Retrofit or New Build: The Flexibility of 95+™ Heater Technology

Introduction

Industrial operators are under increasing pressure to decarbonize and improve efficiency, whether upgrading existing fired heaters or designing new grassroots units. Sulzer’s 95+™ Heater Technology offers unmatched flexibility, enabling both revamps and new builds to achieve industry-leading thermal efficiency of ≥95%. With more than 25 successful references worldwide, this system-wide process solution is redefining what’s possible for fired heaters and furnaces in refineries and petrochemical plants.

The Need for Flexible, High-Efficiency Solutions

Traditional fired heaters are typically limited to maximum 89–92% efficiency due to sulfur dew point corrosion and fouling even when using advanced air preheater (APH) materials.

Upgrading these units or building new ones to meet modern emissions and high efficiency standards often involves high costs, lengthy downtime, and uncertain results.

95+™ Heater Technology: Adaptable for Any Project

Sulzer’s patented 95+™ Heater Technology is designed for maximum adaptability:

• Revamp existing units: The technology can be retrofitted to a all types of fuel gas fired heaters and furnaces, including but not limited to reforming heater, CDU/VDU heater, xylene column heater, cooker heater, hydrotreating heater, and chemical heaters.

• Grassroots projects: For new builds, 95+™ enables designers to achieve ≥95% efficiency from day one, with lowest flue gas temperatures (typically low as 80–85°C) and no risk of corrosion or fouling.

• Universal compatibility: Applicable to all types of fuel gas-fired heaters, regardless of heater services, firing design, natural or force draft, automation systems, monitoring tools, or maintenance programs in place.

  
  

How the Retrofit Process Works

Implementing 95+™ Heater Technology in an existing unit involves:

• Comprehensive system assessment: Reviewing the entire heater system, not just bottleneck equipment.

• Jobsite investigation and design basis review: Understanding current operating issues and original design documents.

• Tailored revamp engineering: Sulzer’s experts develop a custom solution to maximize efficiency and minimize downtime.

• Fast, low-disruption installation: Most projects deliver rapid payback—often less than two or three years—thanks to fuel and carbon tax savings.

  
  

Proven Results in Both Revamps and New Builds

• Highest possible Efficiency: Either the existing heaters or new heaters, it will achieve unbeatable thermal efficiency  of ≥95% with 95+ implementation.

• Low investment with High return: 95+ system is simple, low investment, with no exotic material, while providing tremendous energy saving. Projects report

• Minimal maintenance: The system operates without corrosion or fouling, reducing maintenance needs and extending equipment life.

  
  

Conclusion

Whether you’re planning a new grassroots unit or seeking to revamp an existing fired heater, Sulzer’s 95+™ Heater Technology delivers the flexibility, efficiency, and sustainability required for today’s industrial landscape.

With proven results and rapid ROI, it’s the smart choice for future-ready operations.

Ready to upgrade your fired heater new or old? Contact Sulzer Chemtech to see how 95+™ Heater Technology can transform your project.