Sulfur Recovery Units (SRU) Design and Operation

Introduction

The Sulfur Recovery Units (SRU) Design and Operation Training Course provides a comprehensive and practical foundation for professionals responsible for managing one of the most critical systems in refining and gas-processing operations. As environmental regulations become increasingly stringent and facilities operate with more complex feed stocks, mastering the design, operation, and optimization of SRUs is essential for ensuring compliance, operational excellence, and asset integrity. This training course offers the knowledge and tools required to understand and manage all aspects of sulfur recovery, from the fundamentals of the Claus process to advanced tail gas treatment techniques. Participants will develop a clear understanding of how SRUs convert hydrogen sulfide (H₂S) into elemental sulfur while protecting downstream equipment and reducing emissions. The course explores the thermal and catalytic stages in detail, enabling participants to evaluate equipment design, improve operational efficiency, and maintain safe and reliable performance under varying conditions. Emphasis is placed on identifying system bottlenecks, minimizing operational disruptions, and improving sulfur plant performance in today’s increasingly demanding processing environment. Through real-world case studies and expert-led sessions, participants will also explore troubleshooting practices, energy optimization opportunities, and leading global emission-control strategies. This ensures a well-rounded understanding of SRU functionality and prepares attendees to make informed technical decisions, manage operational challenges, and enhance plant reliability. Whether involved in design, operations, maintenance, or environmental compliance, professionals will find this course exceptionally valuable for strengthening their capability to manage sulfur recovery facilities effectively and safely.

Objectives

By the end of this Sulfur Recovery Units (SRU) Training Course, participants will be able to:

• Understand the fundamental chemistry and principles of the Claus process
• Evaluate the design and performance of SRU components and stages
• Operate SRUs at optimum efficiency while maintaining environmental compliance
• Analyze tail gas treatment units (TGTUs) and select suitable emission-control methods
• Apply troubleshooting techniques to resolve common SRU operational challenges
• Recognize safety considerations when working in H₂S-rich environments
• Interpret key process parameters to prevent corrosion, plugging, and catalyst degradation
• Support performance improvement and optimization initiatives across sulfur plants

Training Methodology

This SRU Design and Operation Training Course uses a structured blend of interactive learning methods to ensure strong retention and practical understanding. Participants will engage in lecture-led sessions explaining key principles and system behaviour, followed by group discussions that reinforce learning through real operational challenges. Practical problem-solving activities, case studies, and analysis of real plant scenarios help bridge the gap between theory and field application. Learning materials include diagrams, process flows, equipment schematics, and troubleshooting guidelines to support visual understanding. Participants are encouraged to share their operational experiences, enabling collaborative learning and collective insight into sulfur recovery issues. By the end of the course, attendees will gain confidence in analysing system performance, diagnosing SRU problems, and managing safe and efficient operations.

Who Should Attend?

This SRU Design and Operation training course is relevant for professionals involved in sulfur plant design, operation, troubleshooting, and environmental management. It is designed to strengthen technical decision-making and operational capabilities across all levels.

This training course will greatly benefit:

• Process and Operations Engineers
• Refinery and Gas Plant Engineers
• Environmental Compliance and HSE Professionals
• Control Room Operators and Plant Supervisors
• Chemical Engineers working in sulfur recovery or treating systems
• Maintenance, Inspection, and Reliability Engineers
• Technical staff supporting SRU performance, monitoring, or optimization

Course Outline

Day 1: Fundamentals of Sulfur Recovery and the Claus Process

• Overview of sulfur compounds in natural gas and refinery gas
• Role of SRUs in gas processing and refining
• Basics of the Claus process: thermal and catalytic stages
• Stoichiometry and reaction chemistry

Day 2: SRU Process Design and Components

• Acid gas composition and feed preparation
• Thermal reactor design and reaction furnace operation
• Waste heat boiler, sulfur condensers, and reheaters
• Catalytic reactors and sulfur recovery stages

Day 3: Tail Gas Treatment and Emissions Control

• Tail gas treatment units (TGTU): SCOT process and alternatives
• Hydrogenation reactors and amine absorbers
• SO₂ emission control and recovery efficiency
• Environmental regulations and compliance requirements

Day 4: SRU Operation, Control, and Troubleshooting

• Process monitoring and control systems
• Sulfur plant start-up and shutdown procedures
• Operational challenges: pressure, temperature, feed variations
• Common issues: sulfur plugging, catalyst deactivation, corrosion

Day 5: Optimization, Safety, and Case Studies

• Improving SRU recovery efficiency
• Energy optimization in sulfur plants
• Safety considerations in H₂S-rich environments
• Case studies: operational improvement, emission reduction, and incident analysis