PACKAGE BOILERS

JOHN THOMPSON has a long history in the boiler industry and

has its roots in the Industrial Revolution of nineteenth-century England. Now,
John Thompson is the Power Division of ACTOM (Pty) Ltd, with its principal
focus on being the best boiler and environmental solutions company. We
specialise in the design and manufacture of package retube boilers and
industrial watertube boilers and also retrot and maintain utility boilers and
environmental equipment.
This brochure covers the products and services of our Package Boilers business
unit. The retube boilers range in steam capacity from 1 t/h up to 32 t/h and
include coal-red boilers, biomass-red boilers, oil / gas-red boilers and custom-
designed waste-heat boilers.
John Thompsons head ofce and factory are located near Cape Town and
during the past 60 years we have supplied over 4 000 retube boilers to
customers in many industries in Africa, Europe, South-East Asia, the Middle-
East, South America and Australia.
All of our boilers now incorporate spiral-tube technology, developed in our
test centre, which enhances thermal efciency and reduces fuel consumption
and CO
2
emission. The boilers are currently designed and manufactured in
compliance with the latest international standard, EN12953, and are inspected
and certied by an Approved Inspection Authority before dispatch.
For further information about John Thompson, its boilers and services,
please visit our website: www.johnthompson.co.za
BOILER PRODUCT RANGE (standard design pressures 1100, 1400, 1725 & 2000 kPa)
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THOMPSON ENVIROPAC
Model number TE500 TE650 TE800 TE1000 TE1200 TE1600 TE2000 TE2600 TE3200
Steam output kg/h 5 000 6 500 8 000 10 000 12 000 16 000 20 000 26 000 32 000
Boiler rating kW 3 134 4 075 5 015 6 269 7 522 10 030 12 537 16 298 20 059
Oil consumption kg/h 302 392 482 602 723 961 1 202 N/A 1 922
Gas consumption Nm
3
/h 329 427 525 656 788 1 047 1 309 1 702 2 094
Oil: GCV 43 400 kJ/kg, efciency 86% on GCV, 92% on NCV
Gas: GCV 41 300 kJ/Nm
3
, efciency 83% on GCV, 89% on NCV
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sTHOMPSON EUROPAC
Model number TU180 TU320 TU500 TU675 TU800 TU1050 TU1600 TU2100
Steam output kg/h 1 800 3 200 5 000 6 750 8 000 10 500 16 000 21 000
Boiler rating kW 1 128 2 006 3 134 4 231 5 015 6 582 10 030 13 164
Coal consumption kg/h 177 314 491 663 785 1 031 1 571 2 062
Coal: GCV 27 500 kJ/kg, peas size grading, efciency 84% on GCV, 87% on NCV
Steam output on biomass is subject to the fuel analysis
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THOMPSON REDIPAC
Model number TR100 TR200 TR300 TR400 TR500
Steam output kg/h 1 000 2 000 3 000 4 000 5 000
Boiler rating kW 627 1 254 1 880 2 507 3 134
Oil consumption kg/h 63 125 189 251 309
Gas consumption Nm
3
/h 69 136 206 273 337
Oil: GCV 43 400 kJ/kg, efciency 84% on GCV, 90% on NCV
Gas: GCV 41 300 kJ/Nm
3
, efciency 82% on GCV, 88% on NCV
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THOMPSON SIMPAC
Model number TS300 TS400 TS500 TS600
Steam output kg/h 3 000 4 000 5 000 6 000
Boiler rating kW 1 880 2 510 3 140 3 760
Wood consumption kg/h 593 791 990 1 186
Wood logs: NCV 15 000 kJ/kg, moisture content 25%, efciency 77% on GCV, 85% on NCV
THOMPSON
SPIRAL-TUBE
Technology
160-
140-
120-
100-
80-
60-
40-
20-
0-
l
10
l
15
l
20
l
25
l
30
l
35
Increase in heat transfer coefficient (%)
S
p
iral-tu
b
e h
eat tran
sfer co
efficien
t
Plain-tube heat transfer coefficient
Heat Transfer Efciency of
Plain-tubes vs Spiral-tubes
Reynolds number x 10
3
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(
%
)
Note: While all information is given in good faith, it should be conrmed before establishing any contractual committment.
SERVICES
Manufacturing
Technical support
Steam out-sourcing
Turnkey installation
Energy management
High technology NDT
Repairs & refurbishment
Metallurgical inspection
Boilerplant management
Commissioning & testing
After sales service & spares
Operator & supervisor training
Coal / Oil / Gas/ Biomass conversions
CFD graphic of an economiser bank Boiler plant 3D model
ENGINEERING CAPABILITIES
Our design and engineering staff undertake
work in the following disciplines:
Boiler design
Pipe stressing
Circulation modelling
Combustion modelling
Pressure vessel design
Instrumentation and control
On-site investigations and audits
Computational uid dynamics (CFD)
Temperature
Contour 1
5.000e
4.945e
4.890e
4.835e
4.780e
4.725e
4.670e
4.615e
4.560e
4.505e
4.450e
[K]
THOMPSON EUROPAC
Coal / Biomass-red Boiler with
MICROPAC
Boiler Management System
FEATURES & BENEFITS
Thermal efciency of 84% with GCV 27 500 kJ/kg provides 10 kg steam per kg coal
Three-pass conventional retube wet-back design with spiral-tubes in both tube passes
Flanged end-plates in place of at end-plates on selected boilers to eliminate tee-butt weld joints.
This reduces susceptibility to corrosion fatigue and extends boiler life
MICROPAC boiler management system to increase efciency and reduce operating and maintenance costs
Variable-speed drives for FD fan, ID fan, feedpumps and stoker to reduce power consumption
Total package incorporates chaingrate stoker, feedwater pumps, control panel, grit collector, fans and
all necessary valves and ttings
THOMPSON TRIUMPH
Chaingrate Stoker
FEATURES & BENEFITS
Swinging chute for uniform fuel distribution
Robust design and construction for long life
Planetary gearbox with electronic shearpin protection
Motorised undergrate dampers for optimal air zoning
Combustion efciency 97% for Peas size coal GCV 27 500 kJ/kg
Combustion efciency 93% for Smalls size coal GCV 25 500 kJ/kg
Total package incorporates a chaingrate stoker with variable-speed
drive, FD fan, combustion controls and control panel
All cast iron components are produced at the John Thompson
foundry under the Meehanite process the international benchmark
for guaranteed quality
BIOMASS FUELS burnt on
our Chaingrate Stoker include
wood pucks, wood chips, wood
pellets, grape pomace pellets,
nut shells, torried biomass and
sunower husks.
FEATURES & BENEFITS
High thermal efciency of up to 91.5% at rated output to reduce fuel consumption and CO
2
emission
(An economiser can be provided for ultra-high efciency)
Three-pass conventional retube wet-back design with spiral-tubes in both tube passes
Flanged end-plates in place of at end-plates on selected boilers to eliminate tee-butt weld joints.
This reduces susceptibility to corrosion fatigue and extends boiler life
Combustion equipment to suit a wide range of oil viscosities and gas compositions
Total package incorporates burner, fan, feedwater pump, control panel and all necessary valves and ttings
Microprocessor-based combustion control system for optimum combustion efciency
Twin burner boilers are available for boiler ratings above 26 000 kg/h
THOMPSON REDIPAC
Oil / Gas-red Boiler
THOMPSON ENVIROPAC
Oil / Gas-red Boiler
FEATURES & BENEFITS
High thermal efciency of up to 90% when oil-red and 88% when gas-red
Three-pass reverse-ame, spiral-tube, wet-back design with a low furnace rating
Combustion equipment to suit a wide range of oil viscosities and gas compositions
Microprocessor-based combustion control system for optimum combustion efciency
Total package incorporates burner, fan, feedwater pump, control panel and all necessary valves and ttings
ANCILLARY PLANT
The following ancillary plant is available:
Pipework
Economisers
Oil ring mains
Blowdown vessels
Ash handling plant
Coal handling plant
Ducting and chimneys
Feedwater storage tanks
Custom-designed waste-heat boilers
Atmospheric and pressure type deaerators
Pulse-jet fabric lters (bag lters) to reduce
particulate emission to below 50 mg/Nm
3
Multi-cyclone grit collectors to reduce particulate
emission to below 250 mg/Nm
3
FEATURES & BENEFITS
High thermal efciency of 85%
Full boiler rating can be achieved with wood moisture content up to 25%
Three-pass conventional wet-back design with spiral-tubes in both tube passes
Fixed-grate of robust construction with high quality Meehanite cast iron grate bars for long life
Total package incorporates a xed-grate, feedwater pumps, control panel, ID fan with variable-speed
control, and all necessary valves and ttings
THOMPSON SIMPAC
Wood-red Boiler
with Fixed-grate
Waste-heat
Boiler
JOHN THOMPSON a division of ACTOM (Pty) Ltd.
Cape Town Head Office PO Box 129, Bellville 7535, RSA Tel:+27 (0)21 959-8400 Fax:+27 (0)21 959-8545
Johannesburg Office PO Box 8382, Edenglen 1613, RSA Tel:+27 (0)11 392-0900 Fax:+27 (0)11 392-0938
Durban Office PO Box 32292, Mobeni 4060, RSA Tel:+27 (0)31 408-9700 Fax:+27 (0)31 408-9722
e-mail: info@johnthompson.co.za www.johnthompson.co.za
JOHN THOMPSON head office and works near Cape Town
JOHN THOMPSON worldwide installations
and representation