Haldor Topsøe is a globally recognized company in the field of heterogeneous catalysis, which involves catalytic elements such as monoliths, that reduce harmful toxins in internal combustion engines. In an attempt to expand its market share, Haldor Topsøe decided to build a factory in southern Brazil’s Santa Catarina region. The factory would specialize in finalizing untreated monoliths in an impregnation and calcination process, preparing them for delivery. Haldor Topsøe collaborated with DIS/CREADIS to develop a simple production line and impregnation machine specifically for the Brazilian factory.
Developing an impregnation machine that met the Brazilian factory's specifications posed several challenges. The machine had to handle three monoliths at a time, unlike the machine developed for the Chinese market that only had to handle one at a time. Additionally, it had to place the monoliths with a maximum deviation of 1 mm, a requirement that placed high demands on the mechanical design and the PLC software. DIS/CREADIS had to develop a solution that could handle items up to 530 mm within the necessary precision, which required material handling function testing in DIS/CREADIS's Aarhus, Denmark workshop.
In cooperation with Haldor Topsøe, DIS/CREADIS developed a user-friendly interface for the impregnation fluid's mixing system from Topsøe's P&I diagrams and calculation input. DIS/CREADIS also prepared all drawings and electrical documentation and programmed the impregnation machine's user interface. The machine was designed to handle three monoliths at a time and place them with a maximum deviation of 1 mm. This requirement demanded a mechanical design and PLC software that could handle high precision, resulting in a material handling function test in the workshop at DIS/CREADIS in Aarhus, Denmark. The testing proved successful, and the system was able to handle items up to 530 mm within the necessary precision.
Haldor Topsøe chose to collaborate with DIS/CREADIS for the second time because of their previous successful work in developing specialty machines for the company. DIS/CREADIS’s consultants contributed positively and flexibly, and their work was delivered on time and performed at a high level. As a result, Haldor Topsøe chose DIS/CREADIS to develop a solution for the Brazilian factory, demonstrating DIS/CREADIS’s ability to deliver high-quality solutions tailored to customer requirements.
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