Boosting Plant Profitability and Sustainability with 95+™ Heater Technology

Introduction

In the race to decarbonize and optimize industrial operations, fired heaters and furnaces are often the largest contributors to both energy consumption and carbon emissions in refineries and petrochemical plants.

Traditional heater designs are limited by sulfur dew point corrosion and fouling, capping efficiency at maximum 89–92% and driving up fuel costs, maintenance, and emissions. Sulzer’s 95+™ Heater Technology is transforming this landscape, enabling plants to achieve ≥95% thermal efficiency, slash emissions, and realize rapid returns on investment.

The Business Case: Efficiency, Emissions, and Cost Savings

Fuel consumption in fired heaters is a primary driver of both operating costs and Scope 1 CO₂ emissions for many plants. By increasing heater efficiency, operators can:

• Significantly reduce fuel gas consumption—directly lowering operating expenses.

• Cut CO₂, SOₓ, and NOₓ emissions—helping meet environmental regulations and avoid carbon taxes.

• Improve Energy Intensity Index (EII) scores—boosting overall plant competitiveness.

  
  

How 95+™ Heater Technology Delivers Profitable Sustainability

95+™ is a total process solution, not just an equipment upgrade. It eliminates sulfur dew point corrosion and fouling, allowing for:

• Deeper heat recovery: Final flue gas temperatures as low as 80–85°C, compared to the ≥120°C typical in traditional units.

• Unmatched efficiency: Heating efficiency rises to ≥95%, unlocking major fuel and emissions savings.

• Worry-free operation: No corrosion, no fouling, and almost no maintenance required, ensuring reliable, long-term performance.

  
  

Quantifiable Impact: Case Studies and ROI

Plants implementing 95+™ Heater Technology to the existing heaters have reported:

• Annual energy savings of up to 15%—for example, one refinery saved 267,872 GJ per year, by a single 95+ system.

• Project investment return of 1.5-3 years.

• CO₂ reductions of 2,000 to 30,000 tons annually per heater, depending on the heater size, contributing a significant portion to the site's annual decarbonization target.

• SO₂ emissions reduced to near zero and NOₓ emissions to 30–50 mg/m³, far below traditional heater levels.

• Minimal maintenance and longer equipment life, further reducing lifecycle costs.

  
  

Enhanced Sustainability Credentials

With over 25 successful references, 95+™ Heater Technology has proven its value in the refining and petrochemical industry.

By slashing emissions and fuel use, operators can:

• Increase plant profitability by reducing fuel consumption as operation cost

• Meet or exceed tightening environmental regulations

• Demonstrate leadership in corporate sustainability

• Future-proof their operations against rising carbon costs

  
  

Conclusion

Sulzer’s 95+™ Heater Technology offers a compelling pathway to greater profitability and sustainability. By delivering ≥95% efficiency, dramatically reducing emissions, and minimizing maintenance, it empowers operators to achieve both economic and environmental goals fast.

Ready to boost your plant’s profitability and sustainability? Contact Sulzer Chemtech to see how 95+™ Heater Technology can transform your operations.