Feng’s 5E Technology
A Major Step Forward
in the Advancement of Clean Coal Technology
Net efficiency reached 46.5% - Next step 49%
Ensuring Safety
Energy Saving
Efficiency Preservation
Environmental Protection
Elevated T-G Unit Technology
Forest Power & Energy Holdings
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Mr. Weizhong Feng is the general manager of both Shanghai Waigaoqiao No. 3 Power Plant and Shanghai Shenergy Energy Technology Co., Ltd.
His other appointments include:
Professor of Tsinghua University, Shanghai Uniersity of Electric Power, and North China Electric Power University;
Vice Chairman of China Energy Society;
◆ Member of the Boiler Committee, Chinese Society of Power Engineering;
◆ Member of the Turbine Committee, Chinese Society for Electrical Engineering;
◆ Vice President of the Automation Committee, Shanghai Society for Electrical Engineering.
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Mr. Feng also has many patents to his name. As the licensor of more than ten patents, he has created a series of technologies
which have been coined as "Feng's 5E Technology".
Ensuring Safety
Energy Saving
Efficiency Preservation
Environmental Protection
Elevated T-G Unit Technology
Environment
nm
ment P
Prrrotection
otection
Efficiency
y Preservation
Energy Sav
ving
Ensuring Safety
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Mr. Feng first joined in the power industry in 1971. Four decades later, his criticalthinking, problem-solving skills and ability to apply engineering solutions in a large scale
has earned him numerous inventor's patents and national and international awards. Mr.
Feng has successfully designed and deployed a portfolio of technologies for the coalfired power industry. His 40 years of experience and his leading talent have molded him
into an exceptional manager.
Many technologies conceived by Mr. Feng are employed in Waigaoqiao Phase III power
plant. These inventions include Energy Saving, Efficiency Preservation, Environmental
Protection, and Elevated T-G Unit Techology. In fact, his energy saving technology set a
new record of coal consumption in power plants. Mr. Feng, with all of these innovations
combined, will revolutionize the coal-fired power plant industry.
Mr. Feng has published 42 academic thesis. His research interests are on the power
generation of ultra-supercritical (USC) unit as well as the energy saving and emission
reduction of coal-fired power plants.
Mr. Feng is:
1. A well-rounded scholar
His research covers various fields in the power industry, such as: boilers, turbines,
electrics, thermal control, metals, system designs, construction, commissioning and
operations. These require a thorough understanding in subjects such as: mathematics,
computer science, simulation, thermodynamics, heat transfer, material mechanics,
fluid mechanics, electro-technology, electronics, etc. His persistence in self-learning
has lead to his comprehensive knowledge of the power industry.
2. A man who capably integrates theories with practice
As a professor at several universities, he has profound theoretical knowledge and
strong research capability. At the same time, he is experienced in the management of
coal-fired power plants and the construction of large-scale power projects. Due to this,
he is able to integrate his field experience into his research.
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3. A man who is knowledgeable about power plants
Mr. Feng is well aware of majors and systems related to power plants, thus every
power plant under his management can be maximally optimized.
4. A man who is able to scientifically implement his theoretical breakthroughs
None of Mr. Feng's many patented technologies came into existence by accident or
chance. Each of his discoveries were developed theoretically, then tested in wellplanned trials and scientifically implemented. By verifying each theory scientifically, he
is able to ensure that his innovative technologies will not fail.
5. A man who is able to lead and train a talented technical team
Under Mr. Feng's leadership, his team members have acquired good work ethics
and strong implementation skills. Mr. Feng's concepts have been able to be carried
out successfully and efficiently with his well-trained team. Through the time the team
members are with Mr. Feng, they have become key personnels in his corporation and
are recognized as specialists in this industry.
Achievements:
As the director in charge of the construction of phase I (4x300MWe), phase II (2x900MWe)
and phase III (2x1000MWe) of Waigaoqiao Power Plant, Mr. Feng has greatly improved,
optimized, and innovated the system design, equipment and commissioning process, due to
which the comprehensive performance of these units is far superior than their original design
and their peers. Waigaoqiao Phase III (2x1000MWe) was put into commercial operation in
2008. The accumulated net efficiency under an average annual load rate of 75% reached
43.53% in 2009 (include FGD, SCR, and the annual circulating cooling water temperature
was from 7 to 33 ). Because of this Waigaoqiao Phase III became the benchmark for all
coal-fired units in the world. Furthermore, as a scholar and a scientist, Mr. Feng has made
a number of great breakthroughs in theoretical research and applied new theories like
General Application of Extraction Energy and Comprehensive SPE Prevention. As his new
inventions such as "Energy Saving High Efficient De-dust Technology", "Energy Balanced
FGD Technology", "Energy Saving High Efficient Whole Day SCR Technology" and "Safe,
Energy Saving, Lifetime Extending Technology of SCR Catalyst" have been implemented
successfully on these units, they have greatly improved the efficiency and environmental
protection. In 2011, the accumulated net efficiency at yearly average load rate of 81% was
promoted up to 44.5% under otherwise equal conditions, which means the net efficiency in
rated operation has reached 46.5%.
Mr. Weizhong Feng has had the following reports in international conferences in recent years:
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“The Comprehensive Management of Steam Oxidization and Solid Particle Erosion for Ultrasupercritical Units”, international conference for supercritical coal fired unit operation and
technology development, organized by ImechE, London, England, January 2007.
“The Energy Saving Technologies of 1000MWe USC in Waigaoqiao Phase III projects”, SinoJapan annual symposium of science and technology, Osaka, Japan, November 2009.
“The Current Situation and the Development of China’s Supercritical Units”, clean coal
conference, Clearwater, USA, June 2010.
“Energy Saving, Optimization and Innovation of the Ultra-supercritical units”, No. 5
Comprehensive Forum of Sino-Japan energy saving and environment protection, Tokyo,
Japan, October 2010.
“The Research of the New Advanced High Efficient Ultra Supercritical Power Generation
Technology”, Coal-Gen Europe 2012, Warsaw, Poland, February 2012.
“Challenging the Efficiency Limitation of the Existing Coal Fired Power Technology”, IEA
CCC Workshop on upgrading and efficiency improvements in coal fired plants, Melbourne,
Australia, April 2012.
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Feng's 5E Technology has been successfully implemented at the Shanghai Waigaoqiao Phase III power plant. This power plant is one of the first 1000MWe class ultra-supercritical
projects in China. Its boilers and turbines were manufactured by Shanghai Electric Corporation (SEC) with ALSTOM and SIEMENS Technologies.
Unit parameters:
Main steam pressure: 28 MPa. Main steam/hot reheat steam temperature: 605
/ 603
Rated steam flow: 2732 t/h. Rated output: 1000MWe.
With Feng's Energy Saving, Efficiency Preservation, Ensuring Safety, Environmental Protection technologies, this power plant has achieved:
Net efficiency 46.5% (including FGD, SCR, under 20 average circulating cooling water);
No efficiency reduction, boiler tubes and turbine blades as good as new;
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◆ Successful FCB tests on March 18 , 2008 and May 21 , 2008;
◆ Energy saving high efficient de-dust, energy balanced FGD, and energy saving high Efficient whole day SCR, energy saving lifetime extending of SCR catalyst, and no blockage
no corrosion of Air Preheater.
With the successful implementation of Feng's Elevated T-G Unit Technology:
◆ the net efficiency will be promoted up to 49%.
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Ensuring Safety
- FCB (Fast Cut Back), Run Back to the House Load
I. Significance of FCB
FCB technology is a rather complicated system technology.
It is well known that the power grid may break down due to accidents, bad weather, war, etc. All thermal power plants are out of operation when the power grid breaks down and
cannot re-start without an external power supply. This leads to large-scale blackouts, or power-outages. In August 2003, North America encountered a massive power failure. Then in
2012, Hurricane Sandy hit the northeast USA, resulting in another major historical blackout. Washington, USA and India also experienced large-scale power-outages in 2012.
The destruction caused by a large-scale blackout is no less than that caused by a hurricane. When a power grid collapses and cannot restore a power supply, the resulting power
failure both directly and indirectly causes disastrous consequences.
However, units with an FCB function are able to disconnect with the grid immediately when the power grid fails and run back to the house load operation. This allows the unit to
restore power supply to the customers and other units in the same grid as soon as the faults are cleared, which greatly enhances the safety of the power grid. The technology has
been implemented successfully in Shanghai WGQ III power plant.
Major features of FCB:
Recover the power grid in minutes when it breaks down, thus guarantee the safety of power grid;
Ensure the safe and economic operation of power plants;
◆ Minimize the consequence caused by accidents, realizing fast cut back to house load, turbine running while generator out of operation, boiler running while turbine trips and
restarting quickly when the failures are cleared;
◆ Minimize the probabilities of boiler shut-down, prevent drop of oxides and shorten the recovery time of the units.
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II. Implementation of FCB
Relative systems configuration and system design optimization:
1. Unit interlock principle-Fast cut back; turbine run while generator out of service;
boiler run while turbine tripped;
2. Suitable configuration of bypass and reheat safety valve;
3. Suitable configuration of feed water pump, deaerator, condenser and HP heaters;
4. Suitable operation mode and system design;
5. Suitable control strategy and electric protection.
III. Successful Trial Operation of FCB
Waigaoqiao Phase III Power Plant has successfully implemented Feng’s FCB technology
in its two units and FCB tests from the full load performed in March 18th, 2008 and May
21st, 2008 demonstrated the wonderful traits, thus it becomes the unique utility in China.
The successful application of FCB ensures the safe and sufficient power supply in
Shanghai, which makes Shanghai more beautiful and bright !
Forest Power & Energy Holdings
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Energy Saving
As one of the core technologies, Feng’s Energy Saving Technology is based on a deep
understanding of the power plant, and takes the power plant as a whole living system.
It is a combination of series technologies and can greatly enhance the efficiency of the
power plants.
The technology has been applied in 2 ×1000MW USC Units in Shanghai Waigaoqiao
Phase III power plant and the net efficiency (with FGD and SCR) of the units was
enhanced to 46.5% from 43.5%. Here is the simple introduction:
I. Rotary Air Preheater All-round Flexible Sealing Technology
Key: Seals with controllable wearing rate are installed in the direction of radial, axial
and circle. By taking advantage of the flexibility and contactable function, it can
compensate the non-linear variation of clearance between dynamic and static
seal, realizing the all-round seal of air preheater.
Advantage:
Without changing the configuration of the original equipment, the all-round flexible
seal can cover the clearance for air-leakage between dynamic and static seal. This
compensates the deformation of rotor and the non-linear variation of clearance.
With controllable rate of wearing, this technology performs quite reliable.
the unit startup process can be accelerated. This can save large amounts of oil
and coal, which helps protect the environment. In addition, during the heating of
the boiler, its auxiliaries need not run, and the station power can be cut down.
Meanwhile the boiler firing can be improved significantly and its startup procedure
becomes very simple and safe. This technology can be used in all kinds of startup.
Reference in Waigaoqiao Phase III power plant
◆ Start-up time ≤ 2 hours( including cold start-up);
◆ Oil consumption ≤15 tons;
◆ Power consumption≤ 80,000kWh;
◆ Coal consumption≤ 200 tons (include the steam used for heating).
Economy:
This technology works best for new units and the investments can be recovered
during the trial operation due to many times of startup and shutdown for
commissioning. For units that are already in operation the investment can be
recovered after 5 to 8 times of boiler starts up.
Experiment in Waigaoqiao No. 3 power plant
◆ The air leakage rate of air preheater and power consumption for the boiler fans
were greatly reduced;
◆ With FGD and SCR operation, the station power rate was reduced to less than 3.5%;
◆ The thermal efficiency of boiler was enhanced;
◆ The efficiency of the unit was enhanced by 0.37%.
Economy: The cost can be recovered in 3 years.
II. Brand New Type and Unconventional Boiler Start Up Technology
Key: This technology changes the conventional boiler startup method, by using steam
instead of oil to heat up the boiler. The feedwater of the startup unit can be
heated up by the available steam in the power plant and the whole boiler can
then be warmed up by the feedwater and again by the generated steam in the
evaporator. Before ignition, the boiler is warmed up uniformly to a certain degree
and pressurized. When the boiler fans start up, the hot air which recovered heat
from the flue gas system will be sent to the furnace and provides better condition
for the boiler combustion.
Advantage:
By taking advantage of the available steam in the power plant to heat the boiler,
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III. Energy Balanced FGD Technology
Key: A special flue gas heat recovery device is installed between the booster fans and the FGD tower. The recovered heat is then sent back to the turbine regeneration system
for more output of the unit. Therefore, the reduced heat rate of the turbine can offset the power consumption of the FGD facilities. By improving the operation mode and the
process, the power consumption of FGD during the rated operation can be balanced.
Advantage:
This specially developed heat recovery device is a kind of equipment with anti-dewing, anti-corrosion and anti-blocking function for the heating surface. It also collects the heat
generated by the ID fan and the Booster fan during their operation. Through the optimization for the system design and the operation mode, the power consumption of the FGD
facilities is reduced to less than 0.8% during its rated operation.
Reference in Waigaoqiao Phase III power plant:
◆ Net efficiency enhanced by 0.4%;
◆ Water spray to the desulfurization tower reduces 45 T/h.
Economy: The cost can be recovered in 3 to 4 years.
IV. General Application of Extraction Energy Technology
Key: By expanding from the classic regenerative cycle based on the feedwater to general regenerative cycle on the input to the boiler (i.e. water, air and coal, etc.), the boiler firing
efficiency increased and at the same time the turbine exhaust loss reduced.
Advantage:
During unit operation, to fully take advantage of the extraction steam in
stead of the fuel, the unit total efficiency can be enhanced, the boiler firing
condition can be improved, and the firing efficiency will be better as well.
During the startup of the unit, to speed up the process of igniting and putting
the coal system into operation with Feng’s brand new startup technology, the
stable firing and lower load running of the boiler can be reached, at the same
time the dewing and blockage of the air preheater can be avoided.
Reference in Waigaoqiao Phase III power plant:
Efficiency enhanced by 0.62%;
The safe operation can be reached.
Economy: The cost can be recovered in 3 to 4 years.
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Energy saving itself is emission reduction and it not only
benefits energy consumption, but also the environment
protection and the whole society!
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Waigaoqiao No. 3 Power Plant Energy Saving Pie Chart (Eff. increment: %)
Efficiency Preservation
- SPE Prevention Technologies
I. Significance of SPE Prevention
With the increase of the steam parameters, especially the steam temperature, new problems and challenges are encountered, that is steam-side oxidization of the tubes and pipes,
and subsequently SPE (solid particle erosion) of the turbine blades, which substantially threatens the safe and economic operation of the units. The following pictures show the
destruction to the equipment of some other power plants.
Bypass Valve Plug Eroded by Solid Particles
Turbine blades Eroded by Solid Particles
Tube Blocked by Oxide Scales
Steam-side oxidization of boiler tubes will make the heat transfer worse, and as tube-wall temperature rising, the oxidization will become more serious. The oxide peeling off will
decrease the flow area of the tubes. It may even cause blockage in the tubes, which may lead to overheating and explosion of the boiler tubes. Solid particle formed by the oxides will
also erode the turbine blades and the bypass valve plugs, thus decreasing the efficiency of the unit. While the erosion of blades is inconvertible, the longer the unit operates, the less
efficient the turbine becomes. SPE issues are common for the newly constructed supercritical and ultra-supercritical units in China. Overheating and explosion of boiler tubes caused
by oxide blocking occurred frequently. In the most severe case, the unit efficiency decreased by 8% within three years of operation.
SPE is a worldwide problem that has been disturbing the supercritical technology field for decades. However, Feng’s technologies can offer a thorough solution.
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Key Points of SPE Prevention
Inspiration from Holistic Remedy with Chinese Traditional Medicine, we have developed a whole set of comprehensive
prevention technologies for steam side oxidation and SPE.
General Strategy:
To prevent and slow down the oxidation;
To avoid oxides from peeling off;
To blow out the dropped oxides from the boiler tubes as soon as possible and avoid them into turbine;
To alleviate the erosion of the turbine blading by solid particles.
Prevention Technologies of SPE cover series of innovation and improvement of units in system design, equipment
selection, construction & commissioning, control strategy, startup procedure and operation mode, etc.
The turbine blading of Waigaoqiao III after 30 months
running
II. Reference of SPE Prevention in Waigaoqiao Phase III Power plant
SPE Prevention Technology had been implemented successfully in two 1000MW units of Shanghai Waigaoqiao Phase
III Power Plant. After 30 months operation of the boiler, the inspection showed that the superheater and reheater tubes
insides are smooth and as good as new. There is no any sign of oxides hoarding and peeling off. The inspection of
the turbine also indicated that blades in the HP casing and IP casing are also as good as new. That means the turbine
efficiency kept unchanged from the first startup. No doubt that there is no any leakage in the bypass valves.
The boiler tubes of Waigaoqiao III after 30 months running
The inside of reheater tubes
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Environmental Protection
Feng’s environment protection includes"Energy Saving High Efficient De-dust Technology", "Energy Balanced FGD Technology", "Energy Saving High efficient Whole Day SCR
Technology", and "Safe, Energy Saving, Lifetime Extending Technology of SCR Catalyst", "Anti-Blocking and Anti-Corrosion Technology for Air Preheater".
I. Illustration of Environmental Protection
1. Energy Saving High Efficient Series of De-dust Technology
◆ The total flue gas has been greatly declined by reducing the leakage of the air preheater, applying high efficient lower oxygen combustion technology and improving the unit
efficiency;
◆ Modify the power supply unit of the electric precipitator by applying high frequency power technology. Change the nominal working frequency to the high frequency operation,
and further optimize and adjust the power supply and operation mode of the electric precipitator.
2. Energy Balanced FGD Technology
◆ The power consumption of FGD facilities is reduced to less than 0.8% during its rated operation by optimizing its system design and the operation mode;
◆ Applying a special heat recovery device, the heat in the flue gas and the heat generated by the ID fan and the Booster fan during their operation can be collected. The
recovered heat can fully offset the power consumption of the FGD facilities.
DeNOx vs. Operating hours (NH3 slip: 3ppm wet)
3. Energy Saving High Efficient Whole Day SCR Technology
◆ To modify the turbine and thermal system, the extraction steam can be increased during low load
operation. This can relatively improve the feedwater temperature in boiler low load and the flue gas
temperature can be enhanced. At the same time, to adjust the boiler heating surface, the catalyst can
run in the safe condition and in the high efficient area during the unit whole load range.
4. Anti-Blocking and Anti-Corrosion Technology for Air Preheater
◆ Expanding the philosophy of regeneration, to improve the intake air temperature can remarkable lift the
average operation temperature of the heating surface in cold end of the air preheater. Thus the dewing
area can be depressed so that the dewing and clinging speed dropped. To ensure the flushing by the flue
gas stronger than the clinging of the attachment, the blockage of the air preheater can be avoided. At the
same time, the corrosion can be easily solved.
5. Safe, Energy Saving, Lifetime Extending Technology of SCR Catalyst
◆ Applying Feng’s brand new startup technology, except for the advantages mentioned in Energy Saving,
catalyst poisoned, carbon and ash deposited, and catalyst sintered, hydrates formed on its surface will
be avoided. The operation lifetime of the catalyst can be extended greatly.
II. Advantage
Feng’s series of environment protection technologies cover de-dust, FGD and SCR and can realize high efficient environment protection based on energy saving. These technologies
have predominant advantages on both economy and environment.
g Surface of Air Preheater
Heating
III. Reference in Waigaoqiao Phase III Power Plant
The emission is greatly reduced
Emission of dust: 11mg/m3
Emission of SO2: 60mg/m3
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◆ Emission of NOx ≤ 30mg/m
◆ SCR efficiency≥89% (40%-100% load)
◆ Preventing the corrosion and blockage of air preheater
◆ Extending the lifetime of SCR catalyst
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Elevated T-G unit technology
I. The Significance of Project:
Improving the coal utilization rate in the thermal power is the effective way to reduce the flue gas pollutants and CO2 emission from their roots, which is also the orientation of the
development of high efficient clean coal power in the world. Feng’s patent technology “a kind of cross-compound steam turbine in a manner of high and low position arrangement”
(ZL-2007-2-0069418.3) arose at the right moment.
The research shows that adopting the above-mentioned patent technology can greatly improve the efficiency of the unit. And the heat rate can be decreased by 5%. Combined with
the Feng’s technology innovation achievements, which have been successfully implemented in two units of Shanghai Waogaoqiao No.3 Power Generation Co.,LTD, the net efficiency
(includes FGD and SCR) of thermal power unit can rise to an epoch-making level of 48.92% on the existing steam parameters 600 level and the circulating water temperature 20.
Once the material for 700 matured, the unit net efficiency can further go up to more than 52%.
II. The Key Technology:
Applying the patent technology “a kind of cross-compound steam turbine in a manner of high and
low position arrangement”, this advanced high efficient ultra-supercritical power plant technology is
a double reheat unit in a cross-compound manner, where the first turbine generator train including
HP&IP1 casing is located near the boiler headers, the second turbine generator train with IP2 &
LP casing and the condenser in the conventional turbine house. The figure on the left shows the
conception design.
Through the above mentioned design, the length of the critical piping can be greatly shortened, that
leads to the tremendous cut in the consumption of the metallic material for the high pressure and
high temperature. Meanwhile, the pressure drop and the heat loss can be reduced enormously.
Based on this concept, double reheat which can remarkably improve the unit efficiency while with
high investment in the conventional design can be reconsidered.
Efficient Ultra Supercritical Plant
Conception Design of Advanced High Efficient
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III. The Project Expectation
1. The effect of energy saving & emission reduction
Combined this technology with Feng’s series of energy saving technologies, the unit net efficiency
can be increased at least to 48.92% (the net standard coal consumption rate is 251 g/kWh). Thus,
compared with the existing conventional 1000MW ultra supercritical units in China, one unit can save
223,000 tons of standard coal per year. It annually reduces 588,000 tons of CO2 emission, 16,400
tons of SO2 emission and 164 tons of NOx emission.
2. Providing a basis for the development of 700
USC technology
700 advanced USC units will use a large quantity of quite expensive nickel-based alloy material. In
order to cut down the Nickel-based material to the minimum, this compact layout would be applied in
the future by 700 advanced technology. Thus high temperature alloy material consumption will be
greatly reduced.
This technology provides the best solution for the design of 700 parameter units under the currently
feasible condition of 600 parameter. So it can become a wonderful attempt and technical reserve
for 700 USC units.
IV. Evaluation
After a deep study of this technology, Siemens has given a high compliment. Dr. Roland Fischer CEO of Siemens Fossil Power Generation stated in his letter that “This concept with
the unique chance to significantly increase efficiency is supporting the reform of a high pollution into a low emission green industry”, “Siemens highly appreciates
this concept. We see it as a consequent continuation of leading coal-based power plant technologies in the world. In case this concept gets a real project, it would
make China the world’s technology leader for the steam power plants”.
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Forest Power & Energy Holdings
Forest Power & Energy Holdings, Inc. and its member companies
are dedicated to the advancement of clean coal technologies as
they are related to energy, environment, sustainability, and security.
Forest Power & Energy Holdings, Inc. is the North American
distributor for Feng's 5E Technology.
Please direct all inquiries to Forest Power & Energy
Holdings, Inc.
6820 Easthaven Boulevard
Houston, Texas 77017
United States of America
Tel: 713-947-2610
Fax: 713-947-2673
http://www.forestpeholdings.com