The sulfur recovery unit converts H2S to elemental sulfur by the Claus process. The process occurs during two combustion and catalytic reactions. Alumina (γ -Al2O3) and bauxite (Al2O3H2O) are the main Claus catalysts in crude oils. The volume distribution ofmicro- and macropores and the parameter of Bethe lattice representing the complex structure of catalyst pellets pores are the most important parameters affecting catalyst performance. This research is aimed at evaluating these parameters impact on effective efficiency of catalyst bed after blocking by liquid sulfur for the second and third reactors. It can be done by considering micro- and macropores as a function of pellet diameter. The results showthat pelletswith a minimum coordination number or Bethe lattice parameter of 6 are more suitable to use in catalytic reactors. There is a great consistency between the modeling results and the industrial ones. In addition, a catalytic pellet with a diameter of 4.55mmhas the most optimal performance for sulfur recycling processes in industrial crude oil.

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