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Industrial boiler room

Steam Boiler Supply for Liverpool firm

Steam Basics – Fuel Saving

Fuel Efficiency is a major advantage of all Clayton Steam Generators and this efficiency, typically, comes from two primary areas – design and operations:

Our Basic Design Concept leads to high fuel-to-steam heat transfer characteristics.
These characteristics include:

  • Counterflow of the feedwater to the combustion gases. That leads to optimum heat transfer
  • Heat exchanger coil design and spacing to ensure turbulent flow of the exhaust gases across the coil, thus facilitating good heat transfer rates
  • Controlled, forced, circulation as opposed to natural circulation used in conventional boilers
  • Low exterior surface area means low area for convection and radiant heat loss. Due to the size of traditional firetube boilers, for example, radiation and convection losses from the boiler to the boiler room will normally run 1.4% to 1.6%. These same losses on a Clayton Steam Generator will run less than 0.75%

Controlled Circulation and Counterflow Heat Exchanger Design, alone, typically accounts for a minimum of a 5% improvement in fuel efficiency over conventional firetube boilers. The stack temperature, a good measure of efficiency, of a Clayton SE Steam Generator will, typically, be 40-60 ºC below the temperature of the steam being produced. Whereas, the typical 5 square metres of heating surface per 100 kW (3 or 4 pass) firetube boiler will have a stack temperature 40 – 60 ºC above the temperature of the steam produced.

Operational Factors that lead to fuel savings include:

  • Quick Start-Up: This may, for instance, eliminate the need to start the boiler 1 to 2 hours before it is needed or to keep a boiler in a warm state during periods of non-use, such as during the evening or on weekends
  • High Steam Quality: Higher quality steam means more kW per kg of steam and, thus, fewer kgs of steam needed
  • Reduced blowdown since a Clayton Steam Generator has typically 1/8th to 1/10th of blowdown of a firetube boiler. Blowdown water contains heat so the less the blowdown the less the loss of heat and the lower the fuel consumption

Since fuel savings result from many factors, savings will depend upon the specifics of the application. However, savings in the range of 5% to 10% are common.

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