Zirconia bricks, as a high-performance special refractory material, are made from natural zirconia as the core raw material. They are widely used in high-temperature industrial fields such as metallurgical continuous casting, glass melting furnaces, ceramic sintering, and high-temperature chemical reactors due to their excellent high-temperature stability, strong resistance to slag erosion, good wear resistance, and low thermal conductivity. They are the preferred choice for the inner lining of key equipment in various harsh operating conditions. The forming quality of zirconia bricks directly determines the product's density, compressive strength, thermal shock resistance, and high-temperature service life. However, the raw material of zirconia bricks is characterized by its hardness, high density, complex particle size distribution, poor fluidity of the mixture, and easy agglomeration, which poses extremely strict requirements on the pressure control accuracy, pressure transmission stability, and process adaptability of the forming equipment, far exceeding those of ordinary refractory materials.

Zhengzhou Haloong Machinery Co., Ltd. has been dedicated to the field of refractory material forming equipment for 45 years. Focusing on the raw material characteristics and forming process pain points of zirconia bricks, it has innovated the technology of servo screw presses to create a dedicated forming solution for zirconia bricks. By leveraging the core advantages of the equipment, it has solved industry challenges and assisted global refractory material enterprises in achieving high-quality mass production of zirconia bricks, leading the refractory material industry towards high-end, refined, and green transformation.

Compared to ordinary refractory bricks, the forming of zirconia bricks is significantly more difficult. The zirconia particles in the raw material are hard, dense, and angular, and the mixture has poor fluidity, a wide particle size distribution, and is prone to agglomeration. This requires extremely high precision in the application of pressure, the speed of pressure application, and the duration of pressure maintenance - it is necessary to achieve densification of the green body through precise pressure application, ensuring that the finished product has a compressive strength of ≥45MPa and a volume density controlled between 2.8-3.2g/cm³, while avoiding the breakage of zirconia particles and the formation of micro-cracks in the green body due to rigid impact. At the same time, it is necessary to precisely control the distribution of pores, disperse the agglomerated raw materials, and ensure the product's thermal shock resistance and erosion resistance.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of zirconia bricks. It has optimized the HLDS series servo screw press with a core technology of permanent magnet synchronous servo motor direct drive + static pressure flexible pressure transmission + intelligent numerical control system, comprehensively upgrading the equipment's precision, stability, and adaptability to precisely match the forming requirements of zirconia bricks. It has become the preferred equipment for high-quality zirconia brick mass production, assisting refractory material enterprises in creating high-quality products suitable for high-temperature industrial fields.

Equipped with a permanent magnet synchronous servo motor direct drive system, it has completely eliminated 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 Haloong self-developed zirconia brick dedicated numerical control pressure control module, which can digitally and precisely set the impact energy, pressure application speed, stepwise pressure application times, and pressure maintenance duration. The energy repetition control accuracy is ≤±1%, ensuring that the pressure applied in each forming process is highly consistent, completely eliminating quality deviations caused by manual operation and mechanical fluctuations. In response to the poor fluidity, easy agglomeration, and hardness of zirconia mixed materials, a customized stepwise flexible pressure application process has been developed. It first applies light pressure to disperse the agglomerated raw materials and quickly expel the residual air inside the green body, then applies pressure step by step to compact it layer by layer, and finally maintains pressure for a long time 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. This not only ensures the density of the green body but also avoids the breakage of zirconia particles, perfectly balancing the core advantages of high strength and thermal shock resistance of the product, with a finished product qualification rate of over 99%.

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 uniform force and slow pressure application, completely avoiding the severe impact force and stress concentration problems caused by traditional rigid pressure application. The pressurization process is smooth and gentle, with uniform and soft pressure transmission. It can not only fully expel the internal pores of the blank, disperse the agglomerated raw materials, and completely eliminate defects such as porosity, delamination, and cracks, but also protect the zircon sand particle structure gently, avoiding particle breakage and blank cracking. This significantly reduces the waste of high-cost raw materials and effectively extends the service life of the mold, lowering the cost of consumables and enhancing the production efficiency of the enterprise.

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 (standard brick, special-shaped brick) of zircon sand bricks, as well as the density requirements, the stroke of the slider, the depth of pressurization, and the pressure intensity can be flexibly adjusted to precisely meet the forming needs of various zircon sand bricks, covering the full range of production scenarios for high-end refractory materials. There is no need to worry about the deviation of raw material filling volume, the difference in zircon sand particle size, and the uneven pressurization caused by raw material agglomeration. Combined with a rapid mold changing system, the mold changing is convenient and efficient, perfectly adapting to the flexible mode of multi-variety and batch production, meeting the batch supply requirements of the high-end field.

The equipment is equipped with a dedicated forming parameter database for zircon sand bricks, integrating the optimal forming process parameters for various specifications, different materials, and different density requirements of zircon sand bricks, including common products such as ordinary dense type, high-strength wear-resistant type, and special-shaped zircon sand 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 product are highly consistent, easily meeting the strict quality requirements of the high-end field at home and abroad, and helping enterprises smoothly open up the overseas high-end 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 zircon sand brick production and meeting the green and low-carbon development needs of the refractory materials industry. At the same time, the static pressure transmission structure has minimal wear, and is combined with a fully automatic forced lubrication system and an oil shortage alarm device, achieving maintenance-free operation, with a low failure rate and a service life far exceeding that of traditional equipment. The later maintenance cost is reduced by more than 40%, comprehensively compressing production, maintenance, and consumable costs, and 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 blanks, and constant-temperature conveying lines, building a fully automatic and intelligent forming production line for zircon sand bricks, achieving unmanned control throughout the process from distribution, pressing, pressure holding, demolding to blank transfer and testing, minimizing human intervention. This not only avoids damage to the blank caused by manual operation but also ensures 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 the production progress and product quality, fully conforming to the global refractory materials industry's trend of intelligent, digital, and green transformation, and helping enterprises build an intelligent production base for high-end zircon sand bricks.

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 materials forming equipment for 45 years, deeply exploring the forming process pain points of zircon sand bricks and other high-end refractory materials, and insisting on empowering the refractory materials industry upgrade with customized technology. 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, size, capacity, and density requirements of the customer's zircon sand bricks, fully meeting the mass production needs of various zircon sand bricks and adapting to the supply of refractory materials in different high-end high-temperature fields.