International Journal of Mechanical Engineering and Robotics Research Vol. 4, No.

3, July 2015

Effect of Choke Ring Position on Thermal and

Fluid Flow in a SRU Thermal Reactor
Chun-Lang Yeh
Department of Aeronautical Engineering, National Formosa University, Huwei, Yunlin 632, Taiwan
Email: [email protected]

Abstract—The effect of choke ring position on the thermal

and fluid flow in a SRU thermal reactor is investigated
numerically. It is found that zone 1 is a higher temperature
region while zone 2 is a lower temperature region. The
average temperature and peak temperature in the SRU
thermal reactor for a rich oxygen supply is higher than
those of a normal oxygen supply. The temperature
difference between zone 1 and zone 2 is smaller for a rich
oxygen supply. The peak temperature for a smaller zone 1 is
higher. The optimal location of the choke ring for the lowest
peak temperature is 6m away from zone 1 corner. The
highest sulfur concentration at exit occurs when zone 1 is
the smallest.

Index Terms—SRU thermal reactor, choke ring, sulfur

recovery (b) enlarged view for the burner section
Figure 1. Configuration and dimensions of the first section of a sulfur
recovery unit for a typical petroleum refinery.
I. INTRODUCTION
Desulfurization is very important in petroleum refining Manenti et al. [1] and [2] proposed a kinetic model
process because oxysulfide arising from petroleum with 2400 reactions and 140 species and implemented it
refining process is one of the major sources of air in a proper reactor network to characterize the thermal
pollution. The most frequently used desulfurization reactor and the waste heat exchanger of sulfur recovery
process is the Claus process which converts the hydrogen units. By doing so, reliable estimation of acid gas
sulfide in natural gas or crude oil into sulfur elements and conversion, elemental sulfur recovery, and steam
thereby reduces the formation of oxysulfide. A sulfur generation are achieved with the possibility to carry out
recovery unit (SRU) thermal reactor is perhaps the most an integrated process-energy optimization at the total
important equipment in a sulfur plant. It can convert the plant scale. Selim et al. [3] examined quality of sulfur
ammonia, hydrogen sulfide and hydrocarbons in the deposits collected from hydrogen sulfide combustion.
reactants into sulfur. Most of the sulfur elements are Sulfur deposits from H2S combustion under various
recovered from the SRU thermal reactor. The first section conditions were captured and analyzed using X-ray
of a sulfur recovery unit based on Claus process is powder diffraction and laser induced breakdown
composed of a burner, a thermal reactor and a waste heat spectroscopy diagnostics. ZareNezhad and Hosseinpour
exchanger. Configuration and dimensions of the first [4] investigated different alternatives for increasing the
section of a sulfur recovery unit for a typical petroleum reactor temperature of Claus SRUs by chemical
refinery are shown in Fig. 1. equilibrium calculations. They found that the acid gas
enrichment is a reliable technique for providing the
required reactor temperature when a high flow of too lean
acid gas is to be processed in a Claus unit. Monnery et al.
[5] studied experimentally the reaction between H2S and
SO2 at practical Claus thermal reactor temperatures
between 850 and 1150oC and residence times between
0.05 and 1.2 seconds. The new kinetic data were used to
develop a new reaction rate expression.
The inner surface of a SRU thermal reactor is
(a) overall view
facilitated by refractory to protect its wall. The interior of
a SRU thermal reactor is divided into two zones by a
choke ring to increase residence time and enhance
Manuscript received April 15, 2015; revised July 11, 2015. chemical reaction. An abrupt temperature rise or an

© 2015 Int. J. Mech. Eng. Rob. Res. 273

doi: 10.18178/ijmerr.4.3.273-277
 International Journal of Mechanical Engineering and Robotics Research Vol. 4, No. 3, July 2015

excessively high temperature may lead to deterioration of thermal reactor is constructed by unstructured grid. Five
the refractory. Therefore, the operating temperature range cell densities are tested to ensure a grid independent
suggested by vendors for the operation of a SRU thermal solution. They include 10,826 cells, 187,354 cells,
reactor should be strictly followed. Because the operating 342,856 cells, 683,672 cells and 1,124,627 cells.
temperature of a practical SRU thermal reactor can be as Computational results show that the corner recirculation
high as 1430oC and the hydrogen sulfide in the reactants zone sizes of zone 1 and zone 2 as well as the cross-
is a highly acid gas, the refractory and heat exchanging sectional average temperature profiles obtained by the
tubes may be deteriorated and the sulfur recovery last two meshes nearly coincide with deviation within
efficiency may be influenced. To resolve the abnormality 0.5%. Therefore, the mesh of 683,672 cells is adopted for
of a SRU thermal reactor under high temperature subsequent discussion. Fig. 2 shows the numerical model
operation, this paper is devoted to a numerical of the SRU thermal reactor investigated. In Fig. 2, the
investigation of thermal and fluid flow in a SRU thermal heat exchanger section consists of 19 cooling tubes of
reactor. The effect of choke ring position in a practical diameter 0.5m, illustrated schematically in Fig. 3. The
SRU thermal reactor is investigated. The purpose of this heat absorption rate of each heat exchanging tube is
paper is to improve the performance and safety of a SRU 40,000 W/m2 and the other walls are adiabatic. No slip
thermal reactor under high temperature operation. condition is applied on any of the solid walls. The exit of
the heat exchanger section is connected to the subsequent
II. NUMERICAL METHODS AND PHYSICAL MODELS equipment at 300K and 1 atm by a pipe of 1.372m in
diameter and 11.5m in length.
In this study, the FLUENT commercial code [6] is
employed to simulate the reacting and fluid flow in a
SRU thermal reactor. The SIMPLE algorithm by
Patankar [7] is used to solve the governing equations. The
discretizations of convection terms and diffusion terms
Figure 2. Numerical model of the SRU thermal reactor investigated.
are carried out by the power-law scheme and the central
difference scheme, respectively. In respect of physical
models, by considering the accuracy and stability of the
models and by referring to the evaluation of other
researchers, the standard k-ε Model [8], P-1 radiation
model [9] and non-premixed combustion model with β–
type probability density function [10] are adopted for
turbulence, radiation and combustion simulations,
respectively. The standard wall functions [11] are used to
resolve the flow quantities（velocity, temperature, and
turbulence quantities）at the near-wall regions. Detailed
governing equations and convergence criterion were
described in the author’s previous study [12].

III. RESULTS AND DISCUSSION

In this study, the numerical model of a practical SRU Figure 3. Illustration of the arrangement of heat exchanging tubes.

TABLE I. BOUNDARY CONDITIONS AT THE ACID GAS INLET HOLES AND THE AIR INLET HOLE
Normal oxygen Rich oxygen
Mole fraction (%) Acid gas to Acid gas to Air inlet Acid gas to Acid gas to Air inlet
zone 1 zone 2 zone 1 zone 2
O2 0 0 19.87 0 0 23.85
N2 0 0 74.98 0 0 71.26
H2O 7.83 4.12 5.15 4.12 27.97 4.89
CO2 1.27 1.5 0 1.48 0 0
H2S 82.06 89.88 0 89.9 39.61 0
CH4 2.28 2.7 0 2.7 0 0
C2H6 1.52 1.8 0 1.8 0 0
NH3 5.04 0 0 0 32.42 0

Temperature (K) 319.92 316.15 403.15 313.15 316.15 397.15

Pressure (N/m2) 76920 75068 74382 75068 75068 89572
Velocity (m/sec) 11.62 2.08 radial tangential 11.46 1.88 radial tangential
12.4 34.1 10.8 29.8

In this study, two cases of oxygen supplies are sulfur recovery. Boundary conditions (including the
investigated: a normal oxygen supply and a rich oxygen species compositions, temperature, pressure and velocity)
supply. A rich oxygen supply is designed to increase the at the acid gas inlet holes of zone 1 and zone 2 as well as

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 International Journal of Mechanical Engineering and Robotics Research Vol. 4, No. 3, July 2015

at the air inlet hole are listed in Table I. Turbulence example, near the zone 1 corner. The peak temperature in
kinetic energy is 10% of the inlet mean flow kinetic the SRU thermal reactor is listed in Table II and labeled
energy and turbulence dissipation rate is computed from in Fig. 6. It can be seen that, although a smaller zone 1
(1). leads to a smaller higher temperature region, the peak
temperature is not necessarily lower. On the contrarily,
k 3/ 2
  C3 / 4 (1) for a smaller zone 1, the peak temperature may be higher
l due to the compression effect of a smaller region. There
where l=0.07L, L is the hydraulic diameter, Cμ=0.09, k exists an optimal location of the choke ring for the peak
and ε are the turbulence kinetic energy and dissipation temperature to be lowest. It is seen that the reactor with
rate, respectively. choke ring away from zone 1 corner by 6m has the lowest
Five positions of the choke ring, away from zone 1 peak temperature. From Table II it is also observed that
corner by 3m, 4m, 5m, 6m and 7m, respectively, are the highest sulfur concentration at exit occurs when the
calculated to investigate the optimal position of a choke choke ring is located at 3m away from the zone 1 corner,
ring. Fig. 4 shows the numerical models of the SRU i.e. when zone 1 is the smallest.
thermal reactor with choke ring at different locations

(a) choke ring away from zone 1 corner by 3m

(b) choke ring away from zone 1 corner by 4m

Figure 5. Comparison of cross-sectional average temperature for the
SRU thermal reactor with choke ring at different locations (normal
oxygen supply).

(c) choke ring away from zone 1 corner by 5m

(d) choke ring away from zone 1 corner by 6m (a) choke ring away from zone 1 corner by 3m

(e) choke ring away from zone 1 corner by 7m

Figure 4. Numerical models of the SRU thermal reactor with choke
(b) choke ring away from zone 1 corner by 4m
ring at different locations.

For a normal oxygen supply, Fig. 5 shows the

comparison of cross-sectional average temperature for the
SRU thermal reactor with choke ring at different
locations. It is observed that zone 1 is a higher
temperature region while zone 2 is a lower temperature
region. Temperature decreases abruptly across the choke (c) choke ring away from zone 1 corner by 5m
ring because of conversion of thermal energy into kinetic
energy across the choke ring due to flow acceleration.
Similar results can be observed in Fig. 6 which shows the
temperature profile for the SRU thermal reactor with
choke ring at different locations. It is seen that a larger
zone 1 leads to a larger higher temperature region. In a
practical SRU thermal reactor, the refractory may be
ruptured due to an excessively high temperature, for (d) choke ring away from zone 1 corner by 6m

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 International Journal of Mechanical Engineering and Robotics Research Vol. 4, No. 3, July 2015

be lowest is 6m away from zone 1 corner, which is the

same as that for a normal oxygen supply. From Table III
it is also observed that the highest sulfur concentration at
the exit occurs when the choke ring is located at 3m away
from the zone 1 corner, i.e. when zone 1 is the smallest,
which is also the same as that for a normal oxygen supply.
(e) choke ring away from zone 1 corner by 7m
Figure 6. Temperature profile for the SRU thermal reactor with choke
ring at different locations (normal oxygen supply).

TABLE II. PEAK TEMPERATURE IN THE SRU THERMAL REACTOR

AND THE SULFUR CONCENTRATION AT EXIT FOR A NORMAL OXYGEN
SUPPLY (a) choke ring away from zone 1 corner by 3m
Separation between Peak Sulfur
zone 1 corner and temperature (K) concentration at
choke ring (m) exit (mole fraction)
3 1932 0.0793
4 1920 0.0788
5 1919 0.0790
6 1902 0.0791
7 1945 0.0791
(b) choke ring away from zone 1 corner by 4m

(c) choke ring away from zone 1 corner by 5m

Figure 7. Comparison of cross-sectional average temperature for the

SRU thermal reactor with choke ring at different locations (rich oxygen (d) choke ring away from zone 1 corner by 6m
supply).

For a rich oxygen supply, Fig. 7 shows the comparison

of cross-sectional average temperature for the SRU
thermal reactor with choke ring at different locations.
Similar to a normal oxygen supply, zone 1 is a higher
temperature region while zone 2 is a lower temperature
region. However, the average temperature for a rich (e) choke ring away from zone 1 corner by 7m
oxygen supply is higher than that of a normal oxygen Figure 8. Temperature profile for the SRU thermal reactor with choke
supply. In addition, the temperature difference between ring at different locations (rich oxygen supply).
zone 1 and zone 2 is smaller for a rich oxygen supply
because of the more complete chemical reaction. Further,
it is seen from Fig. 8 that, similar to the normal oxygen TABLE III. PEAK TEMPERATURE IN THE SRU THERMAL REACTOR
AND THE SULFUR CONCENTRATION AT EXIT FOR A RICH OXYGEN
supply, a larger zone 1 leads to a larger higher SUPPLY
temperature region. The peak temperature in the SRU
thermal reactor for a rich oxygen supply which is listed in Separation between
Peak
Sulfur
Table III and labeled in Fig. 8 is higher than that of a zone 1 corner and choke concentration at
temperature (K)
ring (m) exit (mole fraction)
normal oxygen supply. It can also be seen that, similar to
the normal oxygen supply, although a smaller zone 1 3m 2137 0.0919
leads to a smaller higher temperature region, the peak 4m 2110 0.0907
temperature is not necessarily lower. On the contrarily, 5m 2106 0.0907
for a smaller zone 1, the peak temperature may be higher 6m 2103 0.0902
due to the compression effect of a smaller region. The 7m 2136 0.0916
optimal location of choke ring for the peak temperature to

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 International Journal of Mechanical Engineering and Robotics Research Vol. 4, No. 3, July 2015

IV. CONCLUSION Claus SRU by chemical equilibrium calculations,” Applied

Thermal Engineering, vol. 28, no. 7, pp. 738-744, 2008.
In this paper, the effect of choke ring position on the
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thermal and fluid flow in a SRU thermal reactor is “New experimental data and kinetic rate expression for the Claus
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[6] Ansys Fluent 12 Theory Guide, ANSYS, Inc., April 2009, ch. 8.
temperature region. The average temperature and peak
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supply is higher than those of a normal oxygen supply. [8] B. E. Launder and D. B. Spalding, Lectures in Mathematical
The temperature difference between zone 1 and zone 2 is Models of Turbulence, London England: Academic Press, 1972,
pp. 90-110.
smaller for a rich oxygen supply. The peak temperature
[9] R. Siegel and J. R. Howell, Thermal Radiation Heat Transfer,
for a smaller zone 1 is higher. The optimal location of the Washington DC: Hemisphere Publishing Corporation, 1992, ch.
choke ring for the lowest peak temperature is 6m away 15.
from zone 1 corner. Finally, the highest sulfur [10] Y. R. Sivathanu and G. M. Faeth, “Generalized state relationships
for scalar properties in non-premixed hydrocarbon/air flames,”
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ACKNOWLEDGMENT turbulent flows,” Computer Methods in Applied Mechanics and
Engineering, vol. 3, no. 2, pp. 269-289, 1974.
The author gratefully acknowledges the grant support [12] C. L. Yeh, “Numerical analysis of the combustion and fluid flow
from Formosa Petrochemical Corporation, Taiwan, under in a carbon monoxide boiler,” International Journal of Heat and
the contract 103AF58. Mass Transfer, vol. 59, pp. 172-190, April, 2013.

REFERENCES C. L. Yeh is currently a Professor of

Department of Aeronautical Engineering,
[1] F. Manenti, D. Papasidero, G. Bozzano, and E. Ranzi, “Model- National Formosa University, Huwei, Yunlin,
based optimization of sulfur recovery units,” Computers and Taiwan, ROC. He received B.S. (1987), M.S.
Chemical Engineering, vol. 66, pp. 244-251, July 2014. (1989) and Ph.D. (1993) degrees from
[2] F. Manenti, D. Papasidero, A. Frassoldati, G. Bozzano, S. Pierucci, National Cheng-Kung University, Tainan,
and E. Ranzi, “Multi-scale modelling of Claus thermal furnace and Taiwan, ROC. Dr. Yeh has served as an
waste heat boiler using detailed kinetics,” Computers and engineer in CTCI Corporation, the largest
Chemical Engineering, vol. 59, pp. 219-225, December, 2013. engineering, procurement, and construction
[3] H. Selim, A. K. Gupta, and A. Al Shoaibi, “Effect of reaction firm in Taiwan, from 1995 to 1997, and as a
parameters on the quality of captured sulfur in Claus process,” consultant to Formosa Petrochemical
Applied Energy, vol. 104, pp. 772-776, April, 2013. Corporation in Taiwan, since 2007. He is also the author and reviewer
[4] B. ZareNezhad and N. Hosseinpour, “Evaluation of different of research papers on fluid mechanics, heat transfer, chemical reaction,
alternatives for increasing the reaction furnace temperature of vibration, and stress analysis.

© 2015 Int. J. Mech. Eng. Rob. Res. 277