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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