A process plant and a process for production of sulfur from a feedstock gas including from 15% to 100 vol % H.sub.2S and a stream of sulfuric acid, the process including a) providing a Claus reaction furnace feed stream with a substoichiometric amount of oxygen, b) directing to a Claus reaction furnace operating at elevated temperature, c) cooling to provide a cooled Claus converter feed gas, d) directing to contact a material catalytically active in the Claus reaction, e) withdrawing a Claus tail gas and elementary sulfur, f) directing a stream comprising said Claus tail gas to a Claus tail gas treatment, wherein sulfuric acid directed to said Claus reaction furnace is in the form of droplets with 90% of the mass of the droplets having a diameter below 500 μm, with the associated benefit of such a process efficiently converting all liquid H.sub.2SO.sub.4 to gaseous H.sub.2SO.sub.4 and further to SO.sub.2.

A revamp process for modifying a sulfur abatement plant including a Claus process plant, the Claus process plant including a Claus reaction furnace and one or more Claus conversion stages, each Claus conversion stage including a conversion reactor and a means for elemental sulfur condensation, and a means of Claus tail gas oxidation configured for receiving a Claus tail gas from said Claus process plant and configured for providing an oxidized Claus tail gas, the process revamp including: a) providing a sulfuric acid producing tail gas treatment plant producing sulfuric acid, and b) providing a means for transferring an amount or all of the sulfuric acid produced in said sulfuric acid producing tail gas treatment plant to said Claus reaction furnace, wherein the moles of sulfur in the transferred sulfuric acid relative to the moles of elemental sulfur withdrawn from the Claus process plant is from 3% to 25%.

The process for configuring or reconfiguring a sulfur removal plant having a plurality of Claus units that is greater than the number of downstream tail gas treating units (TGTUs) is disclosed. The process allows for the regeneration of one of the Claus units without shutting down any of the downstream TGTUs or the other Claus units. Specifically, the regeneration tail gas can be diverted to the reaction furnace of an in-service Claus unit, thereby allowing excess oxygen to be used to regenerate the Claus unit more efficiently, and without exceeding environmental SO.sub.2 emission requirements.

A process plant and a process for production of sulfur from a feedstock gas including from 15% to 100 vol % H.sub.2S and a stream of sulfuric acid, the process including a) providing a Claus reaction furnace feed stream with a substoichiometric amount of oxygen, b) directing to a Claus reaction furnace operating at elevated temperature, c) cooling to provide a cooled Claus converter feed gas, d) directing to contact a material catalytically active in the Claus reaction, e) withdrawing a Claus tail gas and elementary sulfur, f) directing a stream comprising said Claus tail gas to a Claus tail gas treatment, wherein sulfuric acid directed to said Claus reaction furnace is in the form of droplets with 90% of the mass of the droplets having a diameter below 500 μm, with the associated benefit of such a process efficiently converting all liquid H.sub.2SO.sub.4 to gaseous H.sub.2SO.sub.4 and further to SO.sub.2.

Described is a control process for oxidation air management in a sulfur recovery unit. The sulfur recovery unit includes a gas feedstock inlet, an oxidation air inlet, a reaction furnace, pre-heaters, a Claus section including multiple sulfur condensers and Claus converters, and a SuperClaus section including a catalyzing SuperClaus converter, a SuperClaus sulfur condenser, and an SuperClaus oxidation air flow control valve. The control process includes analyzing one or more parameters in the sulfur recovery unit to determine a switch from the SuperClaus section to the Claus section. Additionally, conditions in the sulfur recovery unit are continuously monitored so that when a condition reaches a predetermined threshold or range, the SuperClaus oxidation air flow control valve to the SuperClaus section is opened.

A process and a process plant for production of elemental sulfur from a feedstock gas including from 15 vol % to 100 vol % H2S and a stream of sulfuric acid, the process including a) providing a Claus reaction furnace feed stream with a substoichiometric amount of oxygen, b) directing s to a reaction furnace operating at elevated temperature, c) cooling, d) directing to contact a material catalytically active in the Claus reaction, e) withdrawing a Claus tail gas and elemental sulfur, f) directing to a means for sulfur oxidation, g) directing to contact a material catalytically active in SO2 oxidation to SO3, h) converting to concentrated sulfuric acid, i) recycling to the Claus reaction furnace, wherein an amount of combustibles, in the Claus tail gas, is oxidized in the presence of a material catalytically active in sulfur oxidation, at an inlet temperature below 400° C.

A sulfur recovery unit (SRU) and method including feeding acid gas having hydrogen sulfide to a reaction furnace of the SRU, converting via the SRU the hydrogen sulfide into elemental sulfur and recovering the elemental sulfur, feeding fuel gas instead of the acid gas to the reaction furnace, adjusting flow rate of first air fed to the reaction furnace based on composition of the fuel gas, and adjusting flow rate of second air fed to the reaction furnace based on concentration of oxygen gas (O.sub.2) in furnace gas discharged from the reaction furnace.

A process for production of elemental sulfur from a feedstock gas including from 15% to 100 vol % H2S and a stream of sulfuric acid, the process including: a) providing a Claus reaction furnace feed stream substoichiometric oxygen with respect to the Claus reaction, b) directing to a reaction furnace zone operating at elevated temperature such as above 900° C., c) directing to a sulfuric acid evaporation zone downstream said reaction furnace zone, d) cooling to provide a cooled Claus converter feed gas, e) directing to contact a material catalytically active in the Claus reaction, f) withdrawing a Claus tail gas and elemental sulfur, g) directing to a Claus tail gas treatment plant, with the associated benefit of a process involving injection of sulfuric acid in a sulfuric acid evaporation zone allowing high temperature combustion of said feedstock gas, including impurities, without cooling from evaporation and decomposition of sulfuric acid.

A process and a process plant for production of elemental sulfur from a feedstock gas including from 15 vol % to 100 vol % H2S and a stream of sulfuric acid, the process including a) providing a Claus reaction furnace feed stream with a substoichiometric amount of oxygen, b) directing s to a reaction furnace operating at elevated temperature, c) cooling, d) directing to contact a material catalytically active in the Claus reaction, e) withdrawing a Claus tail gas and elemental sulfur, f) directing to a means for sulfur oxidation, g) directing to contact a material catalytically active in SO2 oxidation to SO3, h) converting to concentrated sulfuric acid, i) recycling to the Claus reaction furnace, wherein an amount of combustibles, in the Claus tail gas, is oxidized in the presence of a material catalytically active in sulfur oxidation, at an inlet temperature below 400° C.

A revamp process for modifying a sulfur abatement plant including a Claus process plant, the Claus process plant including a Claus reaction furnace and one or more Claus conversion stages, each Claus conversion stage including a conversion reactor and a means for elemental sulfur condensation, and a means of Claus tail gas oxidation configured for receiving a Claus tail gas from said Claus process plant and configured for providing an oxidized Claus tail gas, the process revamp including: a) providing a sulfuric acid producing tail gas treatment plant producing sulfuric acid, and b) providing a means for transferring an amount or all of the sulfuric acid produced in said sulfuric acid producing tail gas treatment plant to said Claus reaction furnace, wherein the moles of sulfur in the transferred sulfuric acid relative to the moles of elemental sulfur withdrawn from the Claus process plant is from 3% to 25%.