Chapter 3

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

SO
2
remaining = 34.65 kgmol - 10.40 kgmol = 24.25 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