Clayton Steam Generators are known for their fuel-efficiency and this efficiency, typically, comes from two primary areas ? design and operational:

DESIGN The basic design characteristics lead to high fuel-to-steam heat transfer characteristics These characteristics include:

  • Counterflow of the feedwater to the combustion gases. That leads to optimum heat transfer.
  • Heat exchanger coil design and spacing to ensure turbulent flow of the exhaust gases across the coil, thus facilitating good heat transfer rates.
  • Controlled, forced, circulation as opposed to natural circulation used in conventional boilers.
  • Low exterior surface area means low area for convection and radiant heat loss. Due to the size of firetube boilers, radiation and convection losses from the boiler to the boiler room will normally run 1.4% to 1.6%. These same losses on a Clayton Steam Generator will run less than 0.75%.
Controlled Circulation and Counterflow Heat Exchanger Design, alone, typically account for a minimum of a 5% improvement in fuel efficiency over conventional firetube boilers. The stack temperature, a good measure of efficiency, of a Clayton SE Steam Generator will, typically, be 80-100 ºF below the temperature of the steam being produced. Whereas, the typical 5 square feet of heating surface per boiler horsepower (3 or 4 pass) firetube boiler will have a stack temperature 90 ? 100 ºF above the temperature of the steam produced.

OPERATIONAL Operational factors, that lead to fuel savings include:

  • Quick Start-up that may, for instance, eliminate the need to start the boiler 1 to2 two hours before it is needed or to keep a boiler in a warm state during periods of non-use, such as during the evening or on weekends.
  • High Steam Quality Higher quality steam means more BTUS per pound of steam and, thus, fewer pounds of steam needed.
  • Reduced Blowdown. Blowdown in a Clayton Steam Generator is typically 1/8th to 1/10th of blowdown in a firetube boiler. Blowdown water contains heat so the less the blowdown the less the loss of heat and the lower the fuel consumption.
Since fuel savings result from many factors, savings will depend upon the specifics of the application. However, savings in the range of 5% to 10% are common. The FUEL SAVING PROGRAM can be used to estimate savings. Please contact Clayton if you would like a more detailed savings analysis.

Other Advantages include: