The rise of no-burn refractory bricks aligns with the global "dual carbon" strategy and the green transformation trend in the refractory materials industry. Their production process does not require high-temperature sintering, significantly reducing coal consumption and exhaust emissions. Compared to traditional sintered refractory bricks, their energy consumption is reduced by over 60%, highlighting their environmental advantages. However, the quality control of no-burn refractory bricks is more challenging - without the "strengthening stage" of high-temperature sintering, the density uniformity, porosity, and strength of the green body directly determine the service performance of the finished product. Any deviation in the forming process can easily lead to insufficient compressive strength, poor wear and corrosion resistance, and easy powdering and flaking of the finished product, making it unsuitable for industrial applications. Therefore, the forming of no-burn refractory bricks must meet six core requirements: uniform density, dense structure, strength compliance, no cracks, intact edges and corners, and uniform dispersion of binders. It is necessary to ensure uniform density throughout the green body, with a compressive strength of ≥30MPa and an apparent porosity controlled within the reasonable range of 18%-22%, to meet the service requirements of medium and low-temperature conditions. At the same time, the pressure application speed and holding time must be precisely controlled to adapt to the poor fluidity and difficult exhaust of the raw materials of no-burn refractory bricks, avoiding residual pores in the green body that can lead to insufficient strength of the finished product. Moreover, the forming pressure requirements for different specifications and uses of no-burn refractory bricks must be precisely matched to avoid cracking due to overpressure or porosity due to underpressure, while ensuring uniform dispersion of the binders to fully utilize their bonding and strengthening effects. Currently, the technical shortcomings of traditional forming equipment have led to common problems in the production of no-burn refractory bricks, such as uneven density of the green body, non-compliance with strength standards, damaged edges and corners, large dimensional deviations, uneven dispersion of binders, low product qualification rates, and high energy consumption, seriously restricting the large-scale and high-quality development of the no-burn refractory brick industry. 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 no-burn refractory bricks and creating dedicated forming equipment. With the core advantages of precise pressure control, stable pressure transmission, energy efficiency, and intelligent adaptability, it has established a benchmark for high-quality no-burn refractory bricks.

Compared to traditional sintered refractory bricks, no-burn refractory bricks, which do not require high-temperature sintering and rely on binders for forming, have significantly increased forming difficulty. The raw materials for no-burn refractory bricks, such as high-alumina bauxite, quartz sand, and corundum, are used as aggregates, combined with inorganic binders like sodium silicate and phosphate. The raw material particles are hard, have complex gradations, and poor fluidity, and the exhaust during the forming process is difficult. During forming, the application pressure, speed, and rhythm must be precisely controlled to achieve densification of the green body while avoiding cracking and edge damage, and ensuring uniform dispersion of the binders to meet the process requirements of different specifications of products. In addition, no-burn refractory bricks come in various specifications, from ordinary lining bricks and refractory blocks to special-shaped flue bricks and bricks for waste incineration furnaces. 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 no-burn refractory 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, adaptability, and energy efficiency. These advantages precisely match the five key forming requirements of no-burn refractory bricks: uniformity, density, crack resistance, uniform binder dispersion, and energy efficiency. It has become the preferred equipment for mass production of high-quality no-burn refractory bricks, assisting refractory material enterprises in creating high-quality products suitable for medium and low-temperature conditions and environmentally friendly and efficient, seizing the market opportunities in the green refractory materials sector. The core is equipped with a direct drive system of permanent magnet synchronous servo motors, completely eliminating the inefficient transmission structures such as traditional friction discs and clutches. The transmission chain is extremely short, with zero energy loss during transmission and stable and controllable pressure output throughout the process. The equipment is equipped with a dedicated numerical control pressure module for non-fired refractory bricks independently developed by Haloong, which can digitally and precisely set the striking energy, pressurization speed, number of stepwise pressurizations, and pressure holding time. The energy repetition control accuracy is ≤±1%, ensuring that the pressure for each molding is highly consistent and completely eliminating the quality deviations caused by manual operation and mechanical fluctuations. In response to the characteristics of non-fired refractory brick raw materials, such as poor fluidity, difficulty in exhaust of the mixed materials, and high requirements for binder dispersion, a customized stepwise pressurization process of "light pressure exhaust - slow pressure densification - long-term pressure holding" is adopted. First, the raw materials are lightly pressed to slowly expel the residual air inside, then the pressure is steadily increased in steps to compact the layers (the pressure increases slowly to avoid impact), and finally, long-term pressure holding is used for shaping. 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 green body structure with a reasonable open porosity rate, while promoting the uniform dispersion of the binder to fully exert its bonding and strengthening effects, ensuring that the compressive strength of the finished product meets the standards and increasing the qualified rate of the finished product 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 completely avoiding 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. This not only fully expels the internal pores of the green body and ensures its density but also completely eliminates 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 improves the production efficiency of the enterprise, solving the core pain point of traditional equipment, which is "high cracking rate and high scrap rate", and aligning with the green and energy-saving production concept of non-fired refractory bricks.

Breaking through the structural limitation of the fixed bottom dead center of traditional equipment, a stepwise forging molding mode is adopted. According to the material, size, structural complexity (irregular structural parts, lining bricks, flue bricks), density requirements, and raw material ratio (different particle size gradation, binder addition ratio) of non-fired refractory bricks, the stroke of the slider, pressurization depth, and pressurization force can be flexibly adjusted to precisely match the molding requirements of various non-fired refractory bricks, covering the full range of production scenarios for non-fired refractory 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 mixed materials. Combined with a rapid mold changing system, the mold changing process is convenient and efficient, perfectly adapting to the flexible mode of multi-variety and batch production, meeting the batch supply demands in the metallurgy, environmental protection, power, and other fields, and accommodating the molding requirements of both ordinary lining bricks and high-strength non-fired bricks. It can achieve uniform density control for deep cavity and irregular non-fired refractory parts.

The equipment is equipped with a dedicated forming parameter database for non-fired refractory bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, different particle size gradations, different binder addition ratios, and different density requirements of non-fired refractory bricks. It covers the forming parameters of common products such as standard non-fired lining bricks, irregular non-fired bricks, and high-strength non-fired refractory 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 binder dispersion, easily meeting the strict quality requirements of the domestic and international medium and high-end markets, and helping enterprises smoothly open up overseas markets for non-fired refractory bricks. Compared with traditional friction presses, the Haloong servo screw press adopts an intelligent mode of on-demand start-stop and sleep energy-saving, with the servo motor only operating during the pressing process and completely zero energy consumption in standby mode. The comprehensive energy-saving rate is as high as over 55%, and in some working conditions, it can reach up to 60%. This is highly consistent with the energy-saving and environmental protection concept of non-fired refractory bricks, significantly reducing the electricity cost of non-fired refractory brick production and helping enterprises achieve green and low-carbon production. 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 operation and maintenance costs by over 40%. It comprehensively compresses production, operation and maintenance, and material costs, helping enterprises achieve a green, low-carbon, and highly efficient production model, solving the pain points of traditional forming equipment such as "high energy consumption and complex operation and maintenance". Just like the energy-saving and efficiency-increasing results achieved by Jiaozuo Xincheng Group after the transformation, it helps enterprises reduce the overall production cost.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly connected with automatic and precise feeding machines, closed-loop distribution machines, intelligent demolding machines, non-destructive testing equipment for green refractory brick bodies, and constant-temperature conveyor lines, to build a fully automatic and intelligent forming production line for non-fired refractory bricks, achieving unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to brick body transfer and inspection, minimizing human intervention. This not only avoids damage to the brick body caused by manual operation and reduces the risk of cracking, but also ensures the forming accuracy and production efficiency, while ensuring the uniform dispersion of the binder. It also supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, facilitating domestic and foreign customers to remotely and in real-time control the production progress and product quality, fully in line with the global refractory industry's trend of intelligent, digital, and green transformation, helping enterprises build high-end intelligent production bases for non-fired refractory bricks and enhance large-scale mass production capabilities.

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 forming equipment for 45 years, deeply exploring the pain points in the forming process of green refractory products such as non-fired refractory bricks, and insisting on empowering industrial upgrading with customized technology. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T, and can provide one-to-one customized forming solutions based on the customer's requirements for the material, specifications, capacity, density, and raw material ratio (particle size distribution, binder addition ratio) of non-fired refractory bricks, fully meeting the mass production needs of various non-fired refractory bricks, and adapting to different medium and low-temperature, high-wear, and high-corrosion refractory supply fields. It solves the problems of low efficiency, uneven density, and uneven binder dispersion in traditional vibration forming, and can achieve precise forming of micro-porous structure non-fired refractory bricks, with the porosity deviation controlled within ±5%.