The core competitiveness of anti-peeling high aluminum bricks lies in their comprehensive characteristics of "high-temperature strength and toughness, anti-peeling and durability", and this feature is 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 uniform dispersion of anti-peeling agents. It is necessary to ensure uniform density throughout the green body to guarantee 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 thermal shock resistance and anti-peeling 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 high hardness, complex particle size distribution, and difficult exhaust of the raw materials for anti-peeling high aluminum bricks, avoiding residual pores within the green body that could lead to structural peeling during high-temperature service. Additionally, it is necessary to precisely match the forming pressure requirements of different specifications and uses of anti-peeling high aluminum bricks to prevent cracking due to overpressure and porosity due to underpressure, while ensuring the uniform dispersion of anti-peeling agents to fully leverage their anti-peeling effects. Currently, the technical shortcomings of traditional forming equipment have led to widespread issues in the production of anti-peeling high aluminum bricks, such as uneven green body density, excessive porosity, edge and corner damage, large dimensional deviations, uneven dispersion of anti-peeling agents, and low product qualification rates, severely restricting the industrial development of high-end anti-peeling high aluminum 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 pain points of anti-peeling high aluminum bricks and creating dedicated forming equipment. With the core advantages of precise pressure control, stable pressure transmission, and intelligent adaptability, it has established a quality benchmark for high-end anti-peeling high aluminum bricks.

Compared to ordinary high aluminum bricks, the forming difficulty of anti-peeling high aluminum bricks is significantly increased due to the addition of anti-peeling agents, high raw material hardness, and strict forming processes. The mixture for anti-peeling high aluminum bricks is centered around high alumina bauxite, combined with dedicated anti-peeling agents and binders. The raw material particles are hard, have a wide particle size distribution, and are uneven in composition. Moreover, 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 green body while avoiding cracking and edge damage, and ensuring the uniform dispersion of anti-peeling agents to meet the process requirements of different specifications of products. In addition, anti-peeling high aluminum bricks come in various specifications, ranging from furnace lining bricks and hot blast stove bricks in the metallurgical industry to rotary kiln lining bricks in the cement industry and electric furnace bricks in the power industry. The forming pressure, pressure application speed, and holding time for different types of products vary significantly, placing extremely high demands on the process adaptability of the equipment.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade needs of anti-peeling high aluminum 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 four key forming requirements of anti-peeling high aluminum bricks: uniformity, density, crack resistance, and uniform dispersion of anti-peeling agents, making it the preferred equipment for mass production of high-quality anti-peeling high aluminum bricks. It helps refractory material enterprises create high-quality products suitable for high-temperature, strong erosion, and strong scouring 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 Haloong's independently developed anti-peeling high aluminum brick dedicated CNC pressure control module, 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 cycle, completely eliminating quality deviations caused by manual operation and mechanical fluctuations. In response to the high hardness of the raw materials for anti-spalling high alumina bricks, the difficulty in venting the mixed materials, and the high requirement for the dispersion of anti-spalling agents, a customized stepwise pressurization process of "light pressure venting - slow pressure densification - long-term pressure holding" was developed. This process first applies light pressure to loosen the raw materials and slowly expel the residual air inside. Then, it gradually and steadily applies pressure layer by layer (with the pressure increasing slowly to avoid impact), and finally maintains the pressure for a long time to shape the product. This ensures that all parts of the green body, including the center, edges, and corners, are uniformly stressed, with the density fluctuation controlled within a very small range. It also guarantees a dense structure of the green body, with the apparent porosity controlled within a reasonable range. At the same time, it promotes the uniform dispersion of the anti-spalling agent, fully exerting its anti-spalling effect, 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 problems brought 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 ensure its density but also completely eliminate 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 reduces the waste of high-cost raw materials, effectively extends the service life of the mold, reduces material costs, and improves 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 lower dead point of traditional equipment, a progressive 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 distribution, anti-spalling agent addition ratio) of anti-spalling high alumina 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 anti-spalling high alumina bricks, covering the full range of production scenarios for high-end anti-spalling high alumina 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 distribution, and changes in the fluidity of the mixed materials. 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 demands of high-end fields such as metallurgy, cement, and power, while also accommodating the forming requirements of both ordinary lining bricks and high-strength anti-spalling bricks.

The equipment is equipped with a dedicated forming parameter database for anti-spalling high alumina bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, different particle size distributions, different anti-spalling agent addition ratios, and different density requirements of anti-spalling high alumina bricks. It covers the forming parameters of common products such as standard anti-spalling high alumina lining bricks, irregular anti-spalling bricks, and high-strength anti-spalling high alumina 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 and uniform dispersion of the anti-spalling agent, easily meeting the strict quality requirements of high-end fields at home and abroad, and helping enterprises smoothly open up overseas high-end anti-spalling high alumina brick markets.

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%. This significantly reduces the electricity cost of anti-spalling high alumina 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, and is equipped 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 over 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 anti-spalling high alumina 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 cracking, but also ensures forming accuracy and production efficiency, while ensuring uniform dispersion of anti-spalling agents. It also supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, facilitating real-time control of production progress and product quality by domestic and foreign customers from different locations. This fully aligns with the global trend of intelligent, digital, and green transformation in the refractory materials industry, helping enterprises build high-end intelligent production bases for anti-spalling high alumina bricks and enhance large-scale production capacity.

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 refractory materials such as anti-spalling high alumina bricks. It adheres to customizing technology to empower industrial upgrading. 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 the material, specifications, capacity, density, and raw material ratio (particle size distribution, anti-spalling agent addition ratio) of anti-spalling high alumina bricks, it provides one-to-one customized forming solutions, fully meeting the mass production needs of various anti-spalling high alumina bricks. It is suitable for refractory supply in different high-temperature, strong erosion, and strong scouring fields, solving the problems of low efficiency, uneven density, and uneven dispersion of anti-spalling agents in traditional vibration forming.