A process simulation study of hydrogen and sulfur production from hydrogen sulfide using the Fe-Cl hybrid process

Presently, most of the acid gas (H₂S) streams from amine gas sweetening and refinery upgrading operations are treated using the modified Claus process. In this process, sulfur and low-quality steam are produced by partial oxidation of H₂S. Despite the modified Claus process's success in accomplishing the above tasks, it still has some disadvantages. Additional tail gas treatment unit is needed to improve its efficiency. Also, a valuable commodity, hydrogen, is not recovered.In this work, a process simulation study on the Idemitsu Kosan Co. Fe-Cl hybrid process is carried out. The process is capable of producing sulfur and hydrogen from H₂S gas streams. The process was modeled and validated using pilot-scale plant data before been scaled up using the typical acid gas composition profile of one of Abu Dhabi's sulfur recovery plants. The effects the absorber solution flow rate and concentration have on the process' operability were investigated. Operating at high ferric ions concentration was found to be more beneficial compared to high solution flow rate operations. The ferrous ion constituent of the solution proves to be instrumental in the downstream electrolysis process. Cost estimates of the process indicate the suitability of the process to be implemented in Abu Dhabi gas plants to produce sulfur, and most importantly, hydrogen to be used as fuel or chemical feedstock.