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
a 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 firetube boilers and industrial watertube boilers and also retrofit and maintain
utility boilers and environmental equipment.
THOMPSON This brochure covers the products and services of our Package Boilers business unit. The
SPIRAL-TUBE firetube boilers range in steam capacity from 1 t/h up to 32 t/h and include coal-fired boilers,
Technology biomass-fired boilers, oil / gas-fired boilers and custom-designed waste-heat boilers.
John Thompson’s head office and factory are located near Cape Town and during the past
Heat Transfer Efficiency of 60 years we have supplied over 4 000 firetube boilers to customers in many industries in
Plain-tubes vs Spiral-tubes Africa, Europe, South-East Asia, the Middle-East, South America and Australia.
160-
Increase in Heat Transfer (%)

140-
All of our boilers now incorporate spiral-tube technology, developed in our test centre,
120- Increase in heat transfer coefficient (%)
which enhances thermal efficiency and reduces fuel consumption and CO2 emission.
100-
ient
r co
effic The boilers are currently designed and manufactured in compliance with the latest
ansfe
80-
tr
60-
al-tu
be heat international standard, EN12953, and are inspected and certified by an Approved
Spir
40-
sfer coef
ficient Inspection Authority before dispatch.
heat tran
20- Plain-tube
0-l
10
l
15
l
20
l
25
l
30
l
35
For further information about John Thompson, its boilers and services, please visit our
Reynolds number x 103 website: www.johnthompson.co.za

BOILER PRODUCT RANGE (standard design pressures 1100, 1 400, 1 725 & 2 000 kPa, except AQUAGEN)

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
Oil / Gas

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 /h3
329 427 525 656 788 1 047 1 309 1 702 2 094
Oil: GCV 43 400 kJ/kg, efficiency 86% on GCV, 92% on NCV
Gas: GCV 41 300 kJ/Nm3, efficiency 83% on GCV, 89% on NCV
THOMPSON 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 / Biomass

Coal consumption kg/h 177 314 491 663 785 1 031 1 571 2 062
Coal: GCV 27 500 kJ/kg, peas size grading, efficiency 84% on GCV, 87% on NCV
Steam output on biomass is subject to the fuel analysis
THOMPSON AQUAGEN
Model number TQ110 TQ200 TQ310 TQ420 TQ500 TQ650
Generator rating kW 1 100 2 000 3 100 4 200 5 000 6 500
Coal consumption kg/h 164 298 461 625 744 968
Coal: GCV 27 500 kJ/kg, peas size grading, efficiency 88% on GCV, 91% on NCV
Heat output on biomass is subject to the fuel analysis. Design pressure is less than 50 kPa
THOMPSON REDIPAC
Model number TR100 TR200 TR300 TR400 TR500
Steam output kg/h 1 000 2 000 3 000 4 000 5 000
Oil / Gas

Boiler rating kW 627 1 254 1 880 2 507 3 134

Oil consumption kg/h 63 125 189 251 309
Gas consumption Nm /h3
69 136 206 273 337
Oil: GCV 43 400 kJ/kg, efficiency 84% on GCV, 90% on NCV
Gas: GCV 41 300 kJ/Nm3, efficiency 82% on GCV, 88% on NCV
THOMPSON SIMPAC
Model number TS300 TS400 TS500 TS600
Wood

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%, efficiency 77% on GCV, 85% on NCV
Note: While all information is given in good faith, it should be confirmed before establishing any contractual commitment.
SERVICES ANCILLARY PLANT
˜˜ Manufacturing The following ancillary plant is available:

˜˜ Technical support ˜˜ Multi-cyclone grit collectors to reduce particulate emission

to below 250 mg/Nm3
˜˜ Steam out-sourcing
˜˜ Pulse-jet fabric filters (bag filters) to reduce particulate
˜˜ Turnkey installation emission to below 50 mg/Nm3

˜˜ Energy management ˜˜ Atmospheric and pressure type deaerators

˜˜ High technology NDT ˜˜ Custom-designed waste-heat boilers

˜˜ Feedwater storage tanks
˜˜ Repairs & refurbishment
˜˜ Ducting and chimneys
˜˜ Metallurgical inspection
˜˜ Coal handling plant
˜˜ Boilerplant management
˜˜ Ash handling plant
˜˜ Commissioning & testing
˜˜ Blowdown vessels
˜˜ After sales service & spares
˜˜ Oil ring mains
˜˜ Operator & supervisor training ˜˜ Economisers
˜˜ Coal / Oil / Gas / Biomass conversions ˜˜ Pipework

Waste-heat Boiler

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 fluid 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]

CFD graphic of an economiser bank Boiler plant 3D model

 THOMPSON EUROPAC
Coal / Biomass-fired Boiler with
MICROPAC
Boiler Management System

FEATURES & BENEFITS

˜˜ Thermal efficiency of 84% with GCV 27 500 kJ/kg provides 10 kg steam per kg coal
˜˜ Three-pass conventional firetube wet-back design with spiral-tubes in both tube passes
˜˜ Flanged end-plates in place of flat 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 efficiency and reduce operating and maintenance costs
˜˜ Variable-speed drives for FD fan, ID fan, feedpumps and stoker to reduce power consumption
˜˜ Total package incorporates swinging chute, chaingrate stoker, feedwater pumps, control panel,
grit collector, fans and all necessary valves and fittings
 BIOMASS FUELS burnt on
our Chaingrate Stoker include
wood pucks, wood chips, wood
pellets, grape pomace pellets,
nut shells, torrified biomass
and sunflower husks.

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 efficiency 97% for Peas size coal GCV 27 500 kJ/kg
˜˜ Combustion efficiency 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
THOMPSON ENVIROPAC
Oil / Gas-fired Boiler

FEATURES & BENEFITS

˜˜ High thermal efficiency of up to 91.5% at rated output to reduce fuel consumption and CO2 emission
(An economiser can be provided for ultra-high efficiency)
˜˜ Three-pass conventional firetube wet-back design with spiral-tubes in both tube passes
˜˜ Flanged end-plates in place of flat 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 fittings
˜˜ Microprocessor-based combustion control system for optimum combustion efficiency
˜˜ Twin burner boilers are available for boiler ratings above 26 000 kg/h

THOMPSON REDIPAC
Oil / Gas-fired Boiler

FEATURES & BENEFITS

˜˜ High thermal efficiency of up to 90% when oil-fired and 88% when gas-fired
˜˜ Three-pass reverse-flame, 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 efficiency
˜˜ Total package incorporates burner, fan, feedwater pump, control panel and all necessary valves and fittings
THOMPSON SIMPAC
Wood-fired Boiler
with Fixed-grate

FEATURES & BENEFITS

˜˜ High thermal efficiency 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 fixed-grate, feedwater pumps, control panel, ID fan with variable-speed
control, and all necessary valves and fittings

THOMPSON AQUAGEN
Coal-fired Hot Water Generator

FEATURES & BENEFITS

˜˜ Thermal efficiency of 88% with GCV 27 500 kJ/kg
˜˜ Variable-speed drives for FD fan, ID fan and stoker to reduce power consumption
˜˜ Three-pass conventional firetube wet-back design with spiral-tubes in both tube passes
˜˜ Electronic control system to increase efficiency and reduce operating and maintenance costs
˜˜ Total package incorporates swinging chute, chaingrate stoker, control panel, grit collector,
fans and all necessary valves and fittings
 JOHN THOMPSON worldwide
installations and representation

JOHN THOMPSON head office and works near Cape Town

John Thompson a division of ACTOM (Pty) Ltd.

Cape Town Head Office PO Box 129, Bellville, 7535, RSA Tel:+27 (0)21 959-8400
Johannesburg Office PO Box 8382, Edenglen, 1613, RSA Tel:+27 (0)11 392-0900
Durban Office PO Box 32292, Mobeni, 4060, RSA Tel:+27 (0)31 408-9700
e-mail: info@johnthompson.co.za www.johnthompson.co.za