A compact sulfur recovery system is disclosed which comprises a primary
structure including a catalytic partial oxidation reaction zone, a first
temperature-control zone, a first Claus catalytic reaction zone, a second
temperature-control zone, a first liquid sulfur outlet, and a first
effluent gas outlet. In some embodiments, a secondary structure follows
the primary structure and comprises a second Claus catalytic reaction
zone, a third temperature-control zone, a second liquid sulfur outlet,
and a second effluent gas outlet. One or more components of the system
employ heat transfer enhancement material in the temperature-control
zones, and one or more components deter accumulation of liquid sulfur in
the Claus catalytic reaction zones. A process for recovering elemental
sulfur from hydrogen sulfide-containing gas streams comprises regulating
the temperature of certain components to favor the partial oxidation
reaction, and the Claus reaction, as appropriate, and deters pooling of
liquid sulfur on the Claus catalyst(s).