Every industrial steam boiler needs clean water to run efficiently. Over time, minerals and impurities in that water start to accumulate. When water turns to steam, those solids do not evaporate. Instead, they stay behind and become more concentrated.
If left unchecked, that buildup can cause issues like poor heat transfer, inconsistent steam, and unnecessary wear on the system. That is where boiler blowdown comes in.
Boiler blowdown is the process of removing a small portion of water along with the accumulated impurities from the boiler. It is like draining a little bit of water from a pot before the residue starts to burn. This keeps the industrial steam boiler operating cleanly, safely, and efficiently. This is a crucial step for any plant that relies on continuous, high-quality steam production.
The 2 Types of Blowdown
There are two main types of boiler blowdowns: continuous and intermittent, each serving to manage water quality and protect the system.
- Continuous (Surface) Blowdown
Continuous blowdown focuses on the top layer of the boiler water, where most dissolved solids tend to accumulate. These are fine particles and minerals that do not settle but stay suspended near the surface.
This process involves a small, steady flow of water being released from the upper part of the boiler while fresh, treated feedwater replaces it. The goal is to maintain a consistent level of Total Dissolved Solids (TDS) in the system. By doing this continuously, impurities are kept from reaching levels that could cause foaming or steam contamination.
Most modern industrial steam boiler systems from manufacturers like Clayton Industries are designed to automate this process. A conductivity sensor monitors water quality and opens a blowdown valve as needed, so your team does not have to make constant manual adjustments. This keeps the boiler running smoothly while saving water, fuel, and time.
However, Clayton’s approach to blowdown is unique. Traditional boiler designs use both surface and bottom blowdown. Clayton does not. Instead, Clayton systems remove TDS directly from the steam separator, not from a large steam drum. This targeted process removes the most concentrated water while using only 1/10th the amount of heated water compared to a traditional boiler. The result is significant savings in water, energy, and boiler treatment chemicals, a distinct efficiency advantage among leading industrial steam boiler manufacturers.
- Intermittent (Bottom) Blowdown
While continuous blowdown handles dissolved solids, intermittent blowdown targets heavier impurities such as sludge, rust, and other particles that settle at the bottom of traditional boilers.
This process is typically performed once or twice a day, depending on system size and water conditions. A valve near the bottom of the boiler opens briefly to flush out sediment, preventing buildup that could lead to uneven heating, hot spots, or restricted circulation.
In Clayton’s forced-circulation steam generator design, water moves rapidly through the system, making it much harder for solids to settle. As a result, Clayton’s bottom blowdowns occur only at the feedwater (hotwell or deaerator) tank, not on the high-pressure side of the system. This strategic placement efficiently removes sludge without wasting high-pressure, heated water, further improving efficiency and reducing operational costs.
This approach has become a defining advantage for high-pressure steam boiler manufacturers that emphasize sustainability and precision water management.
Why Both Types Matter
Both blowdown methods are essential for keeping a boiler in top condition. Continuous blowdown manages the water chemistry day to day, while intermittent blowdown keeps lower sections free of sediment and sludge. Together, they protect heat surfaces, maintain efficient operation, and extend the system’s lifespan.
That is why trusted industrial boiler companies like Clayton Industries design systems that optimize both processes. By removing TDS from the steam separator and targeting the most concentrated water, Clayton reduces total blowdown volume while maintaining exceptional steam purity and consistent performance.
Understanding Total Dissolved Solids (TDS)
The impurities that build up in boiler water are referred to as Total Dissolved Solids (TDS). Controlling TDS is crucial in every boiler design to prevent scaling, foaming, and corrosion. However, not all systems handle TDS the same way.
For example, a traditional firetube boiler should not operate with TDS above 3,000 ppm. In contrast, a Clayton Steam Generator can tolerate TDS levels as high as 8,500 ppm thanks to its innovative forced-circulation design. The higher the TDS tolerance, the less frequent blowdown is required and the less water, energy, and treatment chemicals are wasted in the process.
This distinction demonstrates why Clayton Industries, a leading industrial steam boiler manufacturer, remains a trusted name in efficiency, reliability, and environmental performance.
The Cost of Blowdown
Blowdown is necessary, but it comes at a cost. Every gallon of water sent down the drain carries away:
- Valuable heat energy
- Treated water that must be replaced
- Boiler chemicals that maintain system balance
In other words, the more blowdown required, the more energy, water, and treatment chemicals are lost. Systems that can maintain higher TDS levels, like Clayton’s industrial steam boilers, minimize this waste by reducing blowdown volume to just a fraction of what traditional boilers require.
For any facility relying on high-efficiency equipment from industrial boiler companies, minimizing blowdown is one of the most direct ways to lower operating costs.
Why Boiler Blowdown Matters
Keeps the System Efficient
When minerals form scale inside the boiler, they act like insulation, slowing heat transfer. Regular blowdown removes that buildup so your boiler operates at top efficiency, saving fuel and reducing costs.
Improves Steam Quality
Clean boiler water produces clean steam. Blowdown prevents foaming and carryover, giving you consistent, high-quality steam for your process, whether that is food production, chemical manufacturing, or power generation.
Prevents Costly Maintenance
Routine blowdown minimizes internal wear, corrosion, and buildup that could shorten the life of the system. That means fewer shutdowns and more uptime for your plant.
Saves Energy, Water, and Chemicals
Clayton’s system targets only the most concentrated water for removal, which means less blowdown is required. This saves water, reduces chemical use, and conserves energy by preventing unnecessary heat loss.
For high-pressure steam boiler manufacturers, efficient blowdown management is one of the most effective ways to boost long-term ROI and sustainability.
How Blowdown Works
Here is what typically happens during a blowdown on a steam boiler industrial setup:
- Check the water level – Make sure the level control system is working properly before blowdown begins.
- Open the quick-opening valve – This releases pressure safely.
- Open the slow-opening valve – Controls the flow rate during the process.
- Monitor water levels – Watch the sight glass to prevent low-water conditions.
- Close the valves – Close the slow-opening valve first, then the quick one.
- Refill with treated water – Bring the boiler back to the proper level with conditioned feedwater.
Many systems today, including those from Clayton Industries, feature automatic blowdown controls that use sensors to measure conductivity and solids content. These systems adjust blowdown automatically, keeping water chemistry consistent while reducing wasted energy.
This level of automation helps key personnel focus on production rather than manual water management, another example of why Clayton Industries is considered a forward-thinking industrial boiler company.
Why Clayton Systems Simplifies Blowdown
As an experienced industrial steam boiler manufacturer, Clayton Industries builds systems that make blowdown simpler, cleaner, and more efficient.
Our unique forced-circulation design moves water rapidly through the system to prevent solids from settling. Without a large steam drum like traditional boilers, there is less water volume to manage and fewer areas for impurities to collect.
That results in:
- Less frequent blowdown
- Higher steam quality
- Lower maintenance requirements
- Faster startups – steam ready in as little as 10 minutes
Clayton’s strategic blowdown design targets the most concentrated water for removal, reducing blowdown volume and increasing efficiency. Because Clayton systems are fully automated, operators can easily monitor performance without needing full-time supervision, depending on local regulations.
Best Practices for Boiler Blowdown
To get the most out of your steam boiler industrial system:
- Perform smaller, frequent blowdowns instead of large, infrequent ones to maintain consistent chemistry.
- Use automatic blowdown controls to maintain optimal conductivity levels and save water and fuel.
- Recover blowdown heat with a flash tank or heat exchanger to minimize energy loss.
- Match blowdown rate to feedwater quality – cleaner water means less frequent blowdown.
- Keep valves and lines clear for reliable operation.
- Track blowdown data for performance trends.
- Work with your water treatment provider to balance chemistry and reduce scaling.
Even small improvements can make a big difference. Reducing blowdown from 8% to 6% of feedwater can save thousands of gallons of water and significant energy each year, savings every industrial boiler company aims to help clients achieve.
Clayton’s Approach to Efficiency
Clayton Industries does not just make boilers; we help customers operate them smarter.
Our Energy Savings Analysis identifies opportunities to recover heat, reduce fuel use, and optimize blowdown rates for maximum efficiency. By combining design innovation with practical operational insight, Clayton helps facilities achieve measurable cost and resource savings, making us a trusted partner among industrial boiler companies worldwide.
Why Choose Clayton Industries
With decades of innovation and reliability, Clayton Industries stands out among industrial steam boiler manufacturers globally. Our systems are known for:
- Rapid startup and shutdown times
- Compact footprints that save valuable floor space
- Consistent, high-quality steam output
- Safer, low-water-content operation
- Minimal operator oversight
Whether you manage a manufacturing line, food processing facility, or power generation plant, Clayton delivers efficient, safe, and reliable steam systems that outperform traditional designs. As a leader among industrial boiler companies, Clayton continues to redefine efficiency and reliability for modern facilities.
Conclusion
Boiler blowdown might seem simple, but it is one of the most important steps in maintaining a clean, efficient, and long-lasting industrial steam boiler system.
By designing steam generators that tolerate higher TDS levels and remove impurities directly from the steam separator, Clayton Industries, a trusted industrial steam boiler manufacturer, reduces blowdown volume to 1/10th that of traditional boilers, which helps with saving water, energy, and treatment chemicals while maintaining exceptional steam quality.
If you are ready to see how much your facility could save through optimized blowdown management, contact Clayton Industries, a global leader among high-pressure steam boiler manufacturers and innovative industrial boiler companies, for a customized Energy Savings Analysis today.
