High-end silica bricks require a high degree of uniformity in density throughout the body, including the center, edges, and corners, without delamination, internal cracks, or porosity. The overall density must meet the standard to maintain volume stability under long-term high-temperature, acid and alkali erosion, and alternating cold and hot conditions, without flaking, deformation, or cracking. However, silica brick raw material quartz sand has a high friction coefficient and poor fluidity, and the difficulty of exhaust during the molding process is high, which poses extreme requirements for the pressure accuracy, uniform force transmission, and pressure application flexibility of the molding equipment.

Zhengzhou Haloong has been deeply involved in refractory molding technology for decades, thoroughly understanding the characteristics of silica brick raw materials and the specific molding process requirements. It has customized and optimized the servo screw press for silica bricks, completely 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 molding solution for silica bricks, comprehensively addressing issues such as uneven density, internal defects, and low pass rate. The equipment performance is on par with international high-end standards, making it the core preferred equipment for domestic and foreign silica brick manufacturers.

Equipped with a direct drive system of permanent magnet synchronous servo motors, it completely eliminates the traditional friction discs and clutch transmission structures, with an extremely short transmission chain and zero energy loss in power transmission. The pressure output is stable and controllable throughout the process. The equipment is equipped with an intelligent numerical control pressure control module independently developed by Haloong, which can digitally and precisely set the impact energy, pressure application speed, stepwise pressure application times, and pressure holding duration. The energy repetition control accuracy is ≤±1%, ensuring that the pressure for each molding is highly consistent and completely eliminating pressure deviations caused by manual operation and mechanical fluctuations. According to the characteristics of silica brick raw materials, a customized stepwise flexible pressure application process is adopted, starting with light pressure for rapid exhaust, followed by stepwise stable pressure application and compaction, and finally long-term pressure holding for shaping. This ensures uniform force application throughout the body, with density fluctuations controlled within a very small range, and the density variation coefficient is far superior to industry standards, ensuring highly uniform performance of the finished silica bricks.

It adopts a fully enclosed static pressure screw, nut, and dedicated heavy-duty bearing transmission structure, forming a stable high-pressure oil film during operation to achieve flexible and uniform force application and pressure release, 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 exhaust the residual air inside the body, completely eliminating porosity and looseness defects, while gently protecting the brittle structure of the silica brick body, avoiding edge and corner damage and internal microcracks, and fundamentally eliminating common problems such as delamination, cracking, and porosity, ensuring the overall structural integrity of the body and increasing the pass rate of silica bricks to over 99%, significantly reducing raw material waste and production costs.

It breaks through the structural limitations of the fixed bottom dead center of traditional equipment and adopts a progressive forging molding mode. According to the specifications and dimensions, raw material ratio, and wall thickness of silica bricks, the stroke of the slider, pressure application depth, and pressure application force can be flexibly adjusted to precisely match the molding requirements of various standard silica bricks, special-shaped silica bricks, and large-sized kiln lining silica bricks. There is no need to worry about uneven pressure application caused by raw material filling volume deviation or complex structure. 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, comprehensively covering the molding production of various silica brick products.

The equipment is equipped with a dedicated silica brick molding parameter database, integrating the optimal molding process parameters for different raw material ratios and product specifications. 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 molding parameters can be permanently saved and reused in batches, ensuring that the density, size, and density of each batch and each silica brick body are highly consistent, meeting the strict quality requirements of high-end glass, coking, and metallurgical projects in Europe, Southeast Asia, the Middle East, Africa, and other regions, helping enterprises smoothly enter the international high-end refractory supply chain and break the dependence on imported high-end silica 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 has a low failure rate and a service life far exceeding that of traditional equipment. The later operation and maintenance cost is reduced by more than 40%, and the mold wear is also significantly reduced. It comprehensively compresses the production, operation and maintenance, and consumable costs, and improves 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 spreading machines, intelligent demolding machines, green body conveying lines, and temperature control and detection equipment to build a fully automatic silicon brick forming production line. It realizes unmanned control of the entire process from spreading, 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.

As a leading enterprise in the domestic electric servo screw press field, Zhengzhou Haloong Machinery Co., Ltd. has been focusing on the research and development and innovation of refractory forming equipment for 45 years, deeply exploring the pain points of the industry process, and insisting 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 specially designed for the forming of various refractory materials. Besides silicon bricks, they can also be adapted to high alumina bricks, magnesia-carbon bricks, checker bricks, and various shaped refractory lining bricks, providing one-stop customized forming solutions.