In this study, the sulfur recovery unit (SRU) was simulated using the Aspen HYSYS. Economic and environmental analysis were carried out. The environmental impacts of the process were analyzed based on the global warming potential (GWP) and acidification potential (AP) of the SRU. The sensitivity analysis of the process was carried out by integrating the HYSYS simulations with MATLAB codes with the aim of improving or optimization of the process. Sensitivity analysis was performed using integration of HYSYS flowsheet with MATLAB. The process was optimized using the single objective as well as multi objective optimization techniques. The PBT of the SRU was found to be 9,39,481 $/year. Normalized and weighted GWP of the process were observed to be 19,353.65 and 21,869.6, respectively. Normalized and weighted AP were estimated to be 34917.189 and 4434483.027, respectively. Results of the sensitivity analysis showed that feed temperature of 40 °C shows the maximum profit, AP of the SRU was found to be independent of the feed temperature, feed temperature of 40 °C showed the minimum GWP of the SRU process. Study of feed pressure showed that feed pressure of 180 bar gives maximum profit, feed pressure of 180 bar shows the minimum AP and feed pressure of 180 bar presents the maximum GWP. Study of combustion air temperature showed that combustion air temperature of 200 °C showed the maximum profit, AP of the SRU was found to be independent of the combustion air temperature and combustion air temperature of 200 °C presents the minimum GWP. Results of SOO based on profit presented that the best fitness value achieved was -958912, SOO based on GWP presented the best fitness value achieved to be 27273.3 and SOO based on AP presented the best fitness value achieved to be 4.399×106. MOO based on the profit and GWP presented that optimum temperature of the feed is 39.9754 °C, optimum pressure of the feed is 152.8723 bar and optimum combustion air temperature is 200.0220 °C.
