The final service life and high-temperature stability of sillimanite bricks are fundamentally rooted in three core indicators during the forming process: uniform density of the green body, dense particle packing, and structural integrity of the green body. Sillimanite raw materials are typical refractory powders with poor plasticity, strict particle size distribution, and great difficulty in exhaust during dry mixing forming. During the forming and pressing process, problems such as particle bridging, local porosity, layering cracks, and insufficient density at the corners and edges are prone to occur. Once the pressure control is unbalanced and the pressure transmission is uneven during the forming stage, quality risks such as thermal shock spalling, structural cracking, and reduced erosion resistance will occur in the subsequent sintering and high-temperature service stages, significantly shortening the service life of kilns and refractory materials. Zhengzhou Haloong Machinery Co., Ltd. has been dedicated to the research and development and manufacturing of refractory forming equipment for 45 years. It accurately understands the forming difficulties and high-end mass production demands of sillimanite bricks from poor raw materials. Relying on the third-generation permanent magnet synchronous servo direct drive core technology, it has optimized and upgraded the HLDS series servo screw press, and tailor-made a specialized forming solution for sillimanite bricks. With multiple core advantages such as precise pressure control, flexible compaction, intelligent adaptation, and energy conservation and durability, it solves the production pain points of sillimanite bricks from the forming source, assisting domestic and foreign refractory enterprises in mass-producing high-quality, high-stability, and long-life sillimanite brick products.

The production of sillimanite bricks uses sillimanite concentrate as the core raw material, mixed and pressed with precisely proportioned binders and mineralizers. The raw material has significant poor plasticity and high requirements for particle packing and forming. The forming process is different from that of conventional refractory products such as clay bricks and high-alumina bricks, and has extremely high requirements for the pressure control accuracy, pressure transmission stability, and pressure application process adaptability of the forming equipment.

Zhengzhou Haloong, based on the characteristics of the poor plasticity of sillimanite raw materials and the core demands of the forming process, has abandoned the technical shortcomings of traditional forming equipment. With a three-in-one core configuration of permanent magnet synchronous servo direct drive technology, static pressure flexible pressure transmission structure, and intelligent numerical control dedicated process system, it has optimized the forming performance of the HLDS series servo screw press. The advantages precisely solve the forming problems of all types of sillimanite bricks, achieving uniform density throughout the green body, dense structure without cracks, and standardized dimensional accuracy, comprehensively improving the quality of finished products and production efficiency.

The equipment is equipped with a self-developed permanent magnet synchronous servo motor direct drive system by Haloong, eliminating traditional low-efficiency and easily damaged transmission components such as friction discs and clutches. The transmission chain is short, and there is zero energy loss in energy transmission. The repeat control accuracy of the forming energy and pressure output is ≤±1%, and the pressure value is digitally precisely controllable. In response to the characteristics of difficult exhaust and difficult particle packing during the forming of poor plasticity sillimanite powder, a dedicated step-by-step staged pressure application process is customized. The parameters of the entire process, including light pressure exhaust, step-by-step compaction, and long-term pressure holding, can be preset with one click. The internal air of the green body is slowly discharged, the particle bridging structure of the raw material is broken, and the pressure is evenly distributed to any part of the green body. It completely solves the problems of green body layering and density deviation. The coefficient of variation of the density of the same batch of sillimanite bricks is strictly controlled within the industry's high-quality standard range. The finished products have high density, low porosity, and significantly improved high-temperature volume stability and erosion resistance.

It adopts a fully enclosed static pressure screw nut heavy-load transmission structure. During operation, a stable high-pressure oil film is formed for protection, achieving flexible and uniform pressure application. It completely abandons the traditional equipment's rigid impact pressure application mode. The pressure application process is smooth and gentle, with uniform and gentle force application. The compaction process is gradual, effectively achieving the dense packing of sillimanite particles and the dense shaping of the green body, without causing stress concentration. It fundamentally eliminates hidden micro-cracks, interlayer separation, and corner damage in the green body. It significantly improves the qualification rate of finished sillimanite bricks, reduces raw material waste and mold loss, extends the service life of molds, and effectively reduces the production material costs of enterprises. Breaking through the structural limitations of the fixed lower dead point of traditional forming equipment, it adopts a successive precise forging forming mode. According to the specifications and dimensions of sillimanite bricks, the thickness of the brick body, the complexity of the structural shape, and the differences in raw material ratios, it can flexibly and precisely adjust the stroke of the slider, the depth of pressure application, and the forming pressure. Whether it is standard sillimanite load-bearing bricks, thick-walled kiln lining bricks, or complex-shaped regenerative chamber structure bricks and customized special sillimanite products, it can be adapted to the forming process with one click. The mold change is convenient, and the debugging is simple. It perfectly suits the production mode of multiple varieties, small batches, and large batches alternately, meeting the diversified production needs of sillimanite bricks for kilns in different industries.

The equipment is equipped with a dedicated digital process database for sillimanite brick forming, which includes the optimal forming parameters for sillimanite bricks with different raw material ratios, different specifications and models, and different performance indicators. The operator can directly start mass production by one-click retrieval, without the need for repeated manual debugging and exploration. All forming process parameters can be permanently stored, batch reused, and one-click replicated, completely eliminating the dependence on manual operation experience and eliminating the quality fluctuations caused by human factors. It ensures that the density, dimensional accuracy, and structural integrity of each batch of sillimanite brick bodies are highly consistent, easily meeting the quality acceptance standards of high-end refractory materials at home and abroad, helping enterprises expand into high-end markets at home and abroad.

It adopts a servo motor on-demand start-stop intelligent energy-saving mode. The motor only operates during the pressing process, and automatically enters sleep mode with zero energy consumption during the feeding, demolding, and standby processes. The comprehensive energy-saving rate is over 55% compared to traditional friction presses, significantly reducing the electricity cost for large-scale production of sillimanite bricks. The static pressure transmission structure has extremely low wear, and is equipped with a fully automatic forced lubrication system and an oil shortage automatic alarm device. The equipment has a low failure rate, a significantly extended service life, and requires less maintenance work and maintenance costs are reduced by more than 40%. The entire process is in line with the core development trend of green, low-carbon, energy-saving, and efficiency improvement in the refractory materials industry, helping enterprises achieve dual upgrades in cost reduction and quality improvement.

The equipment is standardly equipped with standardized industrial communication interfaces, which can be seamlessly connected with automatic and precise feeding machines, intelligent material distribution machines, automatic demolding equipment, and non-destructive testing lines for green bodies, building a fully automatic unmanned forming production line for sillimanite bricks. It realizes unmanned control throughout the entire process from raw material distribution, precise pressing, stable pressure setting, automatic demolding to green body transfer and testing. It supports remote production monitoring, online parameter adjustment, intelligent fault warning, and full traceability of production data, reducing the impact of manual intervention on the forming quality of green bodies, continuously improving production efficiency and product stability, and adapting to the pace of intelligent and digital transformation and upgrading in the global refractory materials industry.

As a leading domestic enterprise in the core research and development and manufacturing of servo screw presses, Zhengzhou Haloong has been deeply engaged in the field of refractory material forming equipment for 45 years. It has always focused on the pain points of various high-end refractory material forming processes and driven the high-quality development of the refractory materials industry through technological innovation. The HLDS series of dedicated servo screw presses for sillimanite bricks have a complete range of tonnages and can provide one-to-one customized overall forming solutions based on customers' production capacity requirements, brick types, and quality standards, fully meeting the mass production needs of various sillimanite bricks.