Clayton Steam Generator versus Traditional Steam Boiler

Steam plays a crucial role in countless industrial processes. However, the way this steam is generated has a major impact on efficiency, safety, maintenance and operational flexibility. Traditional steam boilers are characterised by large water volume, long heat-up times and higher maintenance requirements. The Clayton steam generator, based on the monotube water-tube principle, offers a compact and energy-efficient alternative.

Technical Operating Principle

Clayton Steam Generator

The steam generator uses a helical water tube with forced circulation. A feed pump moves the water through the coil, where it is almost instantly converted into dry steam.

Key characteristics:

Start-up time: Often within 5 minutes, reliably at operating pressure.
Steam quality: ≥ 99.5% dryness thanks to an integrated steam separator with no moving parts.
Water content: Very low, significantly increasing safety levels.
Construction: Compact, easy to integrate into existing installations.
Maintenance: Limited and quick to perform.
Higher efficiency due to counterflow design.

Traditional Steam Boiler

This boiler contains a large volume of water that is indirectly heated by combustion gases.

Typical characteristics:

Start-up time: Can take up to several hours.
Dimensions: Large-scale installations with a significant footprint.
Safety: Higher risk in case of overheating or pressure build-up.
Energy consumption: Less efficient under varying load conditions.
Maintenance: More frequent and labour-intensive.

Clayton Steam Generator vs Quick Steam Generator and Traditional Steam Boiler

Steam is essential in many industrial processes. But the way you generate that steam makes a big difference. While traditional steam boilers are often slow, bulky and maintenance-heavy, the Clayton steam generator offers a modern, compact and efficient alternative. In this comparison, we explain why more and more companies are switching to a Clayton solution.

Feature	Quick Steam Generator	Steam Boiler	Clayton Steam Generator
Steam Quality	Wet steam. Low quality.	Moisture carryover increases during sudden demand.	Steam is 99.5% dry saturated, best available quality.
Quick Start Up	Short heat-up but high losses due to purging.	Up to 60 min startup time due to large water mass.	Startup within 5 min. Low heat requirement.
Rapid Response	Rapid but fluctuating pressures.	Lag limits flexibility.	Rapid adjustments without losing stability.
Safety	No info available.	Risk of steam explosion.	No explosions ever due to no large water storage.
Scale Control	Rapid scale build-up.	Scale forms easily, affects performance.	Easy detection, early corrective action.
Water Level Safeguards	Limited/unreliable safeguards.	Loss of water level can cause catastrophic failures.	No discernable water level, no controls needed.
Burner Operation	Frequent switching causes high fuel use.	Constant switching, high energy waste.	Fully modulating, off when no demand.
Maintenance	High wear and premature corrosion.	Corrosion repairs expensive.	Designed for low maintenance.
Steam Reserve	No steam reserve.	Limited reserve (~2 min).	Reliable pressure control, no issues.
Automatic Operation	Needs trained operators.	Supervision required.	Fully automatic, minimal human intervention.
Running Costs	No info available.	High running costs due to inefficiency.	High efficiency and lower running costs.
Space and Weight	Low space and weight.	Three times larger, up to 7x heavier.	Compact size, low installation costs.
Blowdown Losses	No blowdown, contaminants in steam.	Regular blowdown from entire water volume.	High tolerance, minimal blowdown.

Advantages of Clayton Steam Generators

Ultra-fast availability

Delivers steam instantly for fluctuating or cyclical demand, ideal for batch processes and peak loads.

Maximum process safety

The low water content minimises risks of explosion or overpressure.

Consistent steam quality

Very dry steam (≥ 99.5%) suitable for critical applications in food, pharmaceutical and chemical industries.

Compact design

Requires up to 80% less space than traditional boiler systems, ideal for mobile or modular applications.

High energy efficiency

Modulation from 15–100% for optimal performance, even at low loads.

Minimal maintenance, maximum uptime

No fire tube, few moving parts and easily accessible components reduce maintenance time and downtime.

Additional Configurations

Clayton also supplies:

Container solutions: Fully equipped with steam generator, water treatment and chemical dosing in one plug-and-play unit.
Electric models: Emission-free generation, suitable for sustainable production environments and CO₂ reduction programs.

Products

Industries

Services

Clayton Steam Generator versus Traditional Steam Boiler

Technical Operating Principle

Clayton Steam Generator

Traditional Steam Boiler

Clayton Steam Generator vs Quick Steam Generator and Traditional Steam Boiler

Advantages of Clayton Steam Generators

Ultra-fast availability

Maximum process safety

Consistent steam quality

Compact design

High energy efficiency

Minimal maintenance, maximum uptime

Additional Configurations

Conclusion

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Products

Industries

Services

Clayton Steam Generator versus Traditional Steam Boiler

Technical Operating Principle

Clayton Steam Generator

Traditional Steam Boiler

Clayton Steam Generator vs Quick Steam Generator and Traditional Steam Boiler

Advantages of Clayton Steam Generators

Ultra-fast availability

Maximum process safety

Consistent steam quality

Compact design

High energy efficiency

Minimal maintenance, maximum uptime

Additional Configurations

Conclusion

Want to discover more?

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