Achieving Ultra-Low Emissions: 95+™ Heater Technology for CO₂, SOₓ, and NOₓ Reduction

Introduction

Industrial decarbonization is a top priority for refineries and chemical plants worldwide. Fired heaters are among the largest sources of CO₂, SOₓ, and NOₓ emissions in these facilities, and traditional technologies have struggled to deliver significant improvements. Sulzer’s 95+™ Heater Technology is changing the landscape, enabling operators to achieve heating efficiencies of 95% or higher while dramatically reducing harmful emissions even in existing units.

The Emissions Challenge in Fired Heaters

Conventional fired heaters are limited by sulfur dew point corrosion and fouling, capping their efficiency at maximum 89–92%. As a result, they consume more fuel and emit higher levels of greenhouse gases and pollutants:

• CO₂ from excess fuel combustion

• SOₓ from sulfur compounds in the fuel

• NOₓ from high-temperature combustion processes

  
  

These emissions not only impact the environment but also expose operators to increasing regulatory and carbon tax pressures.

How 95+™ Heater Technology Cuts Emissions

Sulzer’s patented 95+™ Heater Technology is a total process solution, not just an equipment upgrade. Key features include:

• Unparalleled thermal efficiency (≥95%): Less fuel is burned for the same adsorbed duty, directly reducing CO₂ emissions.

• Proprietary sulfur dew point elimination: No risk of sulfuric acid corrosion, allowing for deeper heat recovery and lower flue gas temperatures—down to 80–85°C.

• Reduced SOₓ and NOₓ emissions: Lower combustion temperatures and optimized heat recovery minimize the formation and release of these pollutants.

  
  

Quantifiable Results from Real Projects

• Fuel and CO₂ reduction: Annual fuel and CO2 reduction of 3% to 15% depending on the current heater efficiency.

• SOₓ and NOₓ reduction: Flue gas SO₂ emissions can be reduced to near zero, while NOₓ emissions drop to 30–50 mg/m³, compared to commonly 40–80 mg/m³ for traditional heaters.

• Rapid ROI:  Project investment payback periods typically between 1.5-3 years by fuel cost savings and carbon reduction.

  
  

Applications Across Heater Types

95+™ Heater Technology can be applied to a all types of fuel gas fired heaters, including but not limited to:

• Reforming heaters

• CDU/VDU heaters

• Xylene column heaters

• Coker heaters

• Hydrotreating heaters

• Chemical heaters

  
  

With over 25 successful references worldwide, the technology has proven its value in both new builds and revamps.

Conclusion

Sulzer’s 95+™ Heater Technology is a breakthrough for operators seeking to meet strict emissions regulations and sustainability targets.

By boosting efficiency and slashing CO₂, SOₓ, and NOₓ emissions, it delivers both environmental and economic benefits making it a cornerstone for the decarbonized plant of the future.

Ready to achieve ultra-low emissions in your fired heaters? Contact Sulzer Chemtech to discover how 95+™ Heater Technology can transform your operations.