95+™ Heater technology
Decarbonization by improving fired heater efficiency
Sulzer 95+ Heater Technology is a patented process solution that pushes fired heater efficiency beyond traditional limits, to ≥95% versus the industry cap of 89–92%. By eliminating sulfur dew point corrosion and fouling risks, it enables lower flue gas temperatures (80–85 °C), cutting CO₂, SOx, and NOx emissions in both grassroots and revamp projects. With over 20 successful references, 95+ Heater is the benchmark for energy efficiency and sustainability in refining and petrochemical applications.
≥95% heater efficiency
Maximize efficiency with the lowest flue gas exhaust temperature
Cut emissions & costs
Lower CO₂, NOx, SOx and save on fuel
Maintenance-free & risk-free
No corrosion, no fouling, no downtime
Main benefits
Achieves ≥95% thermal efficiency, significantly reducing fuel gas consumption
Cuts NOx and SOx emissions, helping meet strict environmental regulations
No corrosion or fouling ensures long-term, reliable operation with minimal upkeep
Fast ROI <3 years from fuel savings; <2 years with carbon tax
Proven performance 25+ commercial references worldwide
Key characteristics
Final flue gas temperature: ≤85 °C
Heat efficiency: ≥95% (vs. 80–92% for traditional heaters)
Emission output: NOx: 30–50 mg/m³; SOx: near-zero
No sulfuric acid dew point corrosion
Applicable for: CDU/VDU heater, reforming heater, hydrotreating heater, xylene column heater, coker heater, hydrocracking heater
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GT‑DWC is a unique distillation technique called dividing wall column, that produces three or more purified products in a single tower that otherwise in conventional way is done by 2-3 columns in series.
A vertical wall splits typically the mid‑section into two functional zones so the column can pre‑fractionate the feed on one side while the other side refines the middle cut (heart‑cut) from the top and the bottom cuts. Compared with a conventional in-series distillation columns, this integrated column reduces investment by half of the equipment count, and its internal arrangement reduces remixing that lower the utility consumption as well.
When comparing with the normal column with a side draw, GT-DWC produces the heart‑cut where it is most concentrated with contamination from top & bottom products, and achieves the same (or better) product specs as by the multi-column system.
A two‑column sequence inevitably wastes duty by splitting and then remixing components between shells, causing thermal inefficiency that drives up utility consumptions for reboiling and condensing. GT‑DWC® consolidates that work inside one shell, so the separation is done once without such thermal inefficiency, with one reboiler and one condenser. That means fewer separation efficiency losses, lower internal flows, and smaller overall duty. Where applicable, GT-DWC typically provide 20-30% energy saving comparing with two-column system with the same or better product separation quality.
Yes. GT‑DWC is often a revamp enabler because it replaces two columns with one shell, freeing plot space and reducing energy consumption. It can also be applied for revamping an existing column with sidedraw to greatly improve the middle heartcut purity/quality that benefit its value and downstream units. Sulzer high-efficiency tower internals and proprietary DWC design are key to guarantee the success of the revamp. Dynamic simulation is used to validate start‑up/shutdown procedures as well as the feed variation to prove controllability within your existing utility envelope.
Sulzer supplies the full set of trays or structured packings, along with distributors, collectors, and when needed, custom wall hardware. The internals are engineered to maintain pressure balance and uniform liquid/vapor distribution on both sides of the wall—this is critical to prevent maldistribution, channeling, or cross‑leakage that can degrade efficiency. Selection (trays vs. packing) depends on capacity, turndown, fouling tendency, and pressure drop targets; our design team sizes distributors/redistributors and sealing elements to keep performance stable across the operating range.
Yes. A single shell creates a clean condenser ↔ reboiler pairing that a heat pump can bridge: the overhead releases heat while condensing; VoltaSplit™ lifts that heat to the reboiler temperature replacing a large share of steam with electricity and reusing condenser heat that would otherwise be rejected.
GT‑DWC excels when there is a meaningful middle cut (heart‑cut) to recover, and when the alternative would be a two‑column arrangement. Typical examples include aromatics heart‑cuts, naphtha splitter, reformate splitter, iso/normal-separation column, and light/medium hydrocarbon fractionations where three product slates are needed. As a rule of thumb, if your feed has a clear light, middle, and heavy region—and the middle product purity/yield matters—GT‑DWC is a strong candidate.
We pair a standard temperature/reflux control structure with additional loops to maintain vapor/liquid splits around the dividing wall. It ensures high controllability, and robust operation even facing the feed variation. Dynamic simulation is used to test disturbances (feed swings, utility changes) and to finalize startup/shutdown sequences before commissioning.
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