Electric furnaces are the core and key equipment in the smelting of steel and non-ferrous metals and high-temperature processing. The top part of the electric furnace is constantly exposed to extreme temperatures above 1600°C, high-temperature gas erosion, and frequent temperature fluctuations, making it one of the most vulnerable and frequently replaced parts of the electric furnace. High alumina bricks for electric furnace tops, as the core refractory material, are essential for ensuring the stable, efficient, and long-lasting operation of the electric furnace due to their excellent high-temperature resistance, high strength, good thermal shock resistance, and erosion resistance. However, the raw material characteristics of high alumina bricks for electric furnace tops (high alumina bauxite aggregate, fine powder ratio, low cement binder) and the strict requirements of the forming process, especially the pursuit of uniform density and high density of the green body, make it difficult for traditional forming equipment to meet these demands, becoming a core bottleneck restricting the quality upgrade of high alumina bricks for electric furnace tops and the extension of the service life of electric furnaces.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and service requirements of electric furnaces for high alumina bricks for electric furnace tops. By discarding the inherent shortcomings of traditional transmission equipment, it has adopted a three-in-one core technology of direct drive by permanent magnet synchronous servo motor + static pressure flexible pressure transmission + intelligent numerical control system to optimize the HLDS series servo screw press specifically for high alumina bricks for electric furnace tops. The equipment's precision, stability, and adaptability have been comprehensively upgraded, and its core advantages precisely match the strict forming requirements of high alumina bricks for electric furnace tops, making it the preferred core equipment for the high-quality mass production of high alumina bricks for electric furnace tops and assisting refractory material enterprises in creating high-end refractory products suitable for the long-term operation of electric furnaces.

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 fully stable and controllable throughout the process. The equipment is equipped with a dedicated numerical control pressure control module for high alumina bricks for electric furnace tops independently developed by Haloong, which can digitally and precisely set the striking energy, pressure application speed, number of stepwise pressure applications, and pressure holding time. The energy repetition control accuracy is ≤±1%, ensuring that the pressure in each forming process is highly consistent, completely eliminating the quality deviations caused by manual operation and mechanical fluctuations. In response to the poor fluidity and easy agglomeration of high alumina mixed materials, a customized stepwise flexible pressure application process is adopted. First, light pressure is applied to quickly expel the residual air inside the green body, then stepwise pressure is applied layer by layer to compact it, and finally, long-term pressure holding is used to shape it. This ensures that all parts of the green body, including the center, edges, and corners, are uniformly stressed, and the density fluctuation is controlled within a very small range. The density variation coefficient is far better than the industry standard, perfectly ensuring the uniform and dense quality of the entire green body, significantly enhancing the thermal shock resistance, erosion resistance, and strength of the finished product, and making it suitable for the extreme high-temperature conditions above 1600°C in electric furnaces, thereby extending the service life of electric furnaces.

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 pressure application. The pressure application process is smooth and gentle, which can not only fully expel the internal pores of the green body, completely eliminating the defects of porosity and delamination, but also gently protect the brittle structure of the high alumina bricks for electric furnace tops, avoiding edge and corner damage and internal micro-cracks. This increases the product qualification rate to over 99%, significantly reduces the waste of high alumina raw materials, and effectively extends the service life of molds, reducing material costs and improving the production efficiency of enterprises.

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 (high alumina bauxite, corundum composite, low cement binder), size, and structural complexity (such as standard flat bricks, special-shaped arch bricks, thickened top bricks) of high alumina bricks for electric furnace tops, the stroke of the slider, the depth of pressure application, and the pressure application force can be flexibly adjusted to precisely match the forming requirements of various high alumina bricks for electric furnace tops, covering the refractory material production scenarios of electric furnaces of different tonnages. There is no need to worry about the problems of uneven filling of raw materials and uneven pressure due to complex structure. Combined with a rapid mold changing system, it enables convenient and efficient mold changing, perfectly adapting to the flexible production mode of multiple varieties and batches of high alumina bricks for electric furnace tops, and meeting the batch supply requirements of large-scale electric furnace projects.

The equipment is equipped with a dedicated database of forming parameters for high alumina bricks for electric furnace tops, integrating the optimal forming process parameters for various specifications and different materials of high alumina bricks for electric furnace tops, including common refractory materials such as high alumina bauxite bricks and corundum composite top 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 forming parameters can be permanently saved and reused in batches, ensuring that the density, compactness, and dimensional accuracy of each batch and each piece of high alumina brick for electric furnace tops are highly consistent, easily meeting the strict quality requirements of large-scale electric furnace projects at home and abroad, and helping enterprises smoothly enter the overseas high-end electric furnace refractory materials market.

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 is completely zero energy consumption, with a comprehensive energy-saving rate of over 55%, significantly reducing the electricity cost of high alumina brick production for electric furnace tops, meeting the green and low-carbon development needs of the metallurgical industry. At the same time, the static pressure transmission structure has minimal wear, and is combined with a fully automatic forced lubrication system, equipped with an oil shortage alarm device, achieving maintenance-free operation, with a low failure rate and a service life far exceeding that of traditional equipment, reducing the later operation and maintenance costs by more than 40%, comprehensively compressing production, operation and maintenance, 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 conveyor lines, building an automatic and intelligent forming production line for high alumina bricks for electric furnace tops, achieving unmanned control throughout the process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention, and ensuring forming 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 real-time control production progress and product quality, fully in line with the global refractory materials industry's trend of intelligent, digital, and green transformation, helping enterprises build an intelligent production base for high-end high alumina bricks for electric furnace tops.

As a leading enterprise in the field of electric servo screw presses in China, Zhengzhou Haloong Machinery Co., Ltd. has been focusing on the technological innovation of refractory material forming equipment for 45 years, deeply exploring the pain points of the forming process of high alumina bricks for electric furnace tops and other high-end refractory materials, and insisting on empowering the refractory materials industry with customized technology for high-quality development. The Haloong HLDS series CNC servo screw press covers the full tonnage range from 200T to 1600T, and can provide one-to-one customized forming solutions based on the material, specifications, and production capacity requirements of customers' high alumina bricks for electric furnace tops, fully meeting the mass production needs of various high alumina bricks for electric furnace tops and adapting to the refractory material supply of electric furnace projects of different scales.