Exhaust Boilers
Is your industry one that generates excessive amounts of heat or emissions during your process, that ultimately escapes into the environment? If so, you may wish to considering joining the countless others addressing this issue and finding a way to capture or reuse this wasted heat, transforming it into a way to cut energy costs and reduce emissions. The concept of waste heat recovery involves capturing this otherwise unused heat and converting it into usable energy, not only improving your facility’s carbon footprint, but also lowering fuel consumption and boosting efficiency.
Clayton’s Waste Heat Recovery System is a perfect example of this technology, capable of capturing unused energy to produce steam and hot water, using our patented coil tube design to maximize heat transfer while minimizing the weight and size of the system, all while handling the high temperature operations and providing a variety of configurations to best suit your need. You can trust in Clayton Industries to provide a waste heat solution to save your facility money and lower your carbon footprint.
Key Benefits
Compact Design
Space is likely at a premium in your facility, and Clayton’s compact design can free up space to be better used elsewhere.
High Thermal Efficiency
Our design offers industry leading efficiency, cutting your fuel costs even further.
High Temperature Operation
Our generators are capable of handling exhaust gas temperatures up to 3,000°F and flows between 1,000 to 30,000 pounds per hour.
Configuration Options
Clayton offers a wide range of sizes and configurations, and our waste heat recovery is no exception. Regardless of your specific requirements, Clayton can provide a customized solution tailored to your individual needs.
Safety
Clayton’s design completely eliminates the possibility of a steam explosion, providing peace of mind and guaranteeing the safety of your employees.
Configuration Options
Waste Heat Recovery can be a nuanced practise, and Clayton is up to the challenge. With a wide variety if products and configurations, Clayton Industries is standing by to provide a system designed to meet the individual needs of your facility.
With 24/7 availability and extensive coverage throughout the United States and beyond, our skilled professionals are equipped to keep your steam generator operating at peak performance.
Looking for replacement parts? Clayton has you covered. Between our parts warehouses, manufacturing plants, and service centers located across the globe, Clayton can ensure a quick response to your steam generator needs.
Are you looking for a temporary solution? Or has a shutdown forced you into an emergency situation? Regardless of your situation, Clayton offers a range of rental solutions that will keep you up and running, complete with all of the auxiliary systems required to bring your facility back online.
In addition to our production facilities around the world, Clayton also offers a refurbishment program, providing a quality source of rebuilt units available for sale.
Why wait for an emergency shutdown to schedule maintenance? In addition to our regular and emergency services, Clayton offers extensive Preventive Maintenance programs, tailored to your needs, to ensure your steam generator continues to perform at optimal efficiency.
Feedwater quality is absolutely critical to boiler operation. Keep your system running smoothly with support from Clayton’s Chemical Water Treatment division, which allows you to take full advantage of your steam generation system.
Frequently Asked Question's
An exhaust gas boiler recovers heat from exhaust gases to produce steam or hot water. Clayton’s system transfers this heat through a coil-tube heat exchanger to circulating water, putting energy that would otherwise escape through the exhaust to use within the facility.
An exhaust boiler uses heat supplied by another process, engine, or turbine. A fired steam boiler generates heat using its own burner. Exhaust boilers therefore depend on the availability of the upstream heat source, while fired boilers can provide steam independently of that source.
Potential heat sources include diesel engines, gas turbines, industrial ovens, furnaces, and thermal oxidizers. Clayton offers different waste heat recovery configurations for these applications. Suitability depends on the exhaust temperature, gas flow, composition, and the amount of steam or hot water the facility can use.
Steam output depends on the available exhaust heat, required steam pressure, and feedwater temperature. Because exhaust conditions change with engine or process load, output can vary during operation. Sizing should evaluate normal and part-load conditions as well as the maximum available heat.
Clayton’s current U.S. product page lists exhaust gas temperatures up to 3,000°F for its waste heat recovery offering. The appropriate equipment depends on the application; this temperature capability should not be assumed for every exhaust boiler configuration. Provide actual exhaust conditions when requesting a system recommendation.
Yes. Clayton describes systems that combine waste heat recovery with direct-fired steam generation. The exhaust boiler supplements steam production while the heat source is running, reducing the load on the fired boiler. The fired unit can provide additional steam or support production when recovered heat is unavailable.
Yes. Recovered exhaust heat can replace part of the energy otherwise needed to generate steam or hot water. The savings depend on how much usable heat is available and how consistently the facility needs it. An application-specific assessment is needed to estimate fuel savings and project payback.
Provide the exhaust source, fuel type, gas flow, exhaust temperature, and allowable exhaust pressure drop. For steam applications, include the required steam output, operating pressure, and feedwater temperature. These inputs help Clayton select the heat-transfer surface and system configuration for the application.
An exhaust boiler adds resistance to the gas flow. Its design must fit within the engine or turbine’s allowable exhaust backpressure. Clayton selects coil modules using exhaust flow, allowable backpressure, and required heat output, balancing heat recovery with the operating requirements of the upstream equipment.
Yes. Clayton’s modular exhaust gas boilers can be configured for horizontal or vertical installation, with inlet and outlet arrangements suited to the exhaust path. The final layout should account for available space, ductwork, structural support, auxiliary equipment, and maintenance access.
The system needs a way to balance heat recovery with steam demand. Clayton describes options including an exhaust bypass that regulates heat entering the boiler and a dump condenser that condenses surplus steam. The appropriate control method depends on the heat source, operating conditions, and process demand.
An exhaust boiler uses waste heat to generate steam or hot water. A feedwater economizer typically recovers heat from boiler flue gases to preheat incoming feedwater, reducing the fuel needed by the boiler. The right choice depends on whether the facility needs additional steam generation or feedwater preheating.
Contact a Clayton Representative
The Clayton steam generator is the only piece of equipment I haven’t had to worry about.
Joe Silvestri 
Clayton always has the parts and knows what to do. Whatever the issue is, they’ll fix it, no problem. I would rather pay for a Clayton steam generator than take a free boiler from another manufacturer, simply for the reliability of the product and excellent customer support. Clayton’s service is unreal! What they do, no one else does, and I have experienced it firsthand. It’s one of the most important pieces of equipment in our plant, and it’s worry-free!
Joe Silvestri
We need even, consistent, dry heat to dry our webs to make our wall coverings and the Clayton Steam Generators produce good quality dry steam.
Tim Bluett 
We chose Clayton and their steam generators because they are safe, reliable, and efficient. And specifically, because they have a history of no industrial accidents.
Pat Bluett
I would say Clayton has by far the best service department I have ever worked with when it comes to manufactured equipment. No matter what day, what time or what circumstance, we can always count on Clayton to support us. They offer really amazing services above and beyond on every occasion.
Darin Ezra
The operation costs are fantastic. The burn usage – propane and everything – have been nominal to the degree that we’re not sure how many times we get the tank filled. And we run it hard, six to seven days a week.
Ross Taylor
It’s a good team, Clayton. They didn’t just make the sale and move on. They’re responsive. ‘You’re our priority,’ they told us, and we were. That really matters.
Dali Grabar
Clayton has excellent equipment, ethics and integrity.
David Prince
Clayton’s solution shaved off 10-15 minutes from each cycle. Multiply that by 20 cycles a day, and it frees up 5 hours a day, which gives us the capacity to handle increased volumes without the need to transfer waste.
Daniel Kennedy
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