95+™ Heater Technology: Redefining Fired Heater Efficiency for Decarbonization

Introduction

Decarbonizing fired heaters and furnaces is a critical step toward achieving sustainability goals in the refining, petrochemical, and chemical industries. Traditional fired heaters typically operate at thermal efficiencies capped between 89% and 92% at best, limited sulfur dew point corrosion and fouling. Sulzer’s patented 95+™ Heater Technology breaks through these barriers, delivering unparalleled heating efficiency of 95% or higher.

This breakthrough not only reduces fuel consumption but also significantly cuts CO₂, SOₓ, and NOₓ emissions, making it a game-changer for both grassroots and revamped units.

The Challenge: Limitations of Traditional Fired Heaters

Fired heaters and furnaces are essential for many industrial processes, but their efficiency is often limited by:

• Sulfur dew point corrosion: Causes damage to equipment and limits heat recovery when too much heat is recovered and flue gas temperature reduces to the sulfur dew point.

• Fouling: Deposits on heat exchange surfaces reduce heat transfer efficiency.

• Material constraints: Even special-material or polymer air preheaters (APH) cannot push efficiency beyond 92%, and it posts additional operating problems.

• Environmental impact: Inefficient combustion results in higher CO₂, SOₓ, and NOₓ emissions.

  
  

These challenges create a bottleneck in the path toward cleaner, more efficient operations.

The 95+™ Heater Technology Solution

Sulzer’s 95+™ Heater Technology is a comprehensive, system-wide process solution designed to overcome these limitations by:

• Eliminating sulfur dew point corrosion: Using a proprietary method that eliminate the risk of having corrosive condensation and allows for higher heat recovery.

• Reducing fouling: No risk for sulfur deposits, maintaining optimal heat transfer.

• Boosting thermal efficiency to ≥95%: Achieved unparallel high efficiency consistently across all types of fuel gas fired heaters.

• Cutting emissions: Lower fuel consumption translates directly into reduced CO₂, SOₓ, and NOₓ emissions.

  
  

With over 25 successful references worldwide, 95+™ has proven its ability to transform fired heater performance. Common 95+ applications are in:

• Reforming heaters

• CDU/VDU heaters

• Xylene column heaters

• Coker heaters

• Hydrotreating heaters

• Various chemical heaters

  
  

Real-World Impact: Efficiency and Emissions Benefits

Operators who have adopted 95+™ Heater Technology report:

• Significant fuel savings due to improved thermal efficiency

• Reduced greenhouse gas emissions, supporting compliance with tightening environmental regulations

• Extended equipment life thanks to reduced corrosion and fouling

• Improved operational stability and reduced maintenance costs

  
  

This technology works independently of different heater services, firing design, natural or force draft, existing maintenance plans, automation systems, or monitoring tools—offering a universal upgrade path for fired heaters.

Why Choose 95+™ Heater Technology?

• Proven performance: More than 25 successful installations demonstrate reliability and efficiency gains.

• Versatility: Suitable for both new builds and retrofit projects across multiple heater types.

• Sustainability: Directly supports decarbonization goals by reducing harmful emissions.

• Cost-effectiveness: Lower fuel consumption and maintenance costs improve plant profitability.

  
  

Conclusion

Sulzer’s 95+™ Heater Technology is redefining what’s possible in fired heater efficiency. By breaking through traditional limits and delivering ≥95% thermal efficiency, it offers a powerful solution for operators committed to decarbonization, cost savings, and operational excellence.

Ready to boost your fired heater efficiency and reduce emissions? Contact Sulzer Chemtech today to learn how 95+™ Heater Technology can transform your operations.