Phosphate bricks, as a type of high-performance unshaped refractory material, are widely used in high-temperature industrial fields such as metallurgy, chemical engineering, building materials, and power due to their excellent high-temperature resistance, erosion resistance, wear resistance, and good bonding strength. They are the core materials for the inner linings of boilers, kilns, flues, blast furnace hot blast stoves, and other equipment. Compared with ordinary refractory bricks, phosphate bricks use phosphoric acid or phosphate as the binder, with precise raw material ratios and special forming processes. They have extremely high requirements for the uniformity of the body density, compactness, and defect-free nature - uneven body density will lead to insufficient strength after sintering and poor anti-spalling performance, while internal pores and microcracks will shorten the service life. Traditional forming equipment is difficult to meet their specific forming needs, becoming a key bottleneck restricting the quality improvement and large-scale production of phosphate bricks.

Zhengzhou Haloong has deeply studied the raw material characteristics and forming process logic of phosphate bricks, discarding the inherent shortcomings of traditional transmission equipment. With the core technology of direct drive by permanent magnet synchronous servo motor + static pressure flexible pressure transmission + intelligent numerical control system, the HLDS series servo screw press has been optimized specifically for phosphate bricks. The equipment's precision, stability, and adaptability have been comprehensively upgraded, making it the preferred core equipment for high-quality mass production of phosphate bricks.

Equipped with a direct drive system of permanent magnet synchronous servo motors, it completely eliminates the inefficient transmission structures such as traditional friction discs and clutches, with an extremely short transmission chain and zero energy loss in energy transmission. The pressure output is stable and controllable throughout the process. The equipment is equipped with a phosphate brick-specific numerical control pressure module independently developed by Haloong, which can digitally and precisely set the striking energy, pressurization speed, number of stepwise pressurizations, and pressure-holding time. The energy repetition control accuracy is ≤±1%, ensuring that the forming pressure is highly consistent in each process, completely eliminating the quality deviations caused by manual operation and mechanical fluctuations. According to the characteristics of phosphate brick mixtures, a customized stepwise flexible pressurization process is adopted. First, light pressure is applied to quickly expel the residual air inside the body, then stepwise stable pressure is applied to compact it layer by layer, and finally, long-term pressure holding is used for shaping. This ensures that all parts of the body, including the center, edges, and corners, are uniformly stressed, with density fluctuations controlled within a very small range. The density variation coefficient is far better than the industry standard, perfectly ensuring the uniform and dense nature of the entire body, significantly enhancing the strength and erosion resistance of the finished product.

It adopts a fully enclosed static pressure screw, nut, and dedicated heavy-duty bearing transmission structure. During operation, a stable high-pressure oil film is formed for protection, achieving flexible and uniform pressure application and completely avoiding the severe impact force and stress concentration problems caused by traditional rigid pressurization. The pressurization process is smooth and gentle, which can not only fully expel the internal air holes of the body, completely eliminating porosity and delamination defects, but also gently protect the brittle phosphate brick body structure, avoiding edge and corner damage and internal microcracks. This increases the product qualification rate to over 99%, significantly reduces raw material waste, and effectively extends the service life of the mold, reducing material costs.

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 material, size, and structural complexity (such as standard bricks, special-shaped bricks, and lining bricks) of phosphate bricks, the stroke of the slider, pressurization depth, and pressure application intensity can be flexibly adjusted to precisely meet the forming needs of all specifications of phosphate bricks, including high-alumina phosphate bricks, clay phosphate bricks, and special-shaped phosphate lining bricks. There is no need to worry about the uneven pressurization caused by raw material filling volume deviation or structural complexity. Combined with a rapid mold changing system, mold changing is convenient and efficient, perfectly adapting to the flexible production mode of multiple varieties and batches of phosphate bricks, comprehensively covering various production scenarios of phosphate bricks.

The equipment is equipped with a phosphate brick-specific forming parameter database, integrating the optimal forming process parameters for various specifications and different ratios of phosphate bricks. 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, compactness, and dimensional accuracy of each batch and each piece of phosphate brick are highly consistent, easily meeting the strict quality requirements of high-temperature industrial projects at home and abroad, and helping enterprises smoothly open up overseas markets.

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 over 55%, significantly reducing the electricity cost of phosphate brick production. 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, reducing the later maintenance and operation costs by more than 40%. It comprehensively reduces production, operation, and material costs, helping enterprises achieve a green, low-carbon, and efficient profit-making production model.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly linked with automatic and precise feeding machines, closed-loop distribution machines, intelligent demolding machines, non-destructive testing equipment for green bodies, and constant-temperature conveying lines, building an automatic and intelligent phosphate brick molding production line. It realizes unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention and ensuring molding accuracy and 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 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 technological innovation of refractory molding equipment for 45 years, deeply exploring the pain points of the molding process of phosphate bricks and other refractory products. It adheres to customizing technology to empower the high-quality development of the refractory industry. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to the material, specifications, and production capacity requirements of customers' phosphate bricks, it provides one-to-one customized molding solutions, fully meeting the mass production needs of various phosphate bricks.