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Your Single Worldwide Source For Steam Technology
STEAM GENERATORS &WASTE HEAT BOILERS
FEEDWATER COMPONENTS
CHEMICALS
SERVICE
The Inside Story onAdvanced Steam Technology...
Increasing the Productivity of SteamMaking steam is not difficult. In a manufacturing environment, however, thechallenge lies in harnessing the energy of steamin a manner that makes it available quickly, cost-effectively and safely.
This is where Clayton Industries excels.The design of conventional boilers has changed little since the 19th Century. In simplistic terms,water in a vessel or tube is heated by surroundinghot gases. After sufficient heating, the resultantsteam is discharged.
All Clayton steam generators and waste heatboilers employ more sophisticated principles:Controlled Circulation and Counterflow heat
transfer. A pump continuously supplies feedwater to a helical coil heat exchanger, whichtransfers its heat to the water. The flow offeedwater is counter to the flow of combustiongases, an engineering principle that contributesto high fuel-to-steam efficiency. Water leaving theheat exchanger passes through a mechanicalseparator where the liquid and vapor areseparated. Steam exits the separator to thesteam header. The principles of ControlledCirculation and Counterflow and the resultant lowwater content result in many of the advantagesprovided by Clayton Steam Generators.
Making steam is simple. Making steam withmaximum efficiency is Claytons specialty.
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Exclusive CounterflowControlledCirculationTechnology
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Spiral Spring CoilConstruction allowsrapid start-up withoutthermal stress.
3A Single Source Satisfies
Performing With Drill Team PrecisionEach component of a Clayton steam generator isdesigned for optimal utility. The result is aremarkably efficient unit that functions as smoothly and precisely as a drill team. A heavy-duty positive displacement diaphragm pumpprovides precise water control.
Superbly engineered and ruggedly constructed, aClayton pump is pack-less and seal-less: featuresthat contribute to its remarkable dependability.
A single high-grade carbon steel continuous-coil heat exchanger employs a staggeredconfiguration and spacing of coil sections to helpensure turbulent and high velocity gas flows that facilitate high rates of heat transfer.
A feedwater cooled combustion chamberextracts radiant energy and maintains a coolouter shell.
The third critical component in a Clayton steamgenerator is a fixed-vane separator that yields thedriest saturated steam available. Exceptionalwater separation is achieved at all steamproduction rates when high velocities of steamand water pass through the separator nozzle. Asteam trap diverts excess water to a feedwaterreceiver where it is used to preheat feedwater.
Other components include a burner and blowerassembly that assure complete combustion anddelivery of maximum heat to the coil.
SteamSeparator
Staggered tube spacingcreates turbulent gas flow
Varying tube spacingensures high gas velocity
Upper System50%
75%
100%
Center System
Lower System
ClaytonPump
Efficiency by Design
The Clayton focus on innovation in steamgeneration technology pays off for users in anabundance of very practical ways benefits thattranslate into improved performance on theproduction or processing line, and in measurablecost savings as well.
As a result of unique design and easily provenoperational advantages, Clayton steamgenerators are noted for fuel efficiency, rapidstart-ups, compact size and reduced weight,delivery of high quality steam, safety, and fuelburning versatility. Clayton generators run on
natural gas, light oil, heavy oil, propane, bio-gas,hydrogen, or combinations of these fuels.
Another benefit of innovative design: reducedblowdown. The amount of water removed fromthe system to maintain an acceptable level oftotal dissolved solids (TDS) is greatly reducedcompared to conventional boilers. This results in significant savings in fuel, water and chemicals savings in blowdown are typically90% or greater!
Clayton delivers efficiency by design.
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Fuel Efficient, Quality Steam, Low Blowdown
Typical Conventional Boiler
Standard Clayton
Clayton Model SE
Typical Efficiency vs Firing Rate, Gas Fired
Firing Rate %
Firi
ng T
herm
al E
ffic
ienc
y %
5060
80
100
0 100
Wide Range of Sizes, Uses
Clayton steam generators and fluid heaters are available
in 15 sizes, ranging from 10 to 700 Boiler Horsepower
(BHP), 100 to 6800 KW and producing from 345 to
24,150 pounds of high quality steam per hour. Steam
design pressures range up to 3,000 psig. Clayton
Superheat Units deliver superheated steam and are also
available in a variety of sizes, and for a range of steam
pressures and temperatures. Clayton equipment
provides steam for many purposes, including processing,
building heating and equipment cleaning.
Beijing CCTV Installation.
5A Single Source Satisfies
Start Fast, Finish Strong
Efficiency is proven on the factory floor. Amongthe operating features of Clayton steamgenerators that are valued most by industrialcustomers are quick starts and rapid response tochanging load demands.
Where conventional boilers require extendedstart-ups, a Clayton steam generator can bebrought to a full head of steam in as little as five minutes. The quick start and responsecapabilities result primarily from the low watercontent, forced circulation and helical coil design.
Whats more, corporations worldwide frequently
favor multiple Clayton generators over a single,high capacity conventional boiler. Why? BecauseClayton units, with their small footprints, can beadded to a production line with minimaldisruption. Steam remains available when asingle unit is down for maintenance or repair.Best of all, fluctuating loads are not a problem. Asingle Clayton generator can be fired to meet lowdemand, and others brought on line rapidly assteam requirements increase.
Clayton steam generators are conclusive proofthat time saved is fuel saved and time and fuelcost money.
Fast Start, Rapid Response
A 600 BHP Steam Generatorin a U.S. Cosmetics Plant.
A 300 BHPSteamGenerator.
Preventing Problems Boosts Efficiency
Clayton recognizes that controlling familiar steamproduction problems contributes to production orprocessing line efficiency. Thats why a Claytonsteam generator has features designed to inhibitthe build-up of scale and soot.
Because scale and soot act as insulators thatinhibit heat transfer, both result in wasted fuel.One-sixteenth of an inch of scale requires 15%more fuel; 1/32 of an inch of soot requires 12%
more. Thicker build-ups affect fuel consumptionmore drastically.
Further, a Clayton steam generator provides anautomatic indication of scale build-up: anincrease in feed pump pressure. When a pressureincrease is noted, the operator can takeimmediate corrective action. In addition, Claytonoffers an optional built-in steam soot-blower thatpermits fast, easy cleaning of the heating surface.
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Scale and Soot Control
Two 100 BHP steam generatorsmounted on a single skid withthe feedwater componentsoperating in a U.S. candymanufacturing plant.
Three 600 BHP and one 300BHP steam generators in amidwestern utility plant.
100 BHP SigmaFirepackaged boiler room.
7A Single Source Satisfies
Consider the Advantages of Small
Good things come in small packages, right?And if proof is ever needed, its as close as thenearest Clayton steam generator.
Because every Clayton unit, from smallest tolargest, incorporates counterflow and controlledcirculation design, they occupy considerably lessfloor space than conventional boilers of equalcapacity. Additionally, a Clayton steam generatoris considerably lighter than its conventionalcounterpart. The weight difference can be asmuch as 75%.
The economic advantages to the user areapparent. Clayton steam generators can beinstalled more quickly. Their small footprint requiresless space on the plant floor or utility room.
Another advantage: The Clayton design providesunparalleled safety. There has never been, norcan there be, a steam explosion of a Claytonsteam generator.
Clayton steam generators: Smaller size. Biggerresults.
Low Weight/Space, Safety
Three 250 BHP, 450 psig, steam generatorsin a steel vacuum de-gassing application.
Heat Recovery Delivers Additional Cost BenefitsIn a great many applications, heat is a necessity.In any application, wasted heat is wasted money.Thats why Clayton offers a complete line of heatrecovery systems used worldwide in marine,industrial and power plant operations.
Recovering heat from engines, turbines, ovensand furnaces, Clayton Waste Heat SteamGenerators (WHSGs) and Exhaust Gas Boilers(EGBs) work with input temperatures as low as480F (250C), and as high as 3,500F (1,925C).Available in a variety of steam/water flowconfigurations, WHSGs and EGBs, like the
companys standard steam generators, employthe proven Counterflow and ControlledCirculation heat exchanger concept. They areequally simple, durable and reliable.
Co-generation makes extensive use of thisClayton technology. Here EGB systems recoverheat from reciprocating engines and put it towork meeting a factorys processing orproduction needs.
Recovering heat for productive purposes:another Clayton specialty.
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Exhaust Gas Boiler
Exhaust gas andwaste heat boilersuse the same provendesign as the fi