Advanced heat integration in sulfur recovery unit—SafarClaus

1. A method for heat integration in a sulfur recovery unit, the method comprising the steps of:

introducing an acid gas stream to a reaction furnace, where the acid gas stream comprises hydrogen sulfide;

introducing an air stream to the reaction furnace, where the air stream comprises oxygen;

reacting the acid gas stream and the air stream in the reaction furnace to produce a reaction effluent, where the reaction effluent comprises elemental sulfur, where the hydrogen sulfide and oxygen react to produce the elemental sulfur;

introducing the reaction effluent to a heating extension;

reducing the temperature of the reaction effluent in the heating extension to produce an effluent stream;

introducing the effluent stream to a waste heat boiler;

reducing the temperature of the reaction effluent in the waste heat boiler to produce a cooled effluent stream;

introducing the cooled effluent to a sulfur condenser;

reducing the temperature of the cooled effluent in the sulfur condenser to produce a liquid sulfur stream and a cooled gases stream, where the liquid sulfur stream comprises the elemental sulfur;

introducing the cooled gases stream to the heating extension; and

increasing a temperature of the cooled gases stream to produce a hot gases stream, where the heating extension is configured to capture heat from the reaction effluent and release the heat to the cooled gases stream.

2. The method of claim 1 , further comprising the steps of:

introducing the hot gases stream to a catalytic stage; and

producing a sulfur stream and a discharge gases stream in the catalytic stage, where the sulfur stream comprises elemental sulfur.

3. The method of claim 1 , further comprising the steps of;

introducing a pre-feed acid gas to an acid gas preheater; and

increasing the temperature of the pre-feed acid gas to produce the acid gas stream.

4. The method of claim 1 , further comprising the steps of:

introducing a pre-feed air to an air pre-heater; and

increasing the temperature of the pre-feed air to produce the air stream.

5. A system of heat integration in a sulfur recovery unit, the system comprising:

a reaction furnace, the reaction furnace configured to allow a reaction between an acid gas stream and an air stream to produce a reaction effluent, the reaction effluent comprising hydrogen sulfide;

a heating extension, the heating extension fluidly connected with the reaction furnace, where the heating extension is configured to capture heat from the reaction effluent to produce an effluent stream, where the captured heat is released to a cooled gases stream to produce a hot gases stream;

a waste heat boiler, the waste heat boiler fluidly connected to the heating extension, the waste heat boiler configured to reduce a temperature of the effluent stream to produce a cooled effluent; and

a sulfur condenser, the sulfur condenser fluidly connected to the waste heat boiler, the sulfur condenser configured to reduce the temperature of the cooled effluent to produce a liquid sulfur stream and the cooled gases stream, where the liquid sulfur stream comprises elemental sulfur.

6. The system of claim 5 further comprising:

a catalytic stage, the catalytic stage fluidly connected to the sulfur condenser, the catalytic stage configured to convert the hot gases stream to produce a sulfur stream and a discharge stream.

7. The system of claim 5 further comprising an acid gas preheater, the acid gas preheater configured to increase the temperature of a pre-feed acid gas to produce the acid gas stream.

8. The system of claim 5 further comprising an air preheater, the air preheater configured to increase the temperature of a pre-feed air to produce the air stream.