> lets say I have 5 bad external delivery attempts per hour and these
> will remain persistent for the full 20 attempts.
> within 6 hours all 30 smtp32 process are now in use...

It shouldn't work that way.  The SMTP process/thread shouldn't be dedicated to a 
specific E-mail until it is delivered; it should process an E-mail (either deliver it, 
or defer it) and then move on to the next.  The only circumstance where it shouldn't 
be able to send an E-mail because of threads is if all the threads are being used to 
send an E-mail (are currently connected to or are trying to connect to another server).
                                -Scott
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