CORROSION RISKExtreme Environments
H₂S and SO₂ corrode sensors and structural components rapidly, cutting operational life short.
Continuous Skin Temperature Monitoring for Sulphur Recovery Units (SRU)
AI-powered real-time hotspot detection for Claus Combustors & Thermal Reactors operating up to 1050°C.
Prevent refractory failure, detect hotspots early, and improve sulphur recovery efficiency using XYMA's patented μTMapS ultrasonic waveguide technology.
Applications:Claus CombustorThermal ReactorReaction FurnaceWaste Heat BoilerSulphur CondenserCatalytic Reactor
1050°CPeak Furnace Temp
±1.5°CSensor Accuracy
0.04m²Grid Resolution
14mSensor Coverage
Real-TimeAI Heat Maps
Why SRU Thermal Reactor Monitoring Matters
Claus reactors operate in some of the most extreme environments in industrial processing. Here's how XYMA μTMapS compares against traditional monitoring approaches.
CORE CHALLENGESCORROSION RISK 
STRUCTURAL INTEGRITY
INSTRUMENTATION
COVERAGE GAP
CORROSION RISKSTRUCTURAL INTEGRITYHidden Degradation
Refractory wear advances silently beneath the surface with no visible external warning signs.
INSTRUMENTATIONSensor Failure
Traditional thermocouples break down prematurely under combined heat and chemical stress.
COVERAGE GAPBlind Spots
Point readings leave large shell surface areas completely unobserved and unprotected.
HOW WE COMPARE
Traditional Systems
Reactive · Limited Visibility- Thermocouple corrosion in H₂S and SO₂ environments
- No full surface visibility — only point readings
- Manual inspections create safety risks
- No hotspot prediction capability
- Reactive maintenance after failure occurs
XYMA μTMapS
Predictive · Complete Coverage- Real-time heat maps across the full shell
- AI hotspot prediction before failure occurs
- Non-intrusive, magnetic clamp-on installation
- Complete shell coverage with no blind spots
- Predictive maintenance & refractory health tracking
Patented Ultrasonic Waveguide Technology
Advanced thermal intelligence designed for the demanding requirements of sulphur recovery operations
Non-Intrusive Installation
Magnetic clamp-on installation with zero welding or process penetration.
True Skin Temperature
Measures actual shell skin temperature — not inferred process temperature.
No Electronics in Hot Zone
Waveguide sensing eliminates electronics exposure to high-temperature corrosion.
Multi-Point Monitoring
A single waveguide supports up to 24 simultaneous measurement points
Reaction Furnace
Flame Zone
Waste Heat Boiler
Sulphur Condenser
Catalytic Reactor
AI-Powered
Thermal
Intelligence
Continuous full-shell thermal
visibility paired with predictive
analysis — built for refinery and
gas plant teams.
Live 3D Heat Maps Continuous full-shell thermal visibility.
Predictive Alerts AI detects refractory degradation before failure occurs.
Trend Analysis Track thermal behaviour and refractory health over time.
Asset Intelligence Shared real-time insights for operations, inspection, and maintenance teams.
Operational Benefits for Refineries and Gas Plants
Measurable outcomes for sulphur recovery operations — from efficiency gains to compliance and asset lifespan.
01
Improved Sulphur Recovery
Optimize H₂S conversion efficiency.
02
Prevent Unplanned Shutdowns
Detect hotspots before catastrophic failure.
03
Reduce Maintenance OPEX
Minimize manual inspections and sensor replacements.
04
Emissions Compliance
Reduce COS, CS₂, and unconverted H₂S.
05
Extend Asset Life
Improve refractory and shell lifespan.
06
Cross-Team Visibility
Single dashboard for operations & reliability teams.
1050°CMax Furnace Temp
±1.5°CAccuracy
0.04 m²Grid Size
Clamp-OnInstallation
100–600°CSkin Temp Range
0.5°CResolution
Up to 14 mSensor Area
ATEXCertification
FAQ
Frequently Asked Questions
SRU reactors operate at extreme temperatures where refractory degradation and hotspots can lead to catastrophic shell failure. Continuous skin temperature monitoring reveals thermal anomalies early, protecting both equipment and personnel.
Without proper monitoring, refractory wear goes undetected, hotspots develop silently, and unplanned shutdowns or shell ruptures can occur — leading to costly downtime, safety hazards, and lost sulphur recovery efficiency.
μTMapS uses patented ultrasonic waveguide sensing to measure true skin temperature across the full shell. A single waveguide carries multiple measurement points, building live 3D heat maps without any electronics in the hot zone.
Yes. AI-driven analysis tracks thermal trends across the shell and predicts developing hotspots and refractory degradation before they reach a critical failure point.
The system reliably monitors skin temperatures in the 100–600°C range while supporting furnace process temperatures up to 1050°C.
μTMapS can monitor Claus combustors, thermal reactors, reaction furnaces, waste heat boilers, sulphur condensers, and catalytic reactors.
A single ultrasonic waveguide supports up to 24 simultaneous measurement points, enabling dense, full-shell coverage with minimal installation footprint.
Yes. Because sensing is non-intrusive and ultrasonic, μTMapS performs reliably in flame, smoke, dust, and other harsh conditions that defeat optical and conventional sensors.
Is Your SRU Thermal Reactor Fully Monitored?
Book a technical consultation with XYMA's engineering team. We'll walk through your specific reactor configuration and recommend the right deployment.