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How to Choose a Steam Source for Your Autoclave

Author: Shirley

May. 06, 2024

39 0 0

Tags: Machinery

How to Choose a Steam Source for Your Autoclave

Autoclaves require steam to operate effectively. With various steam generator sources available for laboratory autoclaves, it's essential to choose the right one. Options range from house steam, which comes from the building's boiler system, to steam produced by onboard electric steam generators. This guide delves into some of the most prevalent steam sources for laboratory autoclaves.

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Utilizing House Steam for Autoclaves

The most commonly used steam source for laboratory autoclaves is house steam, produced by the building's boiler system, usually situated in the basement. House steam is generally sufficient if available. However, there are situations where house steam may not meet the necessary requirements:

  • Insufficient steam pressure: To function properly, a laboratory autoclave requires a minimum of 50psi steam pressure. If this isn't available, consider alternative options mentioned below.
  • Poor steam quality: If house steam contains too many impurities due to poor water quality or old plumbing, an inlet filter may be needed to cleanse the steam. Additionally, proper steam saturation must be maintained. Ideally, steam should have a dryness of 0.95 (by weight) and contain less than 3.5% non-condensable gases (by volume).

Electric Steam Generators for Laboratories

An electric autoclave steam generator or boiler uses electric heating elements to generate steam by heating water. There are two primary types of electric steam generators:

  • Integral Boiler: These boilers are integrated within the autoclave's footprint, usually below the chamber, and typically rated at or below 45kW. They are available in carbon steel or stainless steel if clean steam* is required.
  • Remote Boiler: Intended for larger autoclaves with chambers 24x36x60" or larger, remote boilers are larger (>45kW) and need to be mounted externally due to their size. They are also available in carbon steel or stainless steel construction, similar to integral boilers.

Electric boilers are generally available in 208, 240, 380, and 480 voltages and come in single or three-phase connections, with capacities from 20kW to 180kW. They can be constructed from carbon steel or stainless steel.

  • Carbon steel boilers require tap, softened, or RO water with resistivity under 26,000 ohms (recommended 2,000-6,000 ohms).
  • Stainless steel boilers generate clean steam and, as per ASME pressure vessel code, require high purity DI water with >1 megohm•cm resistivity.

(Refer to the feed water requirements for stainless and carbon steel boilers below.)

An automatic autoclave steam generator blow-down option helps extend heating element life by flushing away minerals from the feed water source. This feature is highly recommended for facilities with poor water quality. Even without an automatic blow-down feature, most boilers come with a manual blow-down valve to manually drain the boiler, reducing scale and preserving heating element life. This feature is unnecessary for stainless steel boilers as the feed water is already purified.

Steam-to-Steam Generators for Clean Steam

Steam-to-steam boilers, or indirect heat exchanger boilers, generate clean steam. These boilers are either integral or remotely mounted and made of stainless steel, fed with high purity water (RO/DI) >1 megohm•cm. House steam indirectly heats water within a heat exchanger system, ensuring the produced steam is clean and contaminant-free. These boilers require little maintenance, making them economical to operate. However, they offer less production capacity than electric autoclave steam generators and come with a higher initial cost.

*Clean Steam is steam free of contaminants, derived from high purity (DI) water. It can be produced using either an electric steam boiler or a steam-to-steam heat exchanger.

Guidelines for Choosing Your Next Steam Source

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Feed Water Requirements for Carbon-Steel Boilers

The table below outlines the recommended feed water requirements for a standard steel boiler. If water quality does not meet maximum conditions, purification by an RO or water softening system is necessary. Contact Consolidated if unsure about your facility's water quality for an initial assessment.

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Water Feed Requirements for Carbon Steel Steam Generators
  • Temperature [°F (°C)]: As supplied, 140 (60); Recommended: 40-60 (4-16); Maximum: 70 (21)
  • Total Hardness (mg/L): Recommended: 50-180; Maximum: 350
  • Alkalinity (mg/L): Recommended: 50-180; Maximum: 350
  • Total Dissolved Solids (mg/L): Recommended: 50-200; Maximum: 500
  • pH: Recommended: 7.5-8.5; Maximum: 7.5-9.0
  • Total Silica (mg/L): Recommended: 0.1-1.0; Maximum: 2.5
  • Resistivity [Ω•cm]: Recommended: 2,000-6,000; Maximum: 26,000 (Contact Consolidated if water supplied is greater than 26,000 Ω•cm)

* If water supplied is greater than 26,000 ohm•cm contact Consolidated for recommendation.

Feed Water Requirements for Stainless Steel Generators

Stainless-steel generators require deionized water >1 megohm•cm.

If you have further inquiries about steam sources for laboratory autoclaves or other related queries, please contact us for more information.

Top 10 Reasons to Buy a Clayton Steam Generator

1. FUEL EFFICIENT

Efficiency matters. When choosing the best boiler for your needs, efficiency rating is a critical factor. It significantly impacts cost savings over the boiler's life cycle. With potential expenses for fuel, water treatment, and maintenance, you want a boiler that runs efficiently to reduce operating costs.

Clayton Steam Generator consistently delivers excellent efficiency ratings even below full firing rate, averaging 83% efficiency without an economizer. This efficiency is achieved through three key design features:

Firstly, the Clayton Generator is the only 100% true counterflow boiler. Water enters the boiler at the top, spirals downward towards the bottom-mounted burner, and absorbs rising heat, promoting optimum heat transfer through a controlled counterflow path.

Secondly, the staggered spacing of the feedwater coil forces combustion gases to take a turbulent path, enhancing heat transfer by increasing contact with the coil's surface.

Lastly, the space-saving design of the Clayton unit minimizes exterior surface area, reducing both convection and radiant heat loss significantly compared to traditional boiler setups, translating into lower radiation losses and enhanced efficiency.

Choose Clayton Industries for highly efficient steam generation, ensuring lower operating costs while meeting your steam requirements.

For more information, please visit Electric Steam Boiler.

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