SUSTAINABLE SULFUR RECOVERY: ADAPTING THE SUPERCLAUS PROCESS FOR INDUSTRIAL WASTE MONETIZATION

Abstract

This project focuses on the design and optimization of a sustainable sulfur recovery plant to convert hazardous hydrogen sulfide (H₂S) waste into elemental sulfur while ensuring compliance with the Environmental Quality Act (EQA) 1974 and Clean Air Regulations 2014. Market studies reveal a growing demand for sulfur with supply deficits projected by 2025, highlighting the economic potential of this initiative. After site scoring, Bintulu, Sarawak, was selected due to its strong industrial infrastructure, stable feedstock supply, and export accessibility. Three recovery processes—Claus, LO-CAT, and THIOPAQ—were evaluated, with the Claus–Superclaus process selected for its cost-effectiveness and ability to achieve over 99% recovery efficiency. The design process included mass and energy balances, process flow diagrams (PFD), piping and instrumentation diagrams (P&ID), equipment sizing, and heat integration to enhance energy efficiency. A fixed-bed reactor with a metal-based catalyst was adopted, offering high sulfur selectivity, stability, and operational simplicity. Safety and reliability were addressed through process control strategies and Hazard and Operability (HAZOP) studies. The proposed plant achieved 99.21% overall recovery efficiency, surpassing regulatory requirements, with an economic evaluation showing profitability and an 8-year payback period. These results demonstrate the project’s technical, economic, and environmental feasibility in supporting sustainable industrial waste monetization.