HYSYS TRAINING PROJECT

Prepared By:
Tahir Syed, Process Engineer
 PART-1
Simplified & Detailed SRU Simulation

PART-2
SRU Feed Streams & Combined
Amine, SWS & SRU Simulations

PART-3
References
 Table of Contents - Part 1
1. Introduction
2. SRU Process Simulation Data
3. SRU HYSYS Simulation Steps
4. SRU Detailed HYSYS Simulation Steps
5. HYSYS Conversion Reactors in SRU
Simulation
 Introduction

Light Ends and Sour Water are produced from Refinery Separation
Units (Crude/Vacuum Distillation, and other fractionators) & Reaction
Units (FCC, Hydrocracker, Reformer, Coker, Hydro-treater, etc.) are

treated by Amine and Sour Water Stripper Unit respectively

Treated light ends are recycled back to the process while treated sour
water is used for desalting, injected into process and can also be

upgraded to Boiler Feed-water quality or sent to wastewater treatment.

SRU for sulphur recovery and to reduce sulphur emissions.
The light ends from both the SWS and Amine unit are sent to


This area in the refinery is as exciting as working on Separation
and Reaction units. So, developing working simulation skills is 
worthwhile for new design, operations troubleshooting & revamps.
 SRU Unit Simulation
 This simulation will be done by using Conversion
Reactor as required by SRU Unit Simulation -
Example E15.11 - Page 393. Proposed steps to solve
the problems are discussed in this presentation.

 Youtube links are included to develop step by
step simulation. For SRU, Example E15.11 we
discuss a solution using Conversion Reactors as
well as HYSYS SRU Template.

 For combined Amine, SWS, SRU simulation we
use both the Conversion Reactors and HYSYS SRU
Template.
SRU Problem Statement
SRU Process Flow Diagram
SRU HYSYS Flowsheet
Conversion Reactors
SRU HYSYS Flowsheet
HYSYS Template
SRU Simulation Results
 SRU Plant Configuration
 Plant configuration in Example E15.11 is according
to the FIG. 22-6 of GPSA Data-book which suggests
for 20-55% H2S in the acid gas feed, the process
scheme to be a Straight-through or straight-through
with acid gas and/or air preheat. In this case air is
preheated to 118 degC as there is 40.2 Mole% H2S in
the feed to Claus Plant in Example E15.11.
Sulphur Recovery Efficiency
 The table E15.11 shows 2516 kgmoles/h total
sulphur production which also contains around
506 kgmoles of water which gives around 2010
kgmoles/h of Sulphur. Please note that there is
2010 kgmoles/h in the feed as H2S. The book has
rightly mentioned 2516 kgmoles/h because that is
sulphur to be handled in sulphur degassing,
granulation, etc. Also, the book has mentioned
that all H2S and SO2 has to be converted so a
figure closer to 2010 kgmoles/h is fine. Generally,
we are okay with upto 98% sulphur recovery so
we can tweak conversion in the converters
accordingly.
Combustion Air to Furnace
The amount of H2S in feed is 2010 kgmoles/h. Therefore,
oxygen required for 1/3 rd H2S combustion to SO2
=(1/3)*(3/2)*2010=1005 kgmoles/h, then air =1005/.21=
4786 kgmoles/hr, so Nitrogen is 4786-1005=3781
kgmoles/h. Similarly, oxygen required for the combustion
of Ammonia and Hydrocarbons will also be estimated as
needed. In this project, hydrocarbons getting destructed in
the Incinerator and not in the furnace. Refer to GPSA
Section 22-Sulphur Recovery, Example 22-1 for
hydrocarbon combustion air requirement calculation.
 Waste Heat Boiler
 Waste Heat Boiler downstream front end furnace can be
designed for HP, MP or LP Steam by modifying shell
side outlet pressure. Resulting temperature can be
verified from Steam Tables. Steam Produced can be
used in SWS, Amine Re-boilers and SRU Pre-Converter
Re-Heaters, Power generation (in large plants) and other
users. Total boiler feed water requirements and steam
generation / consumption can be estimated by this
simulation.
 Claus Plant Reactions
Using HYSYS Conversion Reactors
 SRU HYSYS Simulation Steps
using Conversion Reactors

1. Enter the Properties Environment.

2. Add Feed Stream Components As Per Table E15.11, Page
395, Fundamentals of Petroleum Refining. Select
S2_Vapor for thermal and Catalytic stages.
3. There is S1 Vapor considered in Table E15.11. So, the
produced quantities of Sulphur will be half of that in
Table E15.11.
4. Select Peng Robinson as the Fluid Package.
SRU HYSYS Simulation Steps
using Conversion Reactors
5. Add Furnace or Thermal Stage Reactions 15.21 and
15.22 as one set. Rank 15.21 as 1 and 15.22 as rank 0.
Enter conversion (Co) = 100.
6. Add Converter or Catalytic Stage reaction (15.23) as
a separate set. Enter conversion (Co) = 100.
Note: Tweak Converter/Furnace reaction
conversion given above to match the results in
the presentation.
 SRU HYSYS Simulation Steps
using Conversion Reactors
7. Enter the Simulation Environment.
8. Activate Standard HYSYS Object Palette.
9. Set up Feed and Air Streams as per given data.
10. Add Furnace as a Conversion Reactor. Attach
Air and Feed Streams. Select Set 1 for Reactions.
11. Connect the effluent stream from the Furnace to the
tube side of the waste heat boiler which is modeled as
a Shell and Tube Heat Exchanger with Boiler feed-
water stream on the shell side.
 SRU HYSYS Simulation Steps
using Conversion Reactors
11. Route the cooled stream from the Waste Heat
Boiler. Cool the gases in the WHB between 300 to
330 degC
12. Flash it in 2-phase separation vertical vessel and
end vapor to Shell & Tube HX (Sulphur Condenser) with
boiler feed water on shell side to condense sulphur at
135 degC. This should recover 100 kgmole/hr sulphur.
13. It will then be flashed again to separate sulphur
and vapor phase.
14. The vapor phase will be reheated to the
required temperature as per mentioned in the table
E15.11 before being fed to the Catalytic converter.
 SRU HYSYS Simulation Steps
using Conversion Reactors
15. Add Catalytic Converter as a Conversion Reactor
and select Reaction 15.23. Also add an Energy
stream and outlet temperature of 171 deg C.
16. Adjust conversion to match the outlet
Sulphur stream as per table E15.11.
17. Add subsequent Catalytic Converters and Heater
same as above.
18. Sum up bottom streams from the three
converters and from sulphur condenser to find total
Sulphur produced (2516 kgmoles/hr i.e. 2010
kgmoles/hr sulphur+506 kgmoles/hr water).
 SWS Feed Lineup

Sour Water Stripper gases having NH3 can also be lined
up by adding an additional reaction to Furnace reaction
set as 2 NH3 + 3/2 O2 → N2 + 3 H2O and couple of
other reactions. Ideally, ammonia must be fully
destroyed in the furnace but an outlet temp of around
1250 deg C has to be maintained. Furthermore,
combustion  will be recalculated for
air requirements
NH3, H2S, Fuel Gas, etc.

Use References
reactions.
 mentioned in this presentation to identify these


Watch Youtube Video: The Experts Network:

Processing Ammonia in Sulphur Plants.
Link: https://youtu.be/Mu1zEYsxSfA
 Comments

While SRU simulation was conducted using the
Unit Simulation - Example E15.11 - Page 393
 SRU
data, the amount of sulphur condensed from the
1st condenser was 200 kgmoles/hr (as S1). It will
 be 100 kgmoles/hr (as S2).

The same data was used to solve the above
 which yielded about 900 kgmoles/hr.
problem by using HYSYS/SULSIM template


Therefore, I tried to understand the reasons
 taking place in Claus Front End furnace.
and found that there are additional reactions


An effort was made to develop detailed
simulation as presented in the following slides
using additional reactions.
 Detailed SRU Simulations

Add more reactions to the reaction furnace as mentioned in
"Kinetic modeling of a modified Claus Reaction Furnace" thesis
by Aaron Pollock Ellsworth. Also, there are other useful theses
available on this link, including the one by Hawboldt, Kelly
Anne N., . These theses discuss furnace reactions related to
Amine/SWS SRU feeds. The link is prism.ucalgary.ca,
University of Calgary, Prism Library. These reactions will be
added as Conversion reactions to the Furnace reaction set and
 conversion will be adjusted to match Sulsim template results.

 SulphurPro simulator manual at ogtrt.com.

 formation and destruction.
GPSA Section 22 for Sulphur Species formation. COS, CS2


The GPSA problem 22-1 can be solved by using DESIGN II
simulation package as well, both for 3 and 8 Sulphur species.
There is a solved example for each
 case included in the
DESIGN II library (winsim.com).
 Sulphur Species
GPSA Section 22 has a worked example which takes
into account Sulphur allotropes (S2, S3......S8) formed
in the reaction furnace/converters. We can use GPSA
example to estimate the Sulphur allotropes. Their
molecular weights are in the order of 32, 64, 96.....Refer
to GPSA Fig. 22-21 for Distribution of Sulfur
Vapor Species based on temperature.
 HYSYS SRU Templates
 SRU templates (SULSIM) are available with HYSYS
using Sulphur Recovery fluid package and a
dedicated model palette as well as other features.
The template “3 Stage Claus Unit with
Incinerator” can be used to check Example
E15.11 simulation. There is another template for
Sour Water Stripper Gas.
 SULSIM provides a sub-flowsheet/object palette
environment. The variables/parameters have to
be selected manually for running case studies.
 Introduction
 The Conversion Reactors provide flexibility to the process
engineer to alter the conversion of a particular reaction and
 note the impact on the outlet conditions.
 It is highly useful when we have reactor outlet stream analysis
(e.g. from the field). We can adjust Conversion to verify the
field process parameters as appropriate. However,
 conversion values should be realistic and verified.
 GPSA problem 22-1/HYSYS Sulsim templates can help in
estimating the outlet temperature and stream composition
 while adding reactions to the Front End Furnace.
 Furthermore, Conversion reactors can be applied in other
parts of an SRU.
SRU Flow Diagram
 Conversion Reactors in SRU
The Conversion Reactors can be used to model the
following units to develop a comprehensive SRU HYSYS
simulation model:


 Reaction Furnace

 Waste Heat Boiler Outlet Stream

 Sulphur Condensers

 Gas Re-Heaters for Claus Converters feed

 Claus Converters
 Incinerator

A brief description of the reaction sets applicable to each of

the above is presented in the following slides.
 Conversion Reactors Tutorial

A video tutorial “Aspen HYSYS Lecture 08 Conversion

Reactor”. The youtube link is:
https://youtu.be/3F1b0_Vik1g

As mentioned in the video, add an energy stream to the

conversion reactors whereever fixing of the outlet
temperature is required. It will help in fixing outlet
temperature in Converters at 171 degC. It will also help
Waste Heat Boiler outlet stream Sulphur species
conversion and condensation at 135 degC, etc., as
mentioned above). The temperature will be decreased
from 371 degC to 135.1 degC in first conversion reactor
then from 135.1 degC to 135 degC in next conversion
reactor.
 Reaction Furnace
The following are the two main reactions:
  
2H2S + O2 2S + 2H2O
  
 2
2H S + O2 2SO 2 + 2H2O
 Refer to the following theses which discuss furnace reactions
related to Amine/SWS SRU feeds which have to be added as
Conversion reactions to the Furnace reaction set:


 "Kinetic modeling of a Modified Claus Reaction Furnace"
 thesis by Aaron Pollock (pdf pages 98, 132, 133).
 “Kinetic modeling of key reactions in the Modified Claus Plant
Front End Furnace” thesis by Kelly Hawboldt (pdf pages 28, 29).


 The link is prism.ucalgary.ca, University of Calgary, Prism Library.
 Reaction Furnace
 The solution of GPSA problem 22-1 is a handy tool to
find both Sulphur produced in the Furnace (as S2 vapor)
and the outlet temperature. Follow GPSA FIG. 22-27
“Equilibrium Constant for Claus Reaction”, a and b.
 The conversion of various reactions will have to be
adjusted in the simulation to match the sulphur
recovery, outlet temperature etc., as calculated above.
Also, follow GPSA FIG. 22-7 “Potential COS and CS2

Formation in Claus Furnaces” to adjust the conversion of
COS and CS2 forming reactions in the Reaction Furnace.
 In case we also have Sour Water Stripper gas then more
reactions will have to be added to the reaction set and
temperature will be adjusted to approx. 1250 degC.
 Waste Heat Boiler Outlet Stream
 The Reaction Furnace produces Sulphur mainly in the “S2 vapor”
form. The furnace outlet stream will be cooled in the Waste Heat
 Boiler to 370 deg C.
 GPSA FIG. 22-21 “Distribution of Sulfur Vapor Species” can be used
to estimate the conversion of S2 to S6 and S8 vapors respectively at
370 deg C or other outlet temperature as required. Add an energy
 stream to this conversion reactor.
 I have prepared a spreadsheet based on GPSA solution to
determine the conversion of S2 to S6 and S8 respectively. Email me
at [email protected] and I will send you a copy of the
spreadsheet. The following reaction set will be defined for this
 conversion reactor:
  S2 S6 (100% Conversion)
 S2  S8 (100% Conversion)

 Some S2 vapor will remain in the feed to Sulphur Condensers.
 Other sulphur species have been ignored for simplicity.
 Sulphur Condensers
 The condenser can be modeled as a conversion reactor where
the process gas will be cooled to 135 deg C.
 The following reactions will be defined to convert S2, S6 and
 S8 vapor to SLiq (100% Conversion):
 S2  SLiq


  S6 SLiq
 S8 SLiq

 The vapor stream will be then sent to the Catalytic Converter.
 This process will apply to other condensers downstream using
 considering sulphur species existing at that temperature.
 An energy stream will be added to this conversion reactor also
and the outlet temperature of 135 degC will be specified.
 Gas Re-Heaters
 If fuel gas or Acid gas is used as a fuel to pre-heat
Claus Converters feed then a conversion reactor will
produce the effluent to be used in shell & tube
exchanger.
 Claus Converters
The main reaction is:
  
2H2S + SO2 3S + 2H2O
 Please follow GPSA FIG. 22-7 FIG. 22-10 “Hydrolysis of COS
and CS2 with Activated Alumina Catalyst in Sulfur Converter”
to adjust the conversion of COS and CS2 to H2S in the
Catalytic Converter. A separate Reaction set for first Converter
 can be defined.
 We will add two more reactions for COS and CS2 hydrolysis to
st
the
  1 converter reaction set as following:
 COS + H2O CO2 + H2S
 

 CO2 +2 H2S
CS2 + 2H2O
 Refer to GPSA FIG. 22-2 “Theoretical Equilibrium Percent
Conversion of Hydrogen Sulfide to Sulfur in Sulfur Converter“
 Incinerator

It can also be defined as a Conversion reactor. The reaction set will
include reactions  for the 100% oxidation of H2S, COS, CS2,
Hydrocarbons, etc.
 
 Reaction sets used for Front End Furnace can be defined here as well.

An estimate of incinerator inlet and outlet stream compositions
can be made by using Sulsim. The conversion values
adjusted accordingly for this conversion reactor.
 can be

A video tutorial (not in English), “#13 Aspen HYSYS -
Conversion Reactor _ Combustion of Methane _ Set _
BAHASA INDONESIA” can be followed to develop
the simulation. The youtube link is:
https://www.youtube.com/watch?v=fLrkUd0dTpM
 Tail Gas Treating Unit (TGTU)

Usually, the hydrogenation reactor receives process gas from the second Claus catalytic
condenser and, so, treats a gas mixture which contains H2S, SO2, Sx vapor species and lesser
 amounts of CS2 and COS as the sulfur-containing components.

In addition to N2 and H2O, CO and H2 will be present, the amounts being dependent on the feed acid gas
 composition and the operating conditions of the Claus furnace. 

In its original form, a catalytic reduction process utilized a reducing gas generator which served the
 dual purpose of providing supplemental CO and H2 as well as reheating the gas to around 300°C.

H2S is removed by an Amine Treatment unit and  recycled to Claus Front End Furnace while treated gas
from absorber is sent to the Thermal Oxidizer.

 
Various reactions involved are discussed in,

Reaction Pathways For Claus Tail Gas Reduction Catalysts: Relevance To Field
Operations And Industrial Practice by P.D. Clark Director of Research, Alberta Sulphur
Research Ltd. and Professor of Chemistry, University of Calgary & N.I. Dowling and M. Huang
 Senior Research Scientists, Alberta Sulphur Research Ltd.

https://brimstone-sts.com/wp-content/uploads/2015/11/13V12-Clark-Reduction-Pathways-for-

Claus-Tail-Gas-Reduction-Catalysts.pdf
Tail Gas Treating Unit (TGTU)
 PART-2
SRU Feed Streams & Combined
Simulations
Table of Contents – Part 2
1. Introduction
2. Process Simulation Data
 
 Amine Treatment Unit (Amine)
 
 Sour Water Stripper Unit (SWS)

3. Combined Amine, SWS & SRU

Simulations using Main
HYSYS Object Palette
 Introduction

Light Ends and Sour Water are produced from Refinery Separation
Units (Crude/Vacuum Distillation, and other fractionators) & Reaction
Units (FCC, Hydrocracker, Reformer, Coker, Hydro-treater, etc.) are

treated by Amine and Sour Water Stripper Unit respectively

Treated light ends are recycled back to the process while treated sour
water is used for desalting and can also be upgraded
 to Boiler Feed-
water quality or sent to wastewater treatment.

SRU for sulphur recovery and to reduce sulphur emissions.
The waste light ends from both the SWS and Amine unit are sent to


This area in the refinery is as exciting as working on Separation
and Reaction units and developing working simulation skills is 
worthwhile for new design, operations troubleshooting & revamps.
Amine Unit Simulation
Amine Unit Data
Amine Problem Solution
 Amine Circulation Rate
Let's suppose we have 1233 Kgmole/h acid gas coming to
the DEA unit (as in example problem) having a total of
160.3 kgmole/h of Acid gas (H2S+CO2). As per GPSA Fig
21-4, the acid gas pick up, mol/mol amine, normal range is
(0.20–0.80). We take .305 mole acid gas per mole amine
so 100% DEA amount will be 160/.305=525.25 kgmoles/h.
Divide this by the DEA strength i.e., 28%. It gives 1876
kgmoles/h amine circulation rate. Typical lean loading
(H2S+CO2) is 0.01 for regenerated DEA.
Amine Unit PFD
Amine (DEA) Unit HYSYS
Flowsheet
Amine Stream Table
Sour Water Stripper (SWS)
Unit Simulation
SWS Data
SWS Process Flow Diagram
SWS Unit HYSYS Flowsheet
SWS Stream Table
Combined Amine, SWS, SRU
Block Flow Diagram
Amine (DEA)
Unit

Sulphur Recovery Unit

Sour Water (SRU)
Stripper (SWS)
Unit
Combined Process Flow Diagram (PFD)

Combined PFD

Typical Operating Conditions on the following slide

Typical Operating Conditions
Notes
 Proposed Steps for Template
Development
1. Start with HYSYS DEA Unit Template.
2. Add “Peng Robinson” Fluid Package for SRU and
“Sour PR” for Sour Water Stripper (SWS). DEA
template already has “Acid Gas-Chemical Solvents”
package. So, there will be three thermodynamic
packages in combined simulation.
3. Add SRU Furnace as mentioned before.
4. Add reaction sets as mentioned before.
5. Use GPSA Example 22-1 Data to develop SRU furnace
and match Furnace outlet temperature and Sulphur
production/other components. Adjust Conversion of
various reactions in reaction set accordingly.
Proposed Steps for Template
Development
5. Once SRU Furnace is calibrated with GPSA example
data, feed the acid gas stream from the upstream
DEA unit to SRU Furnace and keep on adding rest of
the SRU process as mentioned before.
6. Replicate SWS template available in HYSYS.
7. Feed SWS gas to the SRU as well and adjust
furnace conversion and outlet temperature.
8. Develop two cases for SRU Reaction Furnace.
One with two reactions and the other with
additional reactions. Develop a separate case for
SWS gas lineup.
 HYSYS Case Studies
Developing a combined Amine, SWS and SRU
simulation using the conversion reactors in the main
flowsheet environment will make all variables available
without a need to manually exporting them from sub-
flowsheet environment. This will be particularly useful
while doing process studies, etc.
 Simulation Examples
Reference

The data source is from the book “Fundamentals of

Petroleum Refining”. The problems are solved using
UNISIM but steps are not provided. We can develop
the simulations in HYSYS.

 Amine Unit Simulation - DEA Example E15.6 – Page 387


 SWS Unit Simulation - Example E17.14 - Page 451

 SRU Unit Simulation - Example E15.11 - Page 393
 HYSYS Simulation Tutorial
Yobutube Links

Amine Treatment Unit:

https://youtu.be/B3xwOh2UA0w

Sour Water Stripper Unit:

https://youtu.be/vMXlrlxqVPg

Sulphur Recovery Unit:

https://youtu.be/rQkbhA_x-Fg
 GPSA Reference Figures

GPSA FIG. 22-2 Theoretical Equilibrium Percent
Conversion of Hydrogen Sulfide to Sulfur (Converters)

GPSA FIG. 22-7 Potential COS and CS2 Formation in
Claus Furnaces”

GPSA FIG. 22-10 “Hydrolysis of COS and CS2  with
Activated Alumina Catalyst in Sulfur Converter”

GPSA FIG. 22-27 “Equilibrium
 Constant for Claus
Reaction”, a and b

 22-21 “Distribution of Sulfur Vapor
GPSA FIG.
Species”
 Other Youtube References
• Aspen HYSYS Lecture 08 Conversion Reactor.
• The youtube link is: https://youtu.be/3F1b0_Vik1g

• The Experts Network: Processing Ammonia

in Sulphur Plants.
• The youtube Link: https://youtu.be/Mu1zEYsxSfA

• Aspen HYSYS - Conversion Reactor _ Combustion

of Methane _ Set _ Bahasa Indonesia.
• The youtube link is (not in English):
https://www.youtube.com/watch?v=fLrkUd0dTpM
 Literature References
 Kinetic modeling of a Modified Claus Reaction
Furnace" thesis by Aaron Pollock (pdf pages

98, 132, 133).
 “Kinetic modeling of key reactions in the Modified
Claus Plant Front End Furnace” thesis by Kelly

Hawboldt (pdf pages 28, 29).
 GPSA Engineering Data Book

 HYSYS Documentation

 SulphurPro simulator manual (ogtrt.com)

 DESIGN II Simulation library (winsim.com)
 Tail Gas Treating Unit (TGTU)

Reaction Pathways For Claus Tail Gas Reduction
Catalysts: RelevanceTo Field Operations And
Industrial Practice

By P.D. Clark Director of Research, Alberta Sulphur
Research Ltd. and Professor of Chemistry, University of
Calgary & N.I. Dowling and M. Huang Senior Research
Scientists, Alberta Sulphur Research Ltd.

https://brimstone-sts.com/wp-
content/uploads/2015/11/13V12-Clark-Reduction-Pathways-

for-Claus-Tail-Gas-Reduction-Catalysts.pdf
 Disclaimer
This presentation is intended for personal
learning of process simulation only. A thorough
review with technology suppliers on case by
case basis is recommended for practical
applications, equipment selection, operations
troubleshooting, etc.
 About the Author
Tahir Syed is a Professional Engineer and a Project
Management Professional with 27 years of chemical
industry experience. He has 15 years’ experience with
Engineering Design companies and 12 years’
experience with Operating Companies. He has been part
of the following projects where Amine, SWS and SRU
were included together.


NWR 
Refinery/Upgrader Project, Alberta, Canada-during
EDS/FEED Phase

Kashagan 
Offshore Oil & Gas Field, Kazakhstan-
during Startup & Commissioning Phase

Shah Gas Development Project, Abu Dhabi, UAE-during
Detailed Engineering Phase
 FOR ANY COMMENTS OR QUESTIONS

email: [email protected]

I will update next presentations accordingly.

Knowing about your experience developing

simulations using this presentation will also
be interesting.