Regenerator bricks are mostly made of high-quality refractory materials such as high alumina, mullite, and silica. The raw material particle size distribution is special and the fluidity is weak. Coupled with their thin-walled and porous structure, they have much higher requirements for the accuracy of forming pressure, uniformity of force transmission, and flexibility of pressure application than ordinary refractory bricks. High-end regenerator bricks require that the density of the green body be highly uniform in the center, edges, and cell walls, with no delamination, internal cracks, or porosity. The cell size must be precise and the edges complete to maintain structural stability under long-term high-temperature, alternating hot and cold, and flue gas erosion conditions, and achieve efficient heat storage and heat exchange.

Zhengzhou Haloong has been deeply engaged in refractory forming technology for decades, thoroughly understanding the characteristics of regenerator brick raw materials and the difficulties in structural forming. It has customized and optimized the servo screw press specifically, eliminating the inherent shortcomings of traditional transmission equipment. It adopts a three-in-one core technology of direct drive by permanent magnet synchronous servo motor, static pressure flexible force transmission, and intelligent numerical control system to create a dedicated forming solution for regenerator bricks, comprehensively solving problems such as uneven density, structural defects, and unstable forming. The equipment performance is benchmarked against international high-end standards, making it the preferred core equipment for regenerator brick production enterprises at home and abroad.

Equipped with a direct drive system of permanent magnet synchronous servo motor, it completely eliminates the traditional friction disc and clutch transmission structure, shortening the transmission chain and achieving zero energy loss in energy transmission. The pressure output is stable and controllable throughout the process. The equipment is equipped with Haloong's independently developed intelligent numerical control pressure control module, which can digitally and precisely set the impact energy, pressure application speed, stepwise pressure application times, and pressure holding duration. The energy repeat control accuracy is ≤±1%, ensuring that the forming pressure is highly consistent in each process, completely eliminating pressure deviations caused by manual operation and mechanical fluctuations. In response to the multi-hole and thin-walled characteristics of regenerator bricks, a customized stepwise flexible pressure application process is adopted. It starts with light pressure for air exhaust, then stepwise stable pressure application and compaction, and finally long-term pressure holding and shaping. This ensures that all parts of the green body, including the cell walls, edges, and center, are uniformly stressed, and the density fluctuation is controlled within a very small range. The density variation coefficient is far superior to industry standards, and the performance of the finished bricks is highly uniform.

It adopts a fully enclosed static pressure screw, nut, and special heavy-duty bearing transmission structure. During operation, a stable high-pressure oil film is formed for protection, achieving flexible and uniform force application and pressure reduction, completely avoiding the impact force and stress concentration problems caused by traditional rigid pressure application. The pressure application process is smooth and gentle, which can fully expel the residual air inside the green body, avoiding pore defects, and protect the thin walls and cell holes of the regenerator bricks from impact damage. This eliminates common problems such as delamination, micro-cracks, edge porosity, and cell hole deformation from the root, ensuring the integrity of the green body structure, significantly reducing the scrap rate, and increasing the product qualification rate to over 99%.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a step-by-step forging forming mode. According to the cell shape, wall thickness, size, and specification of the regenerator bricks, the stroke of the slider, the pressure application depth, and the pressure application force can be flexibly adjusted to precisely match the forming requirements of various standard regenerator bricks, special-shaped regenerator bricks, and large-sized heat storage bricks. There is no need to worry about the pressure application unevenness caused by the deviation in raw material filling and the complexity of the structure. Whether it is conventional seven-cell or nine-cell regenerator bricks or customized special-shaped thin-walled bricks, they can all be uniformly compacted throughout the area, with regular cells and distinct edges. Combined with a rapid mold changing system, mold changing is convenient and efficient, perfectly adapting to the multi-variety, small-batch, and customized production mode of enterprises.

The equipment is equipped with a dedicated forming parameter database for regenerator bricks, integrating the optimal forming process parameters for different materials and specifications of products. Operators can retrieve them with one click, eliminating the need for repeated debugging and exploration, and significantly reducing the interference of human factors on product quality. All forming parameters can be permanently saved and reused in batches, ensuring that the density, size, and compactness of each batch and each piece of checker brick are highly consistent, meeting the strict quality requirements of global high-end metallurgical projects in Europe, Southeast Asia, the Middle East, Africa, and other regions for refractory products. This helps enterprises smoothly enter the international high-end supply chain and break the dependence on imported high-end checker bricks.

Compared with traditional friction presses, the Haloong servo screw press adopts an intelligent mode of on-demand start-stop and sleep energy-saving. The servo motor only operates during the pressing process, and the standby state has zero energy consumption. The comprehensive energy-saving rate is as high as over 55%, significantly reducing the production electricity cost. At the same time, the static pressure transmission structure has minimal wear, and combined with the fully automatic forced lubrication system, the equipment failure rate is low, and the service life is much longer than that of traditional equipment. The later operation and maintenance cost is reduced by more than 40%, and the mold wear is also significantly reduced, comprehensively compressing the production, operation and maintenance, and consumable costs, and improving the economic benefits of the enterprise.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly linked with automatic and precise feeding machines, dedicated distribution machines, intelligent demolding machines, green body conveying lines, and temperature control and detection equipment to build a fully automatic checker brick forming production line. It realizes unmanned control throughout the process from distribution, pressing, pressure holding, demolding to green body transfer, reducing labor input and significantly improving production efficiency. At the same time, it supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, facilitating domestic and foreign customers to remotely and in real-time control the production progress and product quality, fully in line with the global refractory industry's trend of intelligent, digital, and green transformation.

Zhengzhou Haloong Machinery Co., Ltd. is a leading enterprise in the domestic electric servo screw press field. For 45 years, it has always focused on the research and development and innovation of refractory forming equipment, delved into the pain points of industry processes, and insisted on empowering the high-quality development of the industry through technological upgrades. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T, and are tailor-made for the forming of various refractory materials. In addition to checker bricks, they can also be adapted to mullite bricks, high alumina bricks, magnesia carbon bricks, and various shaped refractory lining bricks, providing one-stop customized forming solutions.