Sulzer 95+™ Heater Technology – Decarbonization by Improving Fired Heater Efficiency
Sulzer 95+ Heater Technology is a patented process solution that pushes fired heater efficiency beyond traditional limits ≥95% versus the industry cap of 89–92%. By eliminating sulfur dew point corrosion and fouling risks, it enables lower flue gas temperatures (80–85 °C), cutting CO₂, SOx, and NOx emissions in both grassroots and revamp projects. With over 20 successful references, 95+ Heater is the benchmark for energy efficiency and sustainability in refining and petrochemical applications.
≥95% Heater efficiency
Maximize efficiency with lowest flue gas exhaust temperature
Cut Emissions & Costs
Lower CO₂, NOx, SOx and save on fuel
Maintenance-free & Risk-free
No corrosion, no fouling, no downtime
WHITE PAPER
A novel solution for achieving 95% or greater fired heater efficiency
Lower thermal efficiency means more fuel gas consumption for the same absorbed process duty requirement, resulting in higher carbon emissions, higher NOX and higher SOX. As the world strives to decarbonize and minimize harmful emissions, improving the efficiency of fired heaters is one essential solution.
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Main Benefits
Achieves ≥95% thermal efficiency, significantly reducing fuel gas consumption
Cuts NOx and SOx emissions, helping meet strict environmental regulations
No corrosion or fouling ensures long-term, reliable operation with minimal upkeep
Fast ROI:
<3 years from fuel savings
<2 year with carbon tax
Proven Performance: 25+ commercial references worldwide
Key Characteristics
Final Flue Gas Temperature: ≤85°C
Heat Efficiency: ≥95% (vs. 80–92% for traditional heaters)
Emission Output:
NOx: 30–50 mg/m³
SOx: Near-zero
No sulfuric acid dew point corrosion
Applicable for: CDU/VDU heater, Reforming heater, Hydrotreating heater, Xylene Column heater, Coker heater, hydrocracking heater
Get in touch
Charlie Chou
Global licensing director
Contact our expert for more information about 95+ Heater Technology.
The 95+ Heater Technology is a complete fired heater upgrade solution that goes beyond traditional air preheaters. It eliminates the sulfur dew point that caused the limitation of the traditional fired heater efficiency. As a result, it recovers deep energy from flue gases and significantly lowers the final flue gas temperature down to 80–85°C increasing the overall thermal efficiency of the heater to above 95%. This advanced recovery of waste heat results in major reductions in fuel consumption, CO₂ emissions, and energy costs. It’s not an equipment solution, it’s a full-system approach.
95+ has been successfully implemented in over 25 different operating sites and is applicable to all types of fuel gas fired heaters, furnaces, and boilers. The common applications are reforming heaters, CDU/VDU heaters, xylene column heaters, coker heaters, hydrotreater units, and other refining & chemical process heaters. If you are looking for high energy efficiency or debottlenecking on your fired heaters, this technology can likely be integrated to deliver immediate performance and efficiency gains.
One of the strongest advantages of the 95+ Heater is its rapid return on investment. With significant fuel gas savings alone, most projects see a payback in under three years. When carbon tax savings are factored in thanks to substantial CO₂ emission reductions, the ROI often drops below one to two years. This makes it not only a sustainable choice but also a financially compelling one.
Yes. The design of the 95+ Heater Technology ensures operation free from sulfuric corrosion and fouling, which are major causes of maintenance and downtime in conventional systems. Since the system eliminates the sulfuric acid dew point and avoids residue buildup, the risk of system degradation is virtually eliminated. This means less cleaning, fewer shutdowns, longer equipment lifetime, and lower maintenance costs over time.
Absolutely. The 95+ Heater drastically cuts down emissions of NOx and virtually eliminates SOx emissions, helping your plant meet even the strictest environmental standards. By optimizing combustion while maximizing the thermal efficiency, it minimizes the formation of pollutants at the source. This not only supports compliance but also improves your company’s environmental footprint and brand image.
Getting started is simple. Simply fill out our questionnaire (contact us for it), and our team will review your current fired heater performance and help determine the potential fuel and emission savings. We then provide a tailored proposal that includes expected performance, estimated CAPEX & OPEX, expected ROI, and an implementation plan. We’re here to support your transition every step of the way from design to operation.
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