CAPE BOILER & HEATER CO

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CASE STUDY

Customer: CAPE BOILER & HEATER CO.

Location: Cape Town, SA

Year: September 2025

Boiler: THERMAX Thermal Oil Heater

Controller: Autoflame Mini MK9 MM advanced controller, Autoflame MK9 UV O2 Trim scanners, Autoflame Servomotors

Fuel: This patented system is compatible with a wide range of fuels including natural gas, diesel, heavy fuel oil, and biofuels

SCOPE OF WORK

Cape Boiler & Heater Co., in partnership with Combustion Technology, successfully completed the first installation and commissioning in South Africa of an Autoflame Mini Mk9 controller on a newly manufactured THERMAX Thermal Oil Heater designed and built by Cape Boiler & Heater Co.

The existing systems offered limited control accuracy, leading to:

  • Inconsistent combustion performance
  • Higher fuel consumption and energy waste
  • Increased maintenance frequency due to inefficient system tuning, resulting in greater downtime

KEY OBJECTIVES

  • Improve fuel efficiency compared to the customers current systems.
  • Lower emissions and promote cleaner combustion.
  • Enhance safety through real-time oxygen trim and continuous monitoring.
  • Ensure stable operation and precise temperature control throughout the load range.
  • Implement preventative maintenance capabilities to reduce unplanned downtime and improve reliability.

INSTALLATION DETAIL

  • Supplied and commissioned a new THERMAX Thermal Oil Heater equipped with an Autoflame Mini Mk9 advanced controller.
  • Integrated patented instant UV O₂ Trim scanners for precise oxygen measurement and real time combustion optimisation.
  • Configured burner operation to leverage maximum turndown ratios (up to 4:1 on liquid fuels and 10:1 on gas) for efficient load management.
  • Utilised the heaters downward fired, four pass, vertical design with an air cooled outer shell, ensuring enhanced reliability, faster commissioning, and safer operation.
  • Ensure proactive maintenance and fault diagnostics through the Autoflame Mini Mk9’s advanced monitoring system.

BENEFIT AND COST SAVING ACHIEVED

    • Achieved up to 15% energy savings through optimised combustion control.
    • Delivered significant emissions reductions, meeting modern efficiency and environmental standards Improved safety and reliability via continuous O₂ trim and real time performance monitoring.
    • Reduced unplanned downtime and maintenance costs through built in diagnostic and preventative maintenance features.

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