your single worldwide source for steam technology · transfers its heat to the water. the flow of...
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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 Clayton’s 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.
What’s 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. That’s 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, it’s 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.That’s 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 as480°F (250°C), and as high as 3,500°F (1,925°C).Available in a variety of steam/water flowconfigurations, WHSGs and EGBs, like the
company’s 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 factory’s 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 firedsteam generators.
9A Single Source Satisfies
Among the Reasons A Single Source SatisfiesA single source satisfies in a multitude of ways.Among the variety of creatively designedproducts and responsive services designed tomeet the special needs of industry:
• SigmaFire™, a line of steam generators in the 10 to 200 boiler horsepower range (100 to1,940 KW). SigmaFire steam generators useproven Clayton design features in small, light,quiet-running modular units that are quicklyand easily installed.
• Emissions control units designed to meetwhatever your emissions restrictions may be.These optional systems can reduce NOx levelsto as low as 9 ppmv and CO to 50, dependingon the particular generator and the emissioncontrol system chosen.
• Fluid heaters that produce steam in a mannerthat frequently eliminates the need for licensedboiler operators, that may be required by theoperation of conventional boilers.
• Rental skid-mounted steam generationsystems configured to meet emergency ortemporary steam requirements. This popularprogram includes packages from 30 to 300 BHP.
• Compusteam PLC Control Systems forautomated steam generator control, standardon many models. This system offers numerousadvantages, including a simplified panel,improved steam pressure management, andcompatibility with remote monitoring and plantcontrol systems.
• Feedwater analysis and treatment that prolongsequipment life and helps assure optimal steamproduction. Specially trained Clayton personnelcan recommend a program customized to meetyour requirements and arrange delivery of theonly chemicals compounded specifically forClayton steam generators.
Fiber Metal Low NOx Burner
Operator Interface Unit
You’re Covered by Clayton Service Every Step of the WayNeed help? We’ll be right there. Wherever “there”may be.
Clayton delivers factory-direct service throughoutNorth America, Mexico and most of WesternEurope, and assistance is available in many otherparts of the world through an extensive networkof distributors.
Clayton service is available 24 hours per day, 7days per week. As a customer you’ll gain thebenefits of service that continues throughinstallation, training and start-up. Wantsupplemental training for your operators? That’savailable, too. Preventive maintenance contractsthat help keep your equipment operating at peakefficiency can be tailored to your specific needs.
Further, Clayton’s Chemical Division offersanalysis and treatment of feed-water, essentialfor maximizing steam production and prolongingequipment life. You’ll receive a scientificallyprepared optimal treatment program, andCoilguard chemicals formulated specifically forClayton steam generators.
You’re covered in emergencies, too, with rentalgenerators available in the United States, Mexico and Western Europe. Often you can have steam on-line within hours after a unitarrives on site.
Around the world and around the clock, Claytonservice is happy to help.
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Clayton’s friendly customerservice is available 24 hoursper day, 365 days per year.
Clayton also supplies a complete line ofboiler feedwater treatment chemicals.
11A Single Source Satisfies
Serving Major IndustriesSince 1930 Clayton steam generators have metthe needs of a multitude of industries andfacilities around the world, including:
• Aerospace• Animal Feed• Automotive• Beverage• Chemical• Construction• Dairy• Food Processing• Hospitals/Hotels• Marine & Offshore• Mining• Paper• Petroleum• Pharmaceutical• Power Generation Plants• Rubber• Steel• Textile• Tobacco• Wire & Cable• General Manufacturing
A 250 BHP steamgenerator in a U.S. foodmanufacturing plant.
Three 350 BHP steamgenerators in a Spanishpharmaceutical plant.
Two 300BHP steamgenerators ina Romaniansoap plant.
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Printed in U.S.A. G-2006
World Headquarters17477 Hurley Street
City of Industry, CA 91744-5106800.423.4585 tel • 626.435.0180 fax email: [email protected]
www.claytonindustries.com
Latin America HeadquartersManuel L. Stampa 54 • Nueva Industrial VallejoMexico D.F., 07700 Mexico Toll Free: 01.800.888.4422 • (55)55.86.51.00 tel(55)55.86.23.00 fax • email: [email protected]
Europe, Africa & Middle East Headquarters
Rijksweg 30 • B-2880 Bornem, Belgium32.3.890.5700 tel • 32.3.890.5701 fax
email: [email protected]
Clayton Deutschland GmbH Clayton Scandinavia A.S. Clayton de France S.A.R.L.
Clayton Thermal Products Ltd (UK) Clayton Nederland B.V. Clayton Sales & Service Canada
World Leaders in Precision Steam Generators, Fluid Heaters, Heat Recovery Systems and Customer Service
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We’re Here to HelpCall on us for individualized applications engineering help
based on the experience we’ve gained since 1930.
Visit our Web site for informative technical specifications:
www.claytonindustries.com
AROUND THE GLOBE: A Single Source Satisfies