High Efficiency

Clayton Steam Generators are known for their fuel efficiency. This is primarily due to Design Factors and Operational Features:

Design factors that lead to high fuel-to-steam heat transfer characteristics include:

  • Counterflow path of the feedwater to the combustion gases that results in optimum heat transfer.
  • Clayton Industries’ heat exchanger coil design and spacing ensure turbulent flow of the exhaust gases across the coil, facilitating good heat transfer rates.
  • Controlled water circulation via a mechanical pump as opposed to natural circulation used in conventional boilers.
  • Low exterior surface area translates to a 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%.

Clayton’s controlled circulation and counterflow heat exchanger design typically account for a minimum of a 5% improvement in fuel efficiency over conventional boilers. The stack temperature is a good measurement of efficiency of a boiler. A typical firetube boiler (5 square feet of heating surface per boiler horsepower [3 or 4 pass]) will have a stack temperature 90°F to 120°F above the temperature of the steam produced. Typically a Clayton Steam Generator will be 100°F less.

Operational features that lead to fuel savings include:

Quick Startup may eliminate the need to start the boiler 1-2 hours before it is needed, or to keep a boiler in a warm state during periods of nonuse, like during the evening or on weekends.

High Steam Quality means more BTUs per pound of steam, thus requiring fewer pounds of steam.

Reduced Blowdown in a Clayton Steam Generator is typically 1/8th to 1/10th of blowdown in a firetube boiler. Blowdown water contains heat; so less blowdown means less loss of heat and lower fuel consumption.

Since fuel savings result from many factors, they depend on the specific application. Savings ranging from 5% to 15% are common. Please contact Clayton Industries if you would like us to prepare a detailed FREE Energy Savings Analysis based on your specific application.

Return to Design Advantages

For further information email us at
Product Information