The core competitiveness of silica-mullite red bricks lies in their comprehensive characteristics of "high temperature resistance, corrosion resistance, high strength, and anti-spalling", and these characteristics are entirely dependent on precise control during the forming stage. The forming process must meet six core requirements: uniform density, dense structure, no cracks, intact edges and corners, precise dimensions, and excellent bonding. It is necessary to ensure uniform density throughout the body to maintain a stable volume density of the finished product, control the apparent porosity within a reasonable range, and lay a solid foundation for subsequent high-temperature sintering, thereby enhancing the high-temperature strength and anti-erosion performance of the finished product. At the same time, it is essential to precisely control the pressure application speed and holding time to accommodate the complex raw material composition, diverse particle size distribution, and difficult exhaust of silica-mullite red bricks, avoiding internal residual pores in the body that could lead to structural failure during high-temperature service. Additionally, it is necessary to precisely match the forming pressure requirements of different specifications and uses of silica-mullite red bricks to prevent cracking due to overpressure and porosity due to underpressure. Currently, the technical shortcomings of traditional forming equipment have led to widespread issues in silica-mullite red brick production, such as uneven body density, excessive porosity, damaged edges and corners, large dimensional deviations, and low product qualification rates, severely restricting the industrialization of high-end silica-mullite red bricks. Zhengzhou Haloong, relying on the third-generation permanent magnet synchronous servo direct drive core technology, has optimized and upgraded the HLDS series of CNC servo screw presses, specifically addressing the forming challenges of silica-mullite red bricks and creating dedicated forming equipment. With the core advantages of precise pressure control, stable pressure transmission, and intelligent adaptability, it has established a benchmark for high-end silica-mullite red brick quality.

Compared to ordinary refractory bricks, silica-mullite red bricks have a significantly increased forming difficulty due to their complex raw material composition and strict forming process. The silica-mullite red brick mixture is composed of high-alumina bauxite, silicon carbide, and mullite as the core, combined with special binders. The raw material particle size distribution is wide, the composition is uneven, and the mixture has poor fluidity and is difficult to exhaust during the forming process. During forming, it is necessary to precisely control the application force, speed, and rhythm to achieve densification of the body while avoiding cracking and edge damage. At the same time, it needs to adapt to the process requirements of different specifications of products. Moreover, silica-mullite red bricks have a wide range of specifications, from lining bricks for hot blast stoves and metallurgical furnaces in the metallurgical industry to lining bricks for rotary kilns and furnace wall bricks in the cement and boiler industries. The forming pressure, pressure application speed, and holding time for different types of products vary significantly, requiring extremely high process adaptability from the equipment.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of silica-mullite red bricks. With the core technology of permanent magnet synchronous servo motor direct drive + static pressure flexible pressure transmission + intelligent CNC system, it has specifically optimized the HLDS series of servo screw presses, comprehensively upgrading the equipment's precision, stability, and adaptability. The advantages precisely match the triple forming requirements of silica-mullite red bricks: uniformity, density, and anti-cracking, making it the preferred equipment for mass production of high-quality silica-mullite red bricks. It helps refractory material enterprises create high-quality products suitable for high-temperature, strong erosion, and strong erosion conditions, seizing the opportunity in the high-end market.

Equipped with a core permanent magnet synchronous servo motor direct drive system, it completely eliminates traditional low-efficiency transmission structures such as friction discs and clutches, with an extremely short transmission chain and zero energy loss during energy transmission. The pressure output is fully stable and controllable throughout the process. The equipment is equipped with a Haloong self-developed CNC pressure control module specifically for silica-mullite red 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 forming pressure is highly consistent in each process, completely eliminating quality deviations caused by manual operation and mechanical fluctuations. In response to the complex composition of raw materials and the difficulty in exhausting air from the mixture of silicon-magnesia red bricks, a stepwise pressurization process of "light pressure exhaust - slow pressure densification - long-term pressure holding" was customized. This process first lightly presses the loose raw materials to slowly expel the residual air inside, then gradually and steadily applies pressure layer by layer (with pressure increasing slowly to avoid impact), and finally holds the pressure for a long time to shape the brick. 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. It also guarantees a dense structure of the green body and a reasonable open porosity, providing a solid foundation for 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 slow pressurization. This completely avoids the severe impact force and stress concentration caused by traditional rigid pressurization. The pressurization process is smooth and even, with uniform and gentle pressure transmission. It can fully expel the internal pores of the green body, ensuring its density and completely eliminating defects such as porosity, delamination, and micro-cracks. At the same time, it avoids the cracking and edge damage of the green body caused by rigid impact, significantly reducing the waste of high-cost raw materials. It also effectively extends the service life of the mold, reduces material costs, and enhances the production efficiency of the enterprise, solving the core pain point of traditional equipment, which is "high cracking rate and high scrap rate".

Breaking through the structural limitation of the fixed bottom dead center of traditional equipment, a step-by-step forging forming mode is adopted. According to the material, size, structural complexity (irregular structural parts, lining bricks, furnace wall bricks), density requirements, and raw material ratio (different particle size gradation) of silicon-magnesia red bricks, the stroke of the slider, the depth of pressurization, and the pressure application force can be flexibly adjusted to precisely match the forming requirements of various silicon-magnesia red bricks, covering the full range of production scenarios for high-end silicon-magnesia red bricks. There is no need to worry about the problems of uneven pressurization or green body cracking caused by deviations in raw material filling volume, differences in particle size gradation, and changes in the fluidity of the mixture. Combined with a rapid mold changing system, mold changing is convenient and efficient, perfectly adapting to the flexible mode of multi-variety and batch production, meeting the batch supply needs of high-end fields such as metallurgy, cement, and boilers, and accommodating the forming requirements of both ordinary lining bricks and high-strength corrosion-resistant bricks.

The equipment is equipped with a dedicated forming parameter database for silicon-magnesia red bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, different particle size gradations, and different density requirements of silicon-magnesia red bricks. It covers the forming parameters of common products such as standard silicon-magnesia red lining bricks, irregular corrosion-resistant bricks, and high-strength silicon-magnesia red 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, with no cracking or damage to the green body. It easily meets the strict quality requirements of high-end fields at home and abroad, helping enterprises smoothly open up the overseas high-end silicon-magnesia red brick 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%. This significantly reduces the electricity cost of silicon-magnesia red brick production and meets 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. 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 compresses production, operation, and material costs, helping enterprises achieve a green, low-carbon, and efficient profit-making production model, solving the pain points of traditional forming equipment, which are "high energy consumption and complex maintenance". The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly integrated 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 to build a fully automatic and intelligent forming production line for silicon-magnesia red bricks. This enables unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention. It not only avoids damage to green bodies caused by manual operation and reduces the risk of green body cracking, 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 in real-time control production progress and product quality. It fully conforms to the global trend of intelligent, digital, and green transformation in the refractory industry, helping enterprises build high-end silicon-magnesia red brick intelligent production bases and enhance large-scale mass production capabilities.

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 exploring the pain points in the forming process of high-end composite refractory materials such as silicon-magnesia red bricks and has been committed to empowering industrial upgrading with customized technologies. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to the customer's requirements for silicon-magnesia red brick materials, specifications, production capacity, density, and raw material ratios (particle size distribution), it can provide one-to-one customized forming solutions, fully meeting the mass production needs of various silicon-magnesia red bricks and adapting to the supply of refractories in different high-temperature, strong erosion, and strong erosion fields. It solves the problems of low efficiency and uneven density in traditional vibration forming.