Plant Layout

You cannot underestimate the benefits of a properly designed plant. Providing the ideal synergy between raw materials, manufacturing processes, available space and output, it is the basis for the effective management of personnel, equipment, maintenance and materials. A well laid-out plant will be a safer plant. A more productive plant. A more efficient plant. A more flexible plant. Basically, it’s not something you want to get wrong.

Why KHD?

There are not many companies that can bring over 160 years’ experience to cement plant design. We are one of them.

Do you want an OEM that can look beyond its own equipment and see the big picture? An OEM that understands not just how equipment and process design impact plant costs and performance, but plant layout too? The KHD is the OEM for you.

As the old builder’s adage goes, ‘measure twice, cut once’. It sums up our approach to plant layout. Accurate and thorough planning is essential to ensure the most effective approach to plant construction, operation and maintenance. Getting it right on the drawing board will save a lot of headaches later on.

On the flip side, our experience in plant layout allows us to avoid the pitfalls of over-engineering and provide the appropriate balance between accuracy, safety and cost.

With hundreds of projects under our belt and decades of experience erecting plants around the world, we have rare insight into what makes a successful plant layout. In practice, this means we can deliver plants that operate at lower costs, can be delivered in shorter lead times, can produce a range of products, and ensure consistently high product quality.

We can also cope with almost any topography, temperature, height above sea level, or local building regulations, and work closely with other high-quality third-party manufacturers to offer the complete ‘big picture’ plan of your plant. The result is a plant layout that integrates exactly to your unique operational characteristics and circumstances, as cost-effectively as possible.

Core objectives of plant design

Any plant design must meet applicable standards and regulations, production goals, and CAPEX limits, while offering competitive OPEX. To do so, we consider a wide range of factors including how best to use space, optimize material flows, and select the most suitable of available equipment options. We can also recommend the most appropriate positioning of third-party equipment, e.g., material storage, packing plants.

What we provide

Successful plant design combines engineering theory with real-world experience of what will work – and what won’t.

The success of a plant design is tied not only to economical plant construction, operation and maintenance, but also to its ability to adapt to evolving customer demand, technologies, and environmental regulation.

The process starts with the development of an initial process design, based around a basic set of specifications. Appropriate selection of equipment follows. Everything is then combined into an engineering plant design that includes all aspects of the development of the plant – whether a greenfield newbuild or brownfield upgrade.

That’s the simple explanation. It’s a lot more complicated in practice! Errors are easily made. When you choose us to provide your plant layout, however, we can help avoid many of these mistakes with state-of-the-art design practices including:

  • Accurate 3D measuring to avoid problems during design and erection of upgrades to existing plants.
  • Immersive 3D models to show planned changes.

Projects can be fulfilled on an engineering and procurement (EP) basis or, with our Chinese parent company, AVIC, on a turnkey EPC basis. In this later approach, we combine KHD’s engineering excellence with AVIC’s commissioning skill and speed to ensure accurate and timely project execution.

We can also offer both European and Chinese manufactured equipment, depending on your project specifications.


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