Unlocking Double Value: How GT-BTX PluS™ Maximizes Aromatics Recovery While Reducing Sulfur in FCC Gasoline

Introduction

Refineries and petrochemical facilities today face intense pressure to comply with stricter environmental regulations, reduce operating costs, and maximize profits from every barrel. FCC (Fluid Catalytic Cracking) gasoline streams, while containing significant amount of valuable aromatics like benzene, toluene, and xylenes (BTX), also has sulfur compounds that must be removed for clean-fuel mandates without saturating the olefins that provides the octane value.

Sulzer’s GT-BTX PluS™ technology answers this challenge with a groundbreaking, extractive distillation-based process that simultaneously recovers high-value BTX aromatics and removes sulfur from FCC gasoline without saturating olefins in a single step. This integrated solution delivers a unique competitive edge in product quality, operational efficiency, environmental compliance, and plant economics.

Why Combine BTX Recovery and Sulfur Removal?

Traditionally, refineries have managed BTX extraction and gasoline desulfurization as separate processes, often requiring multiple units and complex operations. GT-BTX PluS™ breaks this paradigm. By merging these two core functions into one streamlined, highly efficient unit, businesses can:

• Reduce capital expenditures by minimizing the number of processing units,

• Lower operational and maintenance costs through process simplification,

• Increase yield and profitability by capturing both high-octane, low-sulfur gasoline and petrochemical-grade BTX aromatics.

  
  

This unique approach positions GT-BTX PluS™ as a powerful tool for refineries seeking to maximize ROI while future-proofing their operations.

Main Benefits of GT-BTX PluS™

1. Dual BTX and Sulfur Removal in One Step

GT-BTX PluS™ uses advanced distillation and proprietary solvents to recover high-purity benzene, toluene, and xylenes (BTX), while simultaneously stripping out sulfur. This consolidated approach increases plant throughput and ensures product streams align with stricter environmental and product standards.

2. Low-Sulfur, High-Octane Gasoline

The process produces gasoline that not only meets but exceeds global environmental regulations for sulfur content, while maintaining high octane levels. This enables refiners to access premium fuel markets and avoid costly compliance penalties.

3. Enhanced Profitability

By extracting BTX compounds for the petrochemical sector and retaining gasoline yield, GT-BTX PluS™ transforms every drop of FCC gasoline into maximum value, expanding both revenue streams and margins.

4. Reduced Operating Costs

Compared with conventional multi-step processes, GT-BTX PluS™ significantly reduces energy consumption and hydrogen demand due to its efficient column design and targeted solvent system.

5. Flexible Integration and Proven Performance

Whether implemented as a new installation, retrofit, or expansion, GT-BTX PluS™ adapts to existing refinery layouts and different FCC feed compositions. Backed by Sulzer’s extensive technical support, the technology has proven itself in commercial operations worldwide.

How GT-BTX PluS™ Works The Process in Brief

• Feed Entry: FCC gasoline stream is introduced into the advanced extractive distillation system.

• Distillation & Extraction: Proprietary solvents and high-performance internals enable simultaneous BTX extraction and sulfur compound removal without any saturation of the olefins.

• Product Separation:

  • Overhead Product: A low-sulfur, high-octane gasoline ready for blending and sale.

  • Side & Bottom Products: High-purity BTX aromatics, which are recovered for petrochemical use.

    
    

This integrated flow ensures superior BTX recovery, ultra-low sulfur content, and near-zero octane loss.

Real-World Applications and Results

Refineries implementing GT-BTX PluS™ technology report:

• Regular gasoline product well within (or better than) regulatory sulfur thresholds thresholds (max 10 ppm) and almost no octane loss at gasoline mode operation,

• Very high recovery of BTX aromatics (≥99%) and petrochemical purity at petrochemical mode operation,

• Stable operation across feedstock changes and process upsets,

• Immediate cost savings from reduced energy/hydrogen and fewer required process steps,

• The ability to profitably respond to market and regulatory changes by simply switching the operating mode.

  
  

Conclusion

With GT-BTX PluS™, Sulzer delivers a single, robust solution for tackling today’s refining challenges.

By maximizing aromatics recovery and reducing sulfur content in one efficient process, GT-BTX PluS™ enables refiners to achieve environmental compliance, boost fuel and petrochemical profits, and simplify plant operations for long-term competitiveness.

To learn more about GT-BTX PluS™ solution by Sulzer and get more information, contact us.