H 2 O 0.010 18.80 C 0 H 6 0.0008 0.16 C 3 H 6 0.0001 0.02 Total 1.0 198.80
In the furnace the following chemical reactions are taking place: Main Reactions: 1- H2S + 3/2O2 SO2 + H2O (3.2) 2- SO2 + 2H2S 3/8S8 + 2H2O (3.3) Side Reactions: 3- CH4 + 2O2 CO2 + 2H2O (3.4) 4- C2H6 + 7/2O2 2CO2 + 2H2O (4.5) 5- C3H8 + 5O2 3CO2 + 4H2O (3.6)
SO 2 produced = 34.65 kgmol (from equ. 3.3) H 2 S still available for S 8 production = 104.03 kgmol - 34.65 kgmol= 69.37 kgmol H 2 S consumed for S 8 production = 10.4 kgmol 2 = 20.80 kgmol
H 2 S remaining = 69.37 kgmol - 20.80 kgmol = 48.58 kgmol SO 2 consumed = 34.65 kgmol 0.30 = 10.40 kgmol
O 2 required in SO 2 formation = 52.0 kgmol (from equ. 3.2) O 2 required in CH 4 combustion = 1.90 kgmol (from equ. 3.4) O2 required in C2H6 combustion = 0.55 kgmol (from equ. 3.5) O2 required in C3H8 combustion = 0.10 kgmol (from equ. 3.6) Total O2 required = 52.0 kgmol + 1.90 kgmol + 0.55 kgmol + 0.1 kgmol =54.54 kgmol Air fed to furnace =54.54 kgmol / 0.210 = 259.70 kgmol N2 going in = N2 going out = 259.70 kgmol 0.790 = 205.20 kgmol CO 2 generated in CH 4 combustion = 0.95 kgmol (from equ. 3.4) CO 2 generated in C 2 H 6 combustion = 0.31 kgmol (from equ. 3.5) CO 2 generated in C 3 H 8 combustion = 0.05 kgmol (from equ. 3.6) CO 2 going out = 0.95 kgmol + 0.31 kgmol + 0.05 kgmol + 74.83 kgmol = 205.20 kgmol H 2 O formed in SO 2 production = 34.65 kgmol (from equ. 3.2) H 2 O formed in CH 4 combustion = 1.90 kgmol (from equ. 3.4) H 2 O formed in C 2 H 6 combustion = 0.47 kgmol (from equ. 3.5) H 2 O formed in C 3 H 8 combustion = 0.08 kgmol (from equ. 3.6) H 2 O formed in S 8 production = 20.80 kgmol (from equ. 3.3) Total H 2 O produced = 34.65 kgmol + 1.90 kgmol + 0.47 kgmol + 0.08 kgmol + 20.80 kgmol = 58.0 kgmol H 2 O going out = 58.0 kgmol + 18.80 kgmol = 76.72 kgmol
Now the Stream-02, Stream-03 and Stream-04 compositions are as follows:
Stream-02 composition Component Mole fraction Flow rate-F 02 (kgmol/hr) O 2 0.210 54.54 N 2 0.790 205.20 TOTAL 1.0 259.70 Stream-03 composition Component Mole fraction Flow rate-F 02 (kgmol/hr) H 2 S 0.116 48.58 CO 2 0.183 76.16 N 2 0.50 205.20 SO 2 0.058 24.25 H 2 O 0.140 58.0 S 8 0.010 3.90 Total 1.0 416.0 There is no need for the calculation of material balance across the waste heat boiler B-100 since no material change takes place in there. So the composition of Stream-03 and Stream-04 are identical. Stream-04 composition Component Mole fraction Flow rate-F 04 (kgmol/hr) H 2 S 0.116 48.58 CO 2 0.183 76.16 N 2 0.50 205.20 SO 2 0.058 24.25 H 2 O 0.140 58.0 S 8 0.010 3.90 TOTAL 1.0 416.0
Only energy changes occur and in the subsequent chapter related to the energy balance, calculations are made across it.
S 8 going in Stream-S21 = 3.90 kgmol
H 2 O going in Stream-S21 = 3.91 kgmol 0.111 = 0.004 kgmol
H 2 O going in Stream-05 = 58.0 kgmol 0.004 kgmol = 57.90 kgmol Now the Stream-S21 and Stream-05 compositions are as follows: Stream-S21 composition Component Mole fraction Flow rate-F S21 (kgmol/hr) S 8 0.999 3.90 H 2 O 0.001 0.004 TOTAL 1.0 3.904 Stream-05 composition Component Mole fraction Flow rate-F 05 (kgmol/hr) H 2 S 0.117 48.58 CO 2 0.184 76.16 N 2 0.50 205.20 SO 2 0.058 24.25 H 2 O 0.140 57.90 Total 1.0 412.0 Again there is no need for the application of material balance calculations around the heat exchanger E-101. So the Stream-06 has the same composition as that of Stream-05. Stream-06 composition Component Mole fraction Flow rate-F 06 (kgmol/hr) H 2 S 0.117 48.58 CO 2 0.184 76.106 N 2 0.50 205.20 SO 2 0.058 24.25 H 2 O 0.140 57.90 TOTAL 1.0 412 3.5 Material Balance across Reactor R-100
Now, according to the specifications of the Claus process, the reactor R-100 converts only 70% of the incoming sulfur dioxide into elemental sulfur. Thus SO2 consumed in S8 production = 24.25 kgmol 0.70 = 16.90 kgmol
H2S consumed in S8 production = 16.90 kgmol 2 (from equ. 3.3) = 33.90 kgmol H 2 S remaining = 48.58 kgmol 33.90 kgmol = 14.62 kgmol H2O formed along with S8 = 16.90 kgmol 2 (from equ. 3.3) = 33.90 kgmol H2O going out of reactor = 57.90 kgmol + 33.90 kgmol = 91.86 kgmol S8 produced = 3/8 16.90 kgmol (from equ. 3.3) =6.3375 kgmol Now the Stream-07 composition is as follows: Stream-07 composition Component Mole fraction Flow rate-F 07 (kgmol/hr) H 2 S 0.036 14.62 CO 2 0.190 76.16 N 2 0.5111 205.20 SO 2 0.018 7.27 H 2 O 0.228 91.86 S 8 0.015 6.36 TOTAL 1.0 401.50 3.6 Material Balance across Condenser E-102 As in the previous case all of the produced sulfur is condensed through the condenser and then withdrawn from the collecting pits.
Fig 3.5: Material balance across condenser E-102 S8 going in Stream-S22 = 6.36 kgmol Total amount of Stream-S22 =6.36/0.999 kgmol = 6.37 kgmol H2O going in Stream-S22 = 6.37 0.111 kgmol = 0.006 kgmol H2O going in Stream-08 = 91.86 kgmol 0.006 kgmol = 91.85 kgmol Now the Stream-S22 and Stream-08 compositions are as follows: Stream-S22 composition Component Mole fraction Flow rate-F S22 (kgmol/hr) S 8 0.999 6.37 H 2 O 0.001 0.0067 TOTAL 1.0 6.38 Stream-08 composition Component Mole fraction Flow rate-F 08 (kgmol/hr) H 2 S 0.037 14.62 CO 2
0.192 76.16 N 2
0.520 205.20 SO 2 0.018 7.27 H 2 O 0.232 91.86 TOTAL 1.0 395.12 Again there is no need for the application of material balance calculations around the heat exchanger E- 103. So the Stream-09 has the same composition as that of Stream-08. Stream-09 composition Component Mole fraction Flow rate-F09 (kgmol/hr) H 2 S 0.037 14.62 CO 2
0.192 76.16 N 2
0.520 205.20 SO 2 0.018 7.27 H 2 O 0.232 91.86 Total 1.0 395.12
Now, according to the specifications of the Claus process, the reactor R-101 converts only 80% of the incoming sulfur dioxide into elemental sulfur. Thus: SO 2 consumed in S 8 production = 7.27 kgmol 0.80 = 5.82 kgmol
SO 2 remaining = 7.27 kgmol 5.82 kgmol = 1.45 kgmol H 2 S consumed in S 8 production = 5.82 kgmol 2 (from equ. 3.3)
= 11.64 kgmol H 2 S remaining = 14.62 kgmol 11.64 kgmol = 2.98 kgmol H 2 O formed along with S 8 = 5.82 kgmol 2 (from equ. 3.3)
= 11.64 kgmol H 2 O going out of reactor = 91.86 kgmol + 11.64 kgmol = 103.50 kgmol S8 produced = 3/8 5.82 kgmol (from equ. 3.3) = 2.18 kgmol Now the Stream-10 composition is as follows: Stream-10 composition Component Mole fraction Flow rate-F 10 (kgmol/hr) H 2 S 0.007 2.98 CO 2 0.194 76.16 N 2 0.524 205.20 SO 2 0.003 1.45 H 2 O 0.264 103.50 S 8 0.005 2018 TOTAL 1.0 391.48 3.8 Material Balance across Condenser E-104 As in the previous case all of the produced sulfur is condensed through the condenser and then withdrawn from the collecting pits.
S 8 going in Stream-S23 = 2.18 kgmol Total amount of Stream-S23 =2.18/0.999 kgmol = 2.185 kgmol H 2 O going in Stream-S23 = 2.185 kgmol 0.111 = 0.002 kgmol H 2 O going in Stream-11 = 103.50 kgmol 0.002 kgmol = 103.48 kgmol Now the Stream-S22 and Stream-08 compositions are as follows: Stream-S23 composition Component Mole fraction Flow rate-F S23 (kgmol/hr) S 8 0.999 2.18 H 2 O 0.001 0.002 TOTAL 1.0 2.20 Stream-11 composition Component Mole fraction Flow rate-F 11 (kgmol/hr) H 2 S 0.037 2.98 CO 2
0.192 76.16 N 2
0.520 205.20 SO 2
0.018 1045 H 2 O 0.232 103.48 TOTAL 1.0 389.30 Again there is no need for the application of material balance calculations around the heat exchanger E-105. So the Stream-12 has the same composition as that of Stream-11. Stream-12 composition Component Mole fraction Flow rate-F 12 (kgmol/hr) H 2 S 0.037 2.98 CO 2 0.192 76.16 N 2 0.520 205.20 SO 2 0.018 1.45 H 2 O 0.232 103.48 TOTAL 1.0 389.30 3.9 Material Balance across Reactor R-102
Now, according to the specifications of the Claus process, the reactor R-102 converts only 95% of the incoming sulfur dioxide into elemental sulfur. 1 Thus: SO2 consumed in S8 production = 1.45 kgmol 0.95 = 1.38 kgmol SO2 remaining = 1.45 kgmol 1.38 kgmol = 0.07 kgmol H2S consumed in S8 production = 1.38 kgmol 2 (from equ. 3.3) = 2.76 kgmol H2S remaining = 2.98 kgmol 2.76 kgmol = 0.21 kgmol H2O formed along with S8 = 1.38 kgmol 2 (from equ. 3.3) = 2.76 kgmol H2O going out of reactor = 103.48 kgmol + 2.76 kgmol = 106.27 kgmol S8 produced = 3/8 1.38 kgmol (from equ. 3.3) = 0.51 kgmol Now the Stream-13 composition is as follows: Stream-13 composition Component Mole fraction Flow rate-F 13 (kgmol/hr) H 2 S 0.0005 0.21 CO 2 0.120 76.16 N 2 0.528 205.20 SO 2 0.0001 0.072 H 2 O 0.273 106.27 S 8 0.001 0.51 Total 1.0 388.43 3.10 Material Balance across Condenser E-106
As in the previous cases all of the produced sulfur is condensed through the condenser and then withdrawn from the collecting pits.
S8 going in Stream-S24 = 0.51 kgmol Total amount of Stream-S24 0.51 kgmol/0.9807 =0.52 kgmol H2O going in Stream-S24 = 0.52 kgmol 0.111 = 0.0005 kgmol H2O going in Stream-14 = 106.27 kgmol 0.0005 kgmol = 106.27 kgmol Now the Stream-S24and Stream-14 compositions are as follows: Stream-S24 composition Component Mole fraction Flow rat-FS24 (kgmol/hr) S 8
0.999 0.51 H 2 O 0.001 0.0005 TOTAL 1.0 0.52 Stream-14 composition Component Mole fraction Flow rate-F 14 (kgmol/hr) H 2 S 0.0005 0.21 CO 2
0.196 76.16 N 2 0.530 205.20 SO 2 0.0001 0.072 H 2 O 0.274 106.27 Total 1.0 387.91 3.11 Final Calculations Total S8 produced from SRU = S8 withdrawn from condenser E-100 + S8 withdrawn from condenser E-102 + S8 withdrawn from condenser E-104 + S8 withdrawn from condenser E-106 = 3.90 kgmol + 6.37 kgmol + 2.18 kgmol + 0.51 kgmol = 12.99 kgmol = 80 tons/day