Introduction

Sulfur Recovery Unit (SRU) Operations Training Course is designed to equip refinery and gas processing professionals with advanced competencies in sulfur recovery, Claus process optimization, and environmental compliance. As global energy industries face increasing pressure for low-emission refining, ESG compliance, and hydrogen sulfide (H₂S) management, this training delivers critical knowledge on safe, efficient, and sustainable SRU operations. Participants gain hands-on insights into Claus process chemistry, tail gas treatment units (TGTU), amine systems integration, and real-time process optimization using digital refinery technologies.

This course emphasizes operational excellence, troubleshooting skills, and regulatory adherence aligned with modern refinery digitalization, carbon footprint reduction, and process safety management (PSM) standards. It is structured to bridge the gap between theory and plant-floor execution, enabling professionals to enhance plant reliability, sulfur recovery efficiency, emission control, and energy optimization. With a strong focus on case-based learning, learners will develop the ability to diagnose operational issues, improve catalyst performance, and ensure uninterrupted SRU performance under dynamic refinery conditions.

Programme Curriculum

Sulfur Recovery Unit (SRU) Operations Training Course

Introduction

Course Duration

5 days

Course Objectives

Master Claus Process chemistry and reaction mechanisms for sulfur recovery
Understand SRU unit configuration, design, and operational flow
Optimize sulfur recovery efficiency using advanced process control (APC)
Identify and troubleshoot H₂S and SO₂ emission deviations
Apply process safety management (PSM) in SRU operations
Enhance performance of thermal reactors and catalytic converters
Improve tail gas treatment unit (TGTU) efficiency and compliance
Analyze amine gas treating integration with SRU systems
Implement real-time monitoring and digital twin technologies
Reduce plant downtime through predictive maintenance strategies
Ensure compliance with environmental emission standards
Conduct root cause analysis (RCA) for operational failures
Achieve maximum sulfur recovery efficiency with minimum energy consumption

Target Audience

Refinery Process Engineers
SRU & Gas Plant Operators
Chemical Engineers in Oil & Gas Sector
Maintenance Engineers and Technicians
Process Safety and HSE Professionals
Plant Operations Supervisors
Commissioning and Start-up Engineers
Energy and Environmental Compliance Officers

Course Modules

Module 1: Fundamentals of Sulfur Recovery & Refinery Gas Processing

Overview of SRU systems in oil & gas refineries
Sulfur compounds in hydrocarbon processing
Claus reaction chemistry and thermodynamics
Gas sweetening and H₂S removal basics
Industry benchmarks for sulfur recovery efficiency
Case Study: Analysis of sulfur imbalance in a medium-scale refinery SRU system

Module 2: Claus Process Technology & Reactor Operations

Thermal stage combustion principles
Catalytic converter operations and kinetics
Air-to-gas ratio optimization
Reaction furnace temperature control
Sulfur condensation and separation mechanisms
Case Study: Claus reactor temperature instability and efficiency loss resolution

Module 3: Tail Gas Treatment Unit (TGTU) Optimization

SCOT process and hydrogenation principles
Tail gas cleanup technologies
Emission reduction strategies
Catalyst performance monitoring
Integration with incineration systems
Case Study: TGTU failure leading to regulatory emission breach

Module 4: Amine Gas Treating & SRU Integration

Amine circulation and regeneration systems
CO₂ and H₂S absorption dynamics
Heat stable salt formation issues
Foaming and corrosion control
System integration with upstream units
Case Study: Amine contamination affecting SRU feed quality

Module 5: Process Control & Automation in SRU

Distributed Control Systems (DCS) overview
Advanced Process Control (APC) strategies
Real-time optimization algorithms
Sensor calibration and reliability
Alarm management systems
Case Study: Control system failure causing sulfur recovery drop

Module 6: Safety, Risk Management & Environmental Compliance

Process Safety Management (PSM) in SRU
H₂S toxicity and exposure control
Emergency shutdown (ESD) systems
Environmental emission regulations
Risk assessment methodologies
Case Study: H₂S leak incident and emergency response evaluation

Module 7: Troubleshooting & Root Cause Analysis

Common SRU operational issues
Catalyst poisoning and deactivation
Furnace plugging and fouling
Diagnostic tools and performance indicators
Structured RCA methodologies
Case Study: Catalyst deactivation leading to reduced sulfur yield

Module 8: Energy Efficiency & Digital Refinery Transformation

Energy optimization in SRU operations
Heat recovery systems and integration
Digital twin and predictive analytics
Machine learning for process optimization
Sustainability and carbon reduction strategies
Case Study: Digital optimization improving sulfur recovery by 2.5%

Training Methodology

This course employs a participatory and hands-on approach to ensure practical learning, including:

Interactive lectures and presentations.
Group discussions and brainstorming sessions.
Hands-on exercises using real-world datasets.
Role-playing and scenario-based simulations.
Analysis of case studies to bridge theory and practice.
Peer-to-peer learning and networking.
Expert-led Q&A sessions.
Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@fineskilltrainingcenter.org or call +254769199797

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to Fineskill Training Center account, as indicated in the invoice so as to enable us prepare better for you.

Skills & Software Covered

Acid gas processing Claus process Emission control Sulfur recovery optimization

Programme Fee

Duration: 5 Days

Method: Online or Physical

Online Price: $1,000

Physical Price: $1,500

Certification: Accredited Certificate

View Available Dates 📄 Download Course Outline (PDF)

Available Sessions

Location

Month

Year

Oct 26 2026

26 Oct — 30 Oct 2026

💻 Online / Virtual session

Online $1,000