Aluminum-chrome bricks, as a high-performance alkaline refractory material, are made from a precise blend of aluminum oxide and chromium oxide, formed under high pressure and sintered at high temperatures. They combine the high density and hardness of aluminum oxide with the excellent corrosion resistance and thermal shock resistance of chromium oxide. They can withstand temperatures above 1600°C for long periods. With core properties such as wear resistance, slag resistance, anti-spalling, and strong volume stability, they are widely used in harsh high-temperature conditions such as metallurgical steelmaking (converter, electric furnace, ladle lining), non-ferrous metal smelting, glass kilns, and cement rotary kilns. They are essential refractory components for ensuring the long-term stable operation of high-temperature equipment, reducing maintenance costs, and improving production efficiency. The service performance of aluminum-chrome bricks is fundamentally determined by the quality of the green body formation - density, density uniformity, and dimensional accuracy directly affect their high-temperature erosion resistance and service life. However, the mixture of aluminum-chrome bricks has complex particle size distribution, significant density differences between aluminum oxide and chromium oxide, easy layering during forming, high porosity, and prone to corner cracking. These issues pose extremely strict requirements on the pressure control accuracy, pressure transmission stability, and process adaptability of the forming equipment, far exceeding those for ordinary refractory materials.

Zhengzhou Haloong Machinery Co., Ltd. has been dedicated to the field of refractory material forming equipment for 45 years. Based on the raw material characteristics and forming process challenges of aluminum-chrome bricks, it has innovated the technology of servo screw presses to create a specialized forming solution. By leveraging the core advantages of the equipment, it addresses industry pain points and helps global refractory material enterprises achieve high-quality mass production of aluminum-chrome bricks, leading the high-end refractory material industry towards refinement and high performance.

Compared to ordinary refractory bricks, the forming of aluminum-chrome bricks is significantly more difficult due to the raw material characteristics and performance requirements. The mixture is composed of coarse and fine aluminum oxide powders and chromium oxide micro-powders in precise proportions, with a wide particle size distribution, poor fluidity, and difficult gas expulsion. Moreover, the density difference between aluminum oxide and chromium oxide is considerable (aluminum oxide density is approximately 3.9g/cm³, and chromium oxide density is approximately 5.2g/cm³). During the forming process, layering and agglomeration are highly likely to occur, demanding extremely precise control of the applied pressure, pressure application speed, and holding time. It is necessary to achieve green body densification through precise pressure application while ensuring uniform dispersion of chromium oxide, avoiding layering and corner cracking caused by rigid impact, and efficiently expelling air from the mixture to prevent residual pores from affecting the product's erosion resistance and erosion resistance.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of aluminum-chrome bricks. It has optimized the HLDS series of servo screw presses with a three-in-one core technology of direct drive by permanent magnet synchronous servo motors, static pressure flexible pressure transmission, and intelligent numerical control systems. The equipment's precision, stability, and adaptability have been comprehensively upgraded to precisely match the forming requirements of aluminum-chrome bricks, making it the preferred equipment for high-quality aluminum-chrome brick mass production and assisting refractory material enterprises in creating high-quality products suitable for high-temperature, strong erosion, and strong erosion conditions.

Equipped with a direct drive system of permanent magnet synchronous servo motors, it completely eliminates 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 numerical control pressure control module for aluminum-chrome bricks, which can digitally and precisely set the impact energy, pressure application speed, stepwise pressure application times, and holding time. 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. In response to the complex particle size distribution, difficult exhaust, and easy layering and agglomeration of the aluminum-chromium brick mixture, a customized stepwise flexible pressurization process was developed. This process first lightly presses the loose raw materials to slowly expel the internal residual air, then gradually and steadily applies pressure layer by layer, and finally maintains a long-term pressure to shape the product. This ensures that all parts of the green body, including the center, edges, and corners, are uniformly stressed, with density fluctuations controlled within a very small range. At the same time, it effectively avoids chromium oxide agglomeration and raw material layering, providing a solid foundation for the uniform combination of the bonding phase during subsequent high-temperature sintering, and increasing the qualified product rate to over 99%.

The equipment 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 gradual pressurization. This completely avoids the severe impact force and stress concentration problems caused by traditional rigid pressurization. The pressurization process is smooth and gentle, with uniform and soft pressure transmission. It can not only fully expel the internal pores of the green body and disperse the chromium oxide agglomerates, completely eliminating defects such as porosity, layering, and cracks, but also gently protect the activity of the aluminum oxide and chromium oxide particles, avoiding green body layering and corner cracking, significantly reducing the waste of high-cost raw materials, and effectively extending the service life of the mold, reducing material costs, and improving the production efficiency of the enterprise.

Breaking through the structural limitation of the fixed lower dead point of traditional equipment, a stepwise forging forming mode is adopted. According to the material, size, structural complexity (converter lining bricks, ladle bricks, special-shaped parts), and density requirements of the aluminum-chromium bricks, the stroke of the slider, the pressurization depth, and the applied pressure can be flexibly adjusted to precisely match the forming requirements of various aluminum-chromium bricks, covering the full range of production scenarios for high-end refractories. There is no need to worry about the problems of uneven pressurization caused by deviations in raw material filling volume, differences in particle size distribution, and changes in the fluidity of the mixture. Combined with a rapid mold change system, the mold change 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 aluminum-chromium bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, and different density requirements of aluminum-chromium bricks, including common products such as standard aluminum-chromium bricks, special-shaped aluminum-chromium bricks, and high-strength erosion-resistant aluminum-chromium 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, and the chromium oxide bonding phase is evenly distributed, 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 market.

Compared with traditional friction presses, the Haloong servo screw press adopts an on-demand start-stop and sleep energy-saving intelligent mode. 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 aluminum-chromium brick production, meeting the green and low-carbon development needs of the refractory industry. At the same time, the static pressure transmission structure has minimal wear, combined with a fully automatic forced lubrication system and an oil shortage alarm device, achieving maintenance-free operation, with a low equipment failure rate and a service life far exceeding that of traditional equipment, reducing the later maintenance cost by more than 40%, comprehensively compressing production, maintenance, and material 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 green bodies, and constant-temperature conveyor lines, building an automatic and intelligent forming production line for aluminum-chromium bricks, achieving unmanned control from distribution, pressing, pressure maintenance, demolding to green body transfer and inspection, minimizing human intervention. This not only avoids damage to the green body caused by manual operation but also ensures forming accuracy and production efficiency. It supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, facilitating domestic and foreign customers to manage production progress and product quality in real time from different locations. It fully conforms to the global refractory industry's trend of intelligent, digital, and green transformation, and helps enterprises build an intelligent production base for high-end aluminum-chrome bricks. Zhengzhou Haloong Machinery Co., Ltd., as a leading enterprise in the domestic electric servo screw press field, has been focusing on technological innovation in refractory forming equipment for 45 years. It has been deeply engaged in solving the forming process pain points of high-end refractories such as aluminum-chrome bricks and has been committed to empowering the refractory industry's upgrade with customized technology. Haloong's HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to customers' requirements for the material, specifications, capacity, density, and raw material ratio of aluminum-chrome bricks, it can provide one-to-one customized forming solutions, fully meeting the mass production needs of various types of aluminum-chrome bricks and adapting to the supply of refractories in different high-end high-temperature, strong erosion, and strong erosion fields.