The forming process of phosphate-bonded high alumina bricks is different from that of ordinary sintered refractory bricks. Its bonding system is special, requiring no high-temperature firing but only medium-temperature heat treatment to solidify the bonding phase. Therefore, the density and uniformity of the green body during the forming stage almost determine the final performance of the finished product. In the industry, high-quality phosphate-bonded high alumina bricks require stable volume density, no delamination or cracks inside, intact edges and corners, and minimal density fluctuation within the same batch to meet the long-term wear resistance, anti-spalling, and anti-corrosion requirements under high-temperature conditions.

Relying on decades of refractory forming process experience, Zhengzhou Haloong has deeply adapted to the semi-dry material forming characteristics of phosphate-bonded high alumina bricks and specially optimized the servo screw press. It has abandoned the traditional transmission shortcomings and adopted a three-in-one technology of permanent magnet synchronous servo motor direct drive, static pressure transmission, and intelligent numerical control system to create a dedicated forming solution, ensuring uniform density, density meeting standards, and no internal stress defects of the green body. The equipment performance is on par with international high-end standards and has become the preferred equipment for phosphate-bonded high alumina brick production enterprises at home and abroad.

The core adopts the permanent magnet synchronous servo motor direct drive technology, completely eliminating the traditional clutch and friction disc transmission structure. The transmission chain is shorter, and there is zero energy loss in energy transmission. The equipment is equipped with Haloong's independently developed intelligent pressure control system, which can digitally and precisely preset the striking energy, pressurization speed, and forming times through the numerical control panel. The energy repetition control accuracy is ≤±1%, ensuring that the pressure in each forming process is highly consistent and completely eliminating the pressure fluctuations caused by manual operation and mechanical transmission. According to the raw material characteristics of phosphate-bonded high alumina bricks, a stepwise pressurization process can be flexibly set, first applying light pressure to exhaust air and then applying stable pressure to compact, ensuring that the density of the green body is completely uniform from the center to the edge and from the surface to the inside, with the volume density fluctuation range controlled within a very small range, and the density variation coefficient is far lower than the industry standard, significantly improving the consistency of the finished product strength.

It adopts a fully enclosed static pressure screw, nut, and bearing transmission structure. During operation, a stable oil film is formed for protection, achieving flexible and uniform force transmission and pressure application, avoiding the impact force and stress concentration caused by traditional rigid pressurization. The pressurization process is smooth and controllable, allowing for the full expulsion of air inside the green body, ensuring that the aggregates and binders are evenly bonded and tightly compacted. This eliminates problems such as delamination, micro-cracks, and loose edges and corners of the green body from the root, ensuring the integrity of the overall structure of the green body. At the same time, the equipment operates with low vibration and noise, further ensuring the stability of the forming process, significantly reducing the green body rejection rate, and improving the product yield rate.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a progressive forging forming mode. According to the specifications, dimensions, and shapes (standard bricks, special-shaped bricks, thickened lining bricks, etc.) of phosphate-bonded high alumina bricks, the stroke of the slider, the pressurization depth, and the pressurization angle can be flexibly adjusted. There is no need to worry about the uneven pressurization caused by deviations in raw material filling or complex shapes. Whether it is conventional standard bricks or customized special-shaped wear-resistant bricks, it can achieve uniform pressure application throughout the area, ensuring that the edges and corners are also compacted and dense, perfectly meeting the production needs of enterprises for multiple varieties, small batches, and customization. Combined with a rapid mold changing system, mold replacement is efficient and convenient, significantly reducing production preparation time.

The equipment is equipped with a dedicated forming parameter database for phosphate-bonded high alumina bricks, integrating the optimal forming processes for different raw material ratios and different specifications of products. Operators can call up the parameters with one click, eliminating the need for repeated debugging and significantly reducing the impact of human factors on product quality. The forming parameters can be permanently saved and reused in batches, ensuring that the density, size, and density of each batch and each green body are completely consistent, meeting the strict requirements of high-end high-temperature industrial customers for the batch stability of refractory products and helping enterprises smoothly enter the high-end supply chain system. Compared with traditional friction presses, the Haloong servo screw press adopts an on-demand start-stop and sleep energy-saving mode. The servo motor only operates during the forming process, with zero energy consumption in standby mode. The comprehensive energy-saving rate is over 55%, significantly reducing production energy costs. Meanwhile, the static pressure transmission structure has minimal wear, and in combination with the fully automatic forced lubrication system, the equipment has a low failure rate and a long service life. The later maintenance and operation costs are reduced by more than 40% compared to traditional equipment, and the mold wear is also significantly reduced, comprehensively helping enterprises control production costs and improve economic benefits.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly linked with automatic feeding machines, material distribution machines, demolding machines, and green body conveying lines, etc., to build a fully automatic forming production line for phosphate-bonded high alumina bricks, achieving unmanned control throughout the process from material distribution, pressing, demolding to transfer, reducing labor input and improving production efficiency. At the same time, it supports remote monitoring, parameter adjustment, and fault warning functions, facilitating domestic and foreign customers to manage production remotely, monitor forming quality in real time, and aligning with the global trend of intelligent and digital transformation in the refractory materials industry.

In the field of phosphate-bonded high alumina brick production, the Haloong servo screw press has helped many enterprises break through quality bottlenecks, raising the product qualification rate to over 99%. The finished bricks have uniform density, meet strength standards, and have significantly improved thermal shock resistance and wear resistance, effectively extending the service life of kiln linings and reducing the maintenance costs for end users. In the future, Zhengzhou Haloong will continue to focus on the field of refractory material forming equipment, continuously optimize servo direct drive technology and intelligent control systems, focus on the diversified needs of global refractory material enterprises, and create more efficient, precise, and intelligent forming equipment. Working hand in hand with domestic and foreign partners, it will promote the quality upgrade of refractory products and contribute to the green and efficient development of high-temperature industries.