Post on 14-Apr-2018
transcript
7/30/2019 FLEXI BURN CFB Project Tourunen
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Development of High Efficiency CFB Technology to Provide Flexible
Air/Oxy Operation for Power Plant with CCS
FLEXI BURN CFB
CO2NET seminar and EU CCS conference, 24th 26th May
2011, London
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Aim : to develop and demonstrate FLEXI BURN CFB concept enabling to reach
the target of near zero emission power plantsThe FLEXI BURN CFB concept:
High efficiency Circulating Fluidized Bed (CFB) power plant with CCS capable of air/oxyoperation with a wide rangeof fuels including biomass
Project objective
The FLEXI BURN CFB concept has a set of important advantages:
1. fuel flexibility in order to decrease dependency on imported coals and in order to improve power
plant economics especially with CCS operation
2. operational flexibility in order to apply air-firing and oxygen-firing with CO2 capture
3. lower NOx production due to reduced and more uniform furnace temperature profiles, and lowerSOx concentration in flue gases due to in-furnace capture, thus reducing the need for downstreamflue gas cleaning
4. overall concept for phased transition into CCS technology with minimised risks through highefficiency air-oxy flexible CFB combustion
5. lower specific CO2 emissions from the reduced consumption of fuel due to the intrinsic highefficiency of the technology . In addition, by substituting e.g. 20% of coal input with renewable fuels,CO2 emissions can further be reduced by 15-20%.
6. Provides utilities an attractive alternative to take into use the new technology and decommission oldcapacity with lower efficiency and poorer emission performance
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3
FLEXI BURN CFB diagram allowing operationunder normal air-firing as well as oxygen-firing
with CCS
Large scale
high efficiency
CFB boiler w ith
FLEXI BURN
design
Fuel
Bituminous coalLigniteBiomassPet coke etc.
Air SeparationUnit (ASU) Mixing
Air
Switch
Fluegas(CO2-rich)
Flue gas recirculation
Switch
Stack
95-97% O2
Flue gascleaning
CO2
capture and storage (CCS)
CondensationCompressionPurification
TransportStorage
The FLEXI BURN CFB concept:
High efficiency Circulating FluidizedBed (CFB) power plant with CCScapable of air/oxy operation with awide range of fuels includingbiomass
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Role of FLEXI BURN CFB Partners
Research institutes
Utilities
Development
steps
Indust rial applicability
VTT, LUT, CzUT UNIZAR-LITEC, AICIA
Endesa, EDP, PKE
Laboratory and small
pilot scale test
(0.1-1MWth)Concept
1stCommercial scale
FLEXI BURN CFB Power Plant
FLEXI BURN CFB project
2009 - 2012
Manufacturers
FWEOY, FWESA, ADEX, Siemens, Praxair
UAP
DemonstrationPilot Plant
30 MWth, CIUDEN
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FLEXI BURN CFB - General project approach
5
Comparison of air-
and oxy-fir ing
Development of
design tools
Boiler design
and performance
Power plant integration,
optimization
and economics
Feasibility and readiness for the utili zation of
the technology within different regions in EU
WP1
WP2
WP4 WP5
WP6
Technology demonstration andbackground for the commercialscale design process
Supporting R&D
work
Viable boi ler design Viable power p lant
WP7: Coordination and dissemination
Demonstration tests
at large pilot uni tand commercial
scale air fired unit
WP3
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n
c Xkmt
mr O2c
c
d
d
COefCO Ykt
Y
d
d
)/1/(1 mCOef kk
nrefv ddTAb )/)(/exp(
Model
analyses
COcombustion
Mixing
Charcombustion
Volat
ile,mo
isturer
elease
k W / m2
1D-MODEL
f lue gas
1
n n+ 1
to stack
Primary airSecondary a ir
2
n-1
3
n-2
BENCH SCALE REACTOR (BFB/CFB)
Air
O2, CO2, CO, N2,SO2, NO
Secondaryair
Continuousfuelfeed
Fuelbatchfeed
Cooler/heater
Cooler
PrimarygasheatingPC control anddata logging system
Cyclone
FilterTo Stac k
BENCH SCALE REACTOR (BFB/CFB)
Air
O2, CO2, CO, N2
,SO2, NO
Secondaryair
Continuousfuelfeed
Fuelbatchfeed
Cooler/heater
Cooler
PrimarygasheatingPC control anddata logging system
Cyclone
FilterTo Stac k
Air
O2, CO2, CO, N2
,SO2, NO
Secondaryair
Continuousfuelfeed
Fuelbatchfeed
Cooler/heater
Cooler
PrimarygasheatingPC control anddata logging system
Cyclone
FilterTo Stac k
AGIS ZA 460 MWe supercritical OTU CFB
kW/m 2
Bench scale Pilot scale Boiler scale
EXPERIMENTAL
SCALES
MODELS FOR PHENOMENA 1-D PROCESS MODELS 3-D PROCESS MODELS
MODELS AND
DESIGN TOOLS
M
Secondary
cyclone
Fuelcontainers 1and 2 Zone1
Zone2
Primary
cyclone
Observation port
Deposit probepor t
Zone 3
Zone4
Tostack
Samplingport
Samplingport
Samplingport
Additivecontainer
Air
Secondary gas
Primary gas heating
O2,CO2,N2
PCcontrolanddatalogging system
Samplingport
Samplingport
Gasanalysator
FTIRsamplingp ort
FTIRsampling port
Samplingport
Samplingport
Gascooling
Bag filterFluegasrecirculation
M
Secondary
cyclone
Fuelcontainers 1and 2 Zone1
Zone2
Primary
cyclone
Observation port
Deposit probepor t
Zone 3
Zone4
Tostack
Samplingport
Samplingport
Samplingport
Additivecontainer
Air
Secondary gas
Primary gas heating
O2,CO2,N2
PCcontrolanddatalogging systemPCcontrolanddatalogging system
Samplingport
Samplingport
Gasanalysator
FTIRsamplingp ort
FTIRsampling port
Samplingport
Samplingport
GascoolingBag filterFluegasrecirculation
PILOT SCALE CFB COMBUSTOR
M
Secondary
cyclone
Fuelcontainers 1and 2 Zone1
Zone2
Primary
cyclone
Observation port
Deposit probepor t
Zone 3
Zone4
Tostack
Samplingport
Samplingport
Samplingport
Additivecontainer
Air
Secondary gas
Primary gas heating
O2,CO2,N2
PCcontrolanddatalogging system
Samplingport
Samplingport
Gasanalysator
FTIRsamplingp ort
FTIRsampling port
Samplingport
Samplingport
GascoolingBag filterFluegasrecirculation
M
Secondary
cyclone
Fuelcontainers 1and 2 Zone1
Zone2
Primary
cyclone
Observation port
Deposit probepor t
Zone 3
Zone4
Tostack
Samplingport
Samplingport
Samplingport
Additivecontainer
Air
Secondary gas
Primary gas heating
O2,CO2,N2
PCcontrolanddatalogging systemPCcontrolanddatalogging system
Samplingport
Samplingport
Gasanalysator
FTIRsamplingp ort
FTIRsampling port
Samplingport
Samplingport
GascoolingBag filterFluegasrecirculation
PILOT SCALE CFB COMBUSTOR
Development and demonstration in multiple scales
(1/2)
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Demonstration of FLEXI BURN CFBCIUDEN 30MWth- air-/ oxy-firing with fuel flexibility- CO2 separation
Field measurements at OTU CFBLagisza 460 MWe- scale-up information from the world first and largest OTU CFB- design model validation
Commercialscale FLEXI
BURN CFBTechnology
Scale upcriteria
Development and demonstration in multiple scales
(2/2)
R&D support Design tools Demonstration Boiler designPower plant
concept
CommercialScale
FLEXIBURN
WP1 WP2 WP3 WP4 WP5 WP6
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Process scale-up
CFB technology is scaling up with the latest high-efficiency SC-OTU-referencesLagisza (460 MWe). The Lagisza power plant (460 MWe), located in the southern
Poland, is the world's largest CFB boiler, which is also the world's first supercritical
CFB once-through unit (OTU)
CFB800 agisza Turow 4-6 JEA Turow 1-3
Furnace
- Width m 40 27.6 22.0 26.0 21.2
- Depth m 12 10.6 10.1 6.7 9.9
- Height m 50.0 48.0 42.0 35.1 43.5
Unit Capacity (MWe)
0
100
200
300
400
500
600
1970 1975 1980 1985 1990 1995 2000 2005 2010
Start-Up Year
Pilot PlantOriental Chem
Lagisza
JEA
Turow 1
Vaskiluodon
Nova ScotiaTri-State
General Motors
800800 MWeUnit Capacity (MWe)
0
100
200
300
400
500
600
1970 1975 1980 1985 1990 1995 2000 2005 2010
Start-Up Year
Pilot PlantOriental Chem
Lagisza
JEA
Turow 1
Vaskiluodon
Nova ScotiaTri-State
General Motors
800800 MWe
Reference plant for the project
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Balance test runs at Lagisza CFB boiler
Unit loads (100%MCR, 80%MCR, 60%MCR and 40%MCR) High/low level of bed pressure within combustion chamber
Measurement parameters during test runs :
Temperature within the combustion chamber (rear wall)
Vertical pressure profile within furnace (front wall)
Gas profiles (at level 13.00m)
Process data (including emission data)
Solid samples
coal, limestone, bottom ash, fly ash , in-furnace sample and circulating
material
Location of measurement ports
at OTU-SC 460MWe Lagisza boiler
Load unit : 100% MCR, 80% MCR
Solids Sampling frequency
Bituminous coal 4 (everytwo hours)
Bottomash 4 (everytwo hours)
Flyash 4 (everytwo hours)
In-furnacesample 4 (everytwo hours)
Circulatingmaterial 4 (everytwo hours)
Limestone 1 (in half of test balance)
Load unit : 60% MCR, 40% MCR
Solids Sampling frequency
Bituminous coal 3 (in half of test balance)
Bottomash 3 (in half of test balance)
Flyash 3 (in half of test balance)
In-furnacesample 3 (in half of test balance)
Circulatingmaterial 3 (in half of test balance)
Limestone 1 (in half of test balance)
Validation runs at a 460 MWe SC-OTU CFB boiler
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OTU SC CFB Boiler layout at
PKE S.A. Lagisza Power Plant
Low Emissions
200 250 300 350 400 450 500
50
100
150
200
250
300
350
400
SO2
measuring data
ConcentrationofSO
2
[mg/m3 n]
(atO
2=6%
indryflue
gases)
Unit load [MWe]
200 250 300 350 400 450 500
50
100
150
200
250
300
350
400
NOx
measuring data
ConcentrationofNO
x
[mg/m3 n]
(atO
2=6%
indryflue
gases)
Unit load [MWe]
200 250 300 350 400 450 500
25
50
75
100
125
150
175
200
CO measuring data
ConcentrationofCO[
mg/m
3 n]
(atO
2=6%
indryfluegase
s)
Unit load [MWe]
200 250 300 350 400 450 500 5500
20
40
60
80
100
120140
160
180
200
Dust measuring data
Concentrationofdust[mg/
m2 n]
(atO
2=6%
indryfluegase
s)
Unit load [MWe]
EMISSION ( at 6% O2, dry flue gas)
(follows EUs LCP directive), mg/Nm3
SO2 200NOx (as NO2) 200
CO 200
Dust 30
Validation runs at a 460 MWe SC-OTU CFB boiler
750
775
800
825
850
875
900
925
950
0 5 10 15 20 25 30 35 40 45 50
Temperature[C]
Height [m]
Measured
calculated by model
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BENCH SCALE REACTOR (BFB/CFB)
Air
O2, CO2, CO, N2,
SO2, NO
Secondaryair
Continuousfuelfeed
Fuelbatchfeed
Cooler/heater
Cooler
Primarygas heatingPC controlanddataloggingsystem
Cyclone
FilterTo Stack
BENCH SCALE REACTOR (BFB/CFB)
Air
O2, CO2, CO, N2,
SO2, NO
Secondaryair
Continuousfuelfeed
Fuelbatchfeed
Cooler/heater
Cooler
Primarygas heatingPC controlanddataloggingsystem
Cyclone
FilterTo Stack
Air
O2, CO2, CO, N2,
SO2, NO
Secondaryair
Continuousfuelfeed
Fuelbatchfeed
Cooler/heater
Cooler
Primarygas heatingPC controlanddataloggingsystem
Cyclone
FilterTo Stack
M
Secondary
cyclone
Fuelcontainers1 and2 Zone1
Zone 2
Primarycyclone
Observation port
Depositprobeport
Zone 3
Zone 4
Tostack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primarygas heating
O2,CO2,N2
PCcontroland datalogging system
Samplingport
Sampling port
Gasanalysator
FTIRsampling port
FTIRsampling port
Sampling port
Sampling port
GascoolingBagfilterFlue gasrecirculation
M
Secondary
cyclone
Fuelcontainers1 and2 Zone1
Zone 2
Primarycyclone
Observation port
Depositprobeport
Zone 3
Zone 4
Tostack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primarygas heating
O2,CO2,N2
PCcontroland datalogging systemPCcontroland datalogging system
Samplingport
Sampling port
Gasanalysator
FTIRsampling port
FTIRsampling port
Sampling port
Sampling port
GascoolingBagfilterFlue gasrecirculation
PILOT SCALE CFB COMBUSTOR
M
Secondary
cyclone
Fuelcontainers1 and2 Zone1
Zone 2
Primarycyclone
Observation port
Depositprobeport
Zone 3
Zone 4
Tostack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primarygas heating
O2,CO2,N2
PCcontroland datalogging system
Samplingport
Sampling port
Gasanalysator
FTIRsampling port
FTIRsampling port
Sampling port
Sampling port
GascoolingBagfilterFlue gasrecirculation
M
Secondary
cyclone
Fuelcontainers1 and2 Zone1
Zone 2
Primarycyclone
Observation port
Depositprobeport
Zone 3
Zone 4
Tostack
Sampling port
Sampling port
Sampling port
Additivecontainer
Air
Secondarygas
Primarygas heating
O2,CO2,N2
PCcontroland datalogging systemPCcontroland datalogging system
Samplingport
Sampling port
Gasanalysator
FTIRsampling port
FTIRsampling port
Sampling port
Sampling port
GascoolingBagfilterFlue gasrecirculation
PILOT SCALE CFB COMBUSTOR
VTT
0.3kW
VTT
0.1MW
CANMET
1MW
CIUDEN
30MW
Demonstrationscales
Time
Concept for 300 MWe
2009 2012
FLEXI BURN CFB Demonstration steps
Completed
In progress
Aim : to develop anddemonstrate FLEXIBURN CFB conceptenabling to reach thetarget of near zeroemission power plants
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Operational point of views:
Combustion process dynamics
Transition between air- and oxygenfiring
Small pilot scale CFB experiments (0.1MW) under air- and
oxygen-firing conditions
Air-firing Oxygen-firing Air-firingOxygen-firing
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Small pilot scale CFB experiments (0.1MW) under air- and
oxygen-firing conditions have been completed withtotally 33 experiments
Transition between air- and oxygen firing conditions
could be carried out smoothly and safely with the
renovated automation system which included an
automated transition mode between air- and oxygen-firing
Combustion process could be operated in the both modes
without any major drawbacks
Based on the dynamic tests the reliable control of oxidant
oxygen concentration is very important from the safety
operation and process controllability point of view
If the inlet gas (oxidant) oxygen concentration is controlled
effectively the combustion process stability seems to be
comparable to corresponding air-firing conditions
If flue gas emissions are expressed in milligrams per
megajoules the emission levels between air- and oxygen-
firing have not remarkable differences
Small pilot scale CFB experiments (0.1MW) under air- and
oxygen-firing conditions
Air-firng (Test 19)
CaCO3 [%]
CaO [%]
CaSO4 [%]
Oxygen-firing (Test 2 0)
CaCO3 [%]
CaO [%]
CaSO4 [%]
Bottom ash
Bottom ash
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Model based analysis of the CANMET test data
Detailed analysis of solids mass balance
Furnace vertical temperature profile
Combustion and energy release profile
Solids density profile
Heat flux profile
Furnace heat transfer
500
550
600
650
700
750
800
850
900
950
1000
0 2 4 6
Tem
perature
Furnace height
High loadOXY
High load AIR
15 test weeks
Runs: 88 of which
35 in air combustion
53 in oxy combustion
Test program at CanmetENERGY, Ottawa
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Demonstration runs at a 30 MWth CFB pilot plant
TECHNICAL &
INDUSTRIAL
BUILDINGS
DCS
PC BOILER
GASES RECIRCULATION
AND MIXTURE
CFB BOILER
CO2 COMPRESSION
& PURIFICATION
FLUE GAS CLEANING
FUEL
PREPARATION
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FLY ASH
SILO
FLY ASH
FEEDING SYSTEM
LIMESTONE
SILOLIMESTONE,
DeSOx
LIMESTONE
FEEDING SYSTEM
SAND SILO
SAND FEEDING
SYSTEM
FUEL SILO
FUEL FEEDING
SYSTEM
NATURAL
GAS
START-UPBURNER
SKID
BOILER FEED
WATER
FLUE GAS
BOTTOM ASH
FLY ASH
SYSTEM
PRIMARY
OXIDANTFAN
SECUNDARY
OXIDANTFAN
MIXER
FLYASH
RECIRCULATION
LIMESTONE
SAND
FUELFEED
AMMONIA,
DeNOx
MIXER
MIXER
CB1
CB2
OXYGEN
CIRCULATING FLUIDIZED BED BOILER FLOW DIAGRAM
Demonstration runs at a 30 MWth CFB pilot plant
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17
01 03 04 05 0602 07 09 10 11 1208
20122011
FLEXI BURN
TEST PERIOD
01 03 04 05 0602 07 09 10 11 1208
PLANNING OF
TEST MATRIX
CFB FUNCTIONALITY
TEST
FLEXI BURN
PROJECT DEADLINE
COMPILATION OF
RESULTS
Demonstration runs at a 30 MWth CFB pilot plant
NEXT STEPS
CFB CONSTRUCTION
& COMMISSIONING
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Plant size:
Specifications for a FLEXI BURN CFB
demonstration plant
Two cases considered:
Flexi Burn CFB demonstration plant:
300-350 MWe gross. (Detailed technical scope, main focus)
Full Commercial plant - post-2020:
800 MWe gross (techno-economical feasibility study)
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Operating parameters:
Dynamic requirements for the power plant
Operational Mode Base Load
Load change rate Max ramping 4%/min
Minimum load 40%
Start-up time (cold)
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Other oxycombustion criteria:
Air inleakage: Base case 1% (sensitivity analysis up to 3%).
O2/CO2 ratio: close to air concentration (24% O2 wet).
Oxygen purity:
Oxygen purity 96,6 % volPressure 1,2 bar
Temperature 20 C
Specifications for a FLEXI BURN CFB
demonstration plant
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Current status (1/2)
During the first half of the project a lot of experimental work has been carried out inorder to support the development of FLEXI BURN CFB concept
Combustion tests in different scales and field measurements in a commercial scale
power plant provide a base for development and validation of the design tools needed
in the concept development
Large scalehigh efficiencyCFB boiler with
FLEXI BURNdesign
Fuel
Bituminous coalLigniteBiomassPet coke etc.
Air SeparationUnit (ASU) Mixing
AirSwitch
Fluegas(CO2-rich)
Flue gas recirculation
Switch
Stack
95-97% O2
Flue gascleaning
CO 2 capture and storage (CCS)CondensationCompressionPurificationTransport
Storage
Demonstration tests at different scales:
VTT 0.1MW, CANMET 1MW has beencompleted (totally over 100 test balances)
with encouraging results
If flue gas emissions are expressed inmilligrams per megajoules the emission levels
between air- and oxygen-firing have not
remarkable differences
Emission limits based on the concentrationsand volumetric units are not applicable for
the CCS processes. Emission limits in CCS
applications should be expressed in energy
basis.
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Current status (2/2)
The basic design parameters for a FLEXI BURN CFB plant, from a
technical and functional point of view, have been determined
Two cases considered: 1) Flexi Burn CFB demonstration plant: 300-350 MWe gross
2) Full Commercial plant - post-2020: 800 MWe gross
The initial conceptual design of the FLEXI BURN CFB boiler has been
developed
The first conceptual design for the FLEXI BURN has been
implemented including a preliminary integration with the Air Separation Unit
(ASU) and the Compression and Purification Unit (CPU)
Boiler
CPUASU
Steam
Cycle
Oxidant Flue gas
IntegrationIntegration
Power Utilities Power Utilities
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Next steps
The second test campaign at Lagisza Power Plant is carried out during thefirst half of 2011
Demonstration tests at CIUDEN in the beginning of 2012
Concept optimisation for the boiler island and the integrated power plantunit including dynamic simulation of the plant
Health and safety assessment related to oxygen-firing conditions
Estimate economics for the new concept and evaluate their feasibility on acommercial scale range
Identification of the key success factors of the FLEXI BURN CFB technologycovering the process efficiency, operability, maintainability, environmental
impact and responsiveness to the market requirements, all leading to the
economic performance of this new approach for power generation
Co-operation with Utilit y Advisory Panel (UAP)
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FLEXI BURN CFB - Summary
1) What has been achieved, what do we now know and what can we now do, technically and commercially? Flexible operation under air- and oxygen-firing modes have been successful demonstrated in the small
scales (0.1MW-1MW)
The first validation test campaign with the world first and the largest (460 MWe) OTSC-CFB has beensuccessfully completed
2) What is NOT yet achieved?
Final concept and demonstration in the large scale (30MW-300MWe)
3) What are the next logical steps, i.e.: what do we still need to do within the subject of the presentation
towards the implementation and commercialisation of CCS?
Next logical steps: demonstration tests at CIUDEN (30MW) and development of final concept for 300MWe Development of 2nd generation oxyfuel concept with significantly higher overall plant efficiency Transportation and storage part is not in the scope of the project but it will be the key issue in the
implementation and commercialisation of CCS
Emission limits for CCS plants must be reconsider (concentration based limits are not valid)
4) Who do you think is best placed to take these next steps forward?
Demonstration of FLEXI BURN CFB concept: FLEXI BURN CFB consortium and OXYCFB300 consortium Development of 2ndgeneration oxyfuel concept: Organizations who have been involved in the
development of the 1st generation oxyfuel concepts
Transportation and storage: all together, public acceptance and political decisions are very important Emission limits for CCS: European Commission is working on the issue
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FLEXI BURN CFB Workshops
1st Flexi Burn CFB Workshop was held in Brussels 24th March 2011
More information:
http://www.vtt.fi/sites/flexiburncfb/
2nd FLEXI BURN CFB Workshop will be held in summer 2012
highlighting the final results of the project
Welcome!
Thank You !
http://www.vtt.fi/sites/flexiburncfb/http://www.vtt.fi/sites/flexiburncfb/