Uniform density and compactness, stable casting quality - Empowering high-end forming scenarios for shaped refractory products

High-end shaped refractory products require uniform density throughout the entire body, including the center, edges, and corners, without delamination, internal cracks, or porosity. The external dimensions must also be precisely uniform to maintain volume stability and structural integrity under harsh conditions such as long-term high temperatures, alternating hot and cold, acid and alkali erosion, and dust abrasion, ensuring long-term service life.

Zhengzhou Haloong has been deeply involved in refractory forming technology for decades, thoroughly understanding the characteristics of various shaped refractory raw materials and the requirements of forming processes. It has customized and optimized the HLDS series of servo screw presses for all scenarios, completely eliminating the shortcomings of traditional transmission equipment. By adopting a core technology of direct drive by permanent magnet synchronous servo motors, static pressure flexible pressure transmission, and intelligent numerical control systems, it has created a one-stop forming solution covering all types of shaped refractory products. The equipment performance is on par with international high-end standards, leading in stability, accuracy, and energy efficiency, making it the preferred core equipment for domestic and foreign shaped refractory production enterprises.

Equipped with a direct drive system of permanent magnet synchronous servo motors, it completely eliminates traditional low-efficiency transmission structures such as friction discs and clutches, with an extremely short transmission chain and zero energy loss during 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 striking energy, pressurization speed, stepwise pressurization times, and pressure holding duration. The energy repetition control accuracy is ≤±1%, ensuring that the pressure for each forming process is highly consistent, completely eliminating quality deviations caused by manual operation and mechanical fluctuations. For different shaped refractory characteristics, a customized stepwise flexible pressurization process is provided. It starts with light pressure for rapid exhaust, followed by stepwise stable pressurization and compaction, and finally long-term pressure holding for shaping. This ensures uniform force application to all parts of the body, with density fluctuations controlled within a very small range, and the density variation coefficient far exceeds industry standards, ensuring highly uniform performance of the finished refractory products.

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 pressure application, completely avoiding the impact force and stress concentration problems caused by traditional rigid pressurization. The pressurization process is smooth and gentle, effectively eliminating residual air inside the body and completely eliminating porosity and looseness defects. It also gently protects the brittle body structure, avoiding edge and corner damage and internal micro-cracks, fundamentally eliminating common problems such as delamination, cracking, and porosity, increasing the qualified rate of shaped refractory products to over 99%, significantly reducing raw material waste and production costs, and simultaneously extending the service life of molds.

It breaks through the structural limitations of traditional equipment's fixed bottom dead center and adopts a progressive forging forming mode. According to the specifications, raw material ratios, and wall thickness of shaped refractory products, the stroke of the slider, pressurization depth, and pressurization force can be flexibly adjusted to precisely match the forming requirements of all types of products, including standard firebricks, special-shaped bricks, large-sized kiln lining bricks, checker bricks, magnesia-carbon bricks, and high alumina bricks. There is no need to worry about uneven pressurization caused by raw material filling volume deviations or complex structures. Combined with a rapid mold changing system, mold changing is convenient and efficient, perfectly adapting to the flexible production mode of multiple varieties, small batches, and customization, comprehensively covering all production scenarios of shaped refractory products.

The equipment is equipped with a dedicated forming parameter database for shaped refractory products, integrating the optimal forming process parameters for different raw material ratios and product specifications. Operators can retrieve them with a single click, eliminating the need for repeated debugging and exploration, 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, dimensions, and compactness of each batch and each shaped refractory body are highly consistent, meeting the strict quality requirements of high-end metallurgical, glass, and steel projects in Europe, Southeast Asia, the Middle East, Africa, and the Americas. It helps enterprises smoothly enter the international high-end refractory supply chain and break the monopoly of foreign high-end shaped refractory products. 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 and aligning with the green and low-carbon development trend of the industry. Meanwhile, the static pressure transmission structure has minimal wear, and when 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 maintenance and operation costs are reduced by more than 40%, comprehensively compressing production, maintenance, and material costs, and significantly enhancing the economic benefits of enterprises.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly integrated 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 forming production line for shaped refractory materials. It realizes unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transfer, reducing labor input and greatly 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 material forming equipment for 45 years, delving into the pain points of industry processes, 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 tailor-made for the forming of various shaped and unshaped refractory materials. They can fully adapt to all types of products such as high alumina bricks, magnesia-carbon bricks, silica bricks, checker bricks, special-shaped refractory lining bricks, and special-shaped refractory materials, providing one-stop customized forming solutions.