FEL1 and 2 - The Beginnings of Successful Paper Machine Conversions

摘要

Paper machine conversion projects to alter the machines' major product grades continue to be a prevailing trend in the paper industry. In recent years, the major pulp and paper companies and the professional service firms that provide consulting and engineering to them have adopted a Front-end Loading (FEL) project engineering process similar to other process industries. Effective use of the FEL process can guide companies methodically and consistently to optimize the use of capital project funds. This paper reviews the initial phases of successful paper machine conversion engineering efforts. These phases, the FEL1 and FEL2, are often referred to as the Feasibility Analyses and Conceptual Design phases of the project. An overview of the FEL process and its deliverables, with examples pertaining to converting papermaking operations from producing one grade to another are presented. While others have presented the overall FEL concept to the industry, this paper focuses on the important initial phases where the business case is made, and major technical options are explored and narrowed. Considerations that are particular to paper machine conversions, as well as project approach and stage deliverables are documented. Major sections include: 1. Introduction - including an overview of recent machine conversions and a brief review of phased engineering processes 2. Safety and confidentiality - engagement of paper machine suppliers and others 3. Feasibility phase team selection and process approach with specific examples pertaining to paper machine conversions 4. Feasibility phase deliverables including studies, project definition, risk summary, project milestones, and order-of-magnitude total construction cost estimate 5. Conceptual Phase process approach including technical options and considerations involved in machine conversions 6. Conceptual phase deliverables including design basis, studies, technology comparisons and recommendations, drawings and documentation, project schedule, project scope, and preliminary cost estimate 7. Summary and machine conversion project path-forward.