Preparation method of volcanic rock-like foamed ceramic and volcanic rock-like foamed ceramic

Abstract

The application discloses a preparation method of imitation volcanic stone foamed ceramic, which comprises the following steps: (1) preparing foamed ceramic powder: after a known foamed ceramic base material taking silicon carbide as a foaming agent is prepared into a base powder through ball milling and spray granulation, a pore-forming material is added and uniformly mixed, the mass ratio of the base powder to the pore-forming material is 70-85:15-30, and the particle size range of the pore-forming material is 6-30 meshes; (2) spreading the foamed ceramic powder according to a preset thickness in a refractory kiln, and scraping; (3) sending into a kiln for firing, the firing temperature is 1160-1170 DEG C, and the firing period is 8-13.5 h; (4) removing the refractory kiln after cooling out of the kiln, and thus imitation volcanic stone foamed ceramic is obtained. In step (1), the content of silicon carbide in the pore-forming material is greater than the content of silicon carbide in the foamed ceramic base material. The foamed ceramic after firing can form an imitation volcanic stone decorative effect with pores of different sizes.

Description

Technical Field

[0001] This invention relates to the field of building ceramics, and in particular to a method for preparing imitation volcanic rock foamed ceramics and the imitation volcanic rock foamed ceramics themselves. Background Technology

[0002] With the rapid development of the construction industry, people have increasingly higher requirements for the decoration of building walls, and natural stone is highly regarded for its beautiful natural characteristics and good protective properties. However, natural stone is becoming increasingly scarce due to mining, and its construction process is complex and costly. Furthermore, its use and development are limited by factors such as its origin and environment. Therefore, lower-cost imitation stone is gaining popularity.

[0003] Volcanic rock refers to rock formed from hot magma erupted from deep within the Earth through volcanoes and cooled to the surface. It has an irregular, naturally porous honeycomb structure. This type of stone, due to its porous structure, possesses sound-absorbing and noise-reducing properties and is widely used in the construction and decoration industries.

[0004] In recent years, due to the scarcity and limited development of volcanic rock, a special type of stone resource, some companies have attempted to artificially prepare volcanic rock-like decorative materials. Current technologies typically use volcanic slag combined with cement, mineral powder, water, foaming agents, foam stabilizers, plasticizers, pigments, decorative fillers, and waterproofing agents, employing a chemical foaming process. However, to achieve a realistic volcanic rock effect, the finished material needs to contain air bubbles of varying sizes.

[0005] Foamed ceramic materials are porous materials, and their pore size and pore size distribution range are within a certain range. When they exceed the specific range, large pores will appear, which will put great pressure on cooling. If not careful, thermal stress concentration will occur and cracks will be generated.

[0006] Therefore, there are still technical challenges in making the pores of foamed ceramics vary in size and have an uneven distribution, so as to give it a decorative effect similar to volcanic rock. Summary of the Invention

[0007] The main objective of this invention is to propose a method for preparing volcanic rock-like foamed ceramics. By adjusting the formula components, foamed ceramics with varying pore sizes throughout are directly fired through a stacking process, giving them a decorative effect similar to natural volcanic rock.

[0008] To achieve the above objectives, this invention proposes a method for preparing volcanic rock-inspired foamed ceramics, comprising the following steps:

[0009] (1) Preparation of foamed ceramic powder: The known foamed ceramic base material with silicon carbide as foaming agent is ball-milled into slurry and spray-granulated to prepare base powder. Then, pore-forming material is added and mixed evenly. The mass ratio of the base powder to the pore-forming material is 70-85:15-30, and the particle size range of the pore-forming material is 6-30 mesh.

[0010] (2) Spread the foamed ceramic powder in the refractory kiln furniture according to the preset thickness and scrape it level;

[0011] (3) The product is placed in a kiln for firing at a temperature of 1160-1170℃ for a period of 8-13.5 hours.

[0012] (4) After cooling and exiting the kiln, the refractory kiln furniture is removed to obtain the imitation volcanic rock foamed ceramic;

[0013] In step (1), the silicon carbide content in the pore-forming material raw material component is greater than the silicon carbide content in the foamed ceramic base material raw material component by mass percentage.

[0014] This scheme adopts a formulation system that adds pore-forming material to basic powder. The pore-forming material with larger particle size is added to the basic powder and mixed evenly. Since the foaming agent content added to the pore-forming material is greater than that in the basic powder, the larger particles of pore-forming material are evenly distributed in the basic powder, and the foaming is more intense. Therefore, the foamed ceramic obtained after firing can form an irregular, elongated oval shape with varying sizes of pores, creating a decorative effect similar to volcanic rock.

[0015] Preferably, the difference in silicon carbide content between the pore-forming material and the foamed ceramic base material, by mass percentage, is ≥0.2%. By adjusting the difference in the proportion of foaming agent in the pore-forming material and the base powder, the proportion of pores of different sizes can be controlled, resulting in a better volcanic rock-like decorative effect. Simultaneously, by controlling the content of foaming agent in both materials, normal production can be ensured, and cracking of the boards can be reduced.

[0016] Preferably, the pore-forming material contains 0.15-0.5% silicon carbide by mass percentage, and the foamed ceramic base material contains 0.05-0.4% silicon carbide by mass percentage.

[0017] Preferably, the raw materials for the pore-forming material, by weight percentage, include the following components: 50-80% sand and mud tailings, 25-50% waste clinker, and 0-10% magnesia clay. Using this formulation system, the pore-forming material allows large particles to be evenly distributed within the matrix network structure, thus improving overall wear resistance and strength.

[0018] Preferably, based on the total amount of raw materials in the pore-forming material, the raw materials in the pore-forming material further include: 0.15-0.5% silicon carbide, 0-0.3% manganese oxide, 1.0-2.0% liquid degumming agent, and 0-0.35% preform reinforcing agent.

[0019] Preferably, by mass percentage, the foamed ceramic base material includes at least two of the following three formulation systems:

[0020] Component A: Sodium sand 5-15%, pressed mud 40-65%, waste ceramic fiber 0-3%, talc 5-10%, frit 0-8%, potassium feldspar 8-18%, cordierite 0-5%, wollastonite 0-3%;

[0021] Component B: 10-30% mine tailings, 10-25% pressed mud, 0-10% glass tailings, 5-40% waste clinker, 0-10% sand, 10-20% waste soil, and 4-6% magnesia clay;

[0022] Component C: tailings 10-45%, waste clinker 5-15%, attapulgite 45-65%.

[0023] Preferably, based on the total amount of raw materials in the foamed ceramic base material, the raw materials in the foamed ceramic base material further include: 0.05-0.4% silicon carbide, 0-0.5% manganese oxide, 1.0-2.0% liquid debinding agent, and 0-0.35% green body reinforcing agent.

[0024] The formulation system of the foamed ceramic base material was adjusted to ensure that the density of the volcanic rock-like foamed ceramic obtained after firing was within the range of 700–1000 kg / m³. 3 Its compressive strength can reach over 25MPa.

[0025] Preferably, the process parameters of the base powder are: bulk density ≥ 0.87 g / mL, powder moisture content 5.5-6.0%, 1-2% above 20 mesh sieve, 45-70% of 20-40 mesh, 80-97% of 20-60 mesh, ≤1.5% below 100 mesh sieve, and green body strength higher than 1.3 MPa.

[0026] In another aspect, this invention provides a volcanic rock-like foamed ceramic obtained by the above-described preparation method. This volcanic rock-like foamed ceramic has pores of varying sizes, irregularly distributed, providing a decorative effect similar to natural volcanic rock. Furthermore, when combined with a specific foamed ceramic formulation system, it can achieve a density ranging from 700 to 1000 kg / m³. 3 It has high strength characteristics, with a compressive strength of over 25MPa. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the surface effect of the imitation volcanic rock foamed ceramic prepared in Example 2-1;

[0029] Figure 2 This is a schematic diagram of the surface effect of the imitation volcanic rock foamed ceramic prepared in Example 3-2.

[0030] The realization of the purpose, functional features and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0031] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0032] Furthermore, the technical solutions of the various embodiments can be combined with each other, but only if they are feasible for those skilled in the art. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0033] A method for preparing volcanic rock-inspired foamed ceramic includes the following steps:

[0034] (1) Preparation of foamed ceramic powder: The known foamed ceramic base material with silicon carbide as foaming agent is ball-milled into slurry and spray-granulated to prepare base powder. Then, a pore-forming material is added and mixed evenly. The mass ratio of the base powder to the pore-forming material is 70-85:15-30. The particle size range of the pore-forming material is 6-30 mesh, preferably 8-10 mesh. The process parameters of the base powder are: bulk density ≥0.87g / mL, powder moisture content 5.5-6.0%, 1-2% above 20 mesh sieve, 45-70% of 20-40 mesh, 80-97% of 20-60 mesh, and ≤1.5% below 100 mesh sieve. Under the above conditions, the green body strength can be higher than 1.3MPa.

[0035] (2) Spread the foamed ceramic powder in the refractory kiln furniture to a thickness of 45-75 mm and scrape it flat;

[0036] (3) The product is placed in a kiln for firing at a temperature of 1160-1170℃ for a period of 8-13.5 hours.

[0037] (4) After cooling and exiting the kiln, the refractory kiln furniture is removed to obtain the imitation volcanic rock foamed ceramic;

[0038] In step (1), the silicon carbide content in the pore-forming material raw material component is greater than the silicon carbide content in the foamed ceramic base material raw material component by mass percentage. Specifically, the same type of silicon carbide with the same composition and particle size is added to both the foamed ceramic base material raw material component and the pore-forming material raw material component.

[0039] It should be noted that in conventional foamed ceramic processes, the pore size distribution of the produced foamed ceramics is usually within a certain range, and the pore size and distribution are uniform. Exceeding this range, the appearance of large pores will put immense pressure on the cooling process, and even slight mishaps can lead to thermal stress concentration and cracking. Pore size can usually be adjusted by modifying the formulation and the amount of foaming agent. However, in current technologies, to obtain larger pores, it is usually necessary to simultaneously increase the firing temperature to over 1200℃, and the corresponding holding and cooling time also needs to be extended. This process not only easily leads to overfiring, but also results in relatively uniformly large pores after firing, making it difficult to achieve the volcanic rock-like effect with varying pore sizes. Even if foamed ceramics with uneven pores are obtained, the matrix strength is poor, typically with a compressive strength not exceeding 9 MPa.

[0040] This method involves adding large-particle pore-forming material to the base powder and then firing it. At the same time, the proportion of foaming agent in the pore-forming material is greater than that in the base powder. The larger particles of pore-forming material are evenly distributed in the base powder, and the foaming is more intense. Therefore, the foamed ceramic obtained after firing can form an irregular, elongated oval shape with varying sizes of pores, creating a decorative effect similar to volcanic rock.

[0041] In some embodiments, the difference between the silicon carbide content in the pore-forming material raw material component and the silicon carbide content in the foamed ceramic base material raw material component, by mass percentage, is ≥0.2%.

[0042] By adjusting the difference in the proportion of foaming agent in the pore-forming material and the base powder, the proportion of pores of different sizes can be controlled, resulting in a better decorative effect similar to volcanic rock. At the same time, by controlling the content of foaming agent in both materials, normal production can be ensured, and cracking of the boards can be reduced.

[0043] In some embodiments, the pore-forming material contains 0.15-0.5% silicon carbide by weight, and the foamed ceramic base material contains 0.05-0.4% silicon carbide. By limiting the range of silicon carbide usage, the problems of increased firing temperature and decreased porosity caused by excessive silicon carbide addition are avoided.

[0044] Specifically, by mass percentage, the raw materials for the pore-forming material include the following components: 50-80% sand and mud tailings, 25-50% waste clinker, and 0-10% magnesia clay.

[0045] The sand and mud tailings in foamed ceramic raw materials typically include construction waste, mineral flotation pressing mud, and industrial by-products. Waste clinker typically includes glass tailings, ceramic waste, and foamed ceramic scraps. Using this formulation system for pore-forming materials ensures that large particles are evenly distributed within the matrix network structure, thus improving overall wear resistance and strength.

[0046] Specifically, based on the total amount of raw materials in the pore-forming material, the raw materials in the pore-forming material also include: 0.15-0.5% silicon carbide, 0-0.3% manganese oxide, 1.0-2.0% liquid degumming agent, and 0-0.35% preform reinforcing agent.

[0047] In some embodiments, the foamed ceramic base material comprises at least two of the following three formulation systems by weight percentage:

[0048] Component A: Sodium sand 5-15%, pressed mud 40-65%, waste ceramic fiber 0-3%, talc 5-10%, frit 0-8%, potassium feldspar 8-18%, cordierite 0-5%, wollastonite 0-3%;

[0049] Component B: 10-30% mine tailings, 10-25% pressed mud, 0-10% glass tailings, 5-40% waste clinker, 0-10% sand, 10-20% waste soil, and 4-6% magnesia clay;

[0050] Component C: tailings 10-45%, waste clinker 5-15%, attapulgite 45-65%.

[0051] Specifically, based on the total amount of raw materials in the foamed ceramic base material, the raw materials in the foamed ceramic base material also include: 0.05-0.4% silicon carbide, 0-0.5% manganese oxide, 1.0-2.0% liquid debinding agent, and 0-0.35% green body reinforcing agent.

[0052] Foamed ceramics, due to their porous structure, suffer from low density, strength, and poor mechanical properties. Volcanic rock-imitation foamed ceramics, with their varying pore sizes, further exhibit these reduced mechanical properties. Therefore, we offer a formulation system of three basic powders that can improve the density, compressive and flexural strength of foamed ceramics, enabling them to achieve both a volcanic rock-imitation decorative effect and good mechanical properties, with a density range of 700–1000 kg / m³. 3 The compressive strength exceeds 25 MPa. In particular, the addition of attapulgite to component C significantly improves the matrix strength.

[0053] The technical solution of the present invention will be further described in detail below with reference to specific embodiments. It should be understood that the following embodiments are only used to explain the present invention and are not intended to limit the present invention.

[0054] The specific chemical composition of each ceramic preparation raw material in the following embodiments is detailed in the table below (by mass percentage, in %):

[0055]

[0056]

[0057] Note: If the chemical composition of the raw materials in the table above is less than 100%, it is mainly due to the presence of other undetected impurities.

[0058] The silicon carbide used in this plan was purchased from Foshan Changyuan New Materials Co., Ltd., the manganese oxide used in this plan was purchased from Foshan Yuhui Trading Co., Ltd., the preform reinforcement was purchased from Foshan Xinjinhui Economic and Trade Co., Ltd., and the liquid degumming agent was purchased from Jiangxi Keben New Materials Technology Co., Ltd.

[0059] The attapulgite used in this plan is a crystalline hydrated magnesium aluminum silicate mineral, mined from Linze County, Gansu Province.

[0060] Liquid deflocculants mainly consist of inorganic salts and polyelectrolytes. Among them, inorganic salt liquid deflocculants mainly include water glass, sodium carbonate, sodium tripolyphosphate, and sodium hexametaphosphate.

[0061] Green body reinforcing agents are classified into organic and inorganic types. Organic green body reinforcing agents typically include polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC), modified starch, sodium polyacrylate, modified polysaccharides, polyacrylates, and lignin. Organic green body reinforcing agents can improve the plasticity, flowability, and suspension properties of the green body, as well as increase its drying strength and abrasion resistance. Inorganic green body reinforcing agents include water glass, phosphates, bentonite, sodium humate, lignin sulfonate, and alkali lignin. Inorganic green body reinforcing agents can enhance the density and abrasion resistance of the green body, while also improving its plasticity and rheological properties.

[0062] Example 1

[0063] We use a set of standard foamed ceramic raw material formulas as the base material, and the raw material components are shown in the table below by mass percentage:

[0064]

[0065] Note: Silicon carbide, liquid deflocculant, preform reinforcement, and manganese oxide are introduced by external means.

[0066] Add a pore-forming material with a granulation size of 8-10 mesh to the above base material. The raw material composition of the pore-forming material, by mass percentage, is shown in the table below:

[0067]

[0068] Note: Silicon carbide, manganese oxide, liquid deflocculant, and preform reinforcement are introduced by external means.

[0069] The addition ratio of base material to pore-forming material is shown in the table below:

[0070]

[0071] The difference in silicon carbide content between the base material and the pore-forming material is shown in the table below:

[0072]

[0073] The preparation method of the volcanic rock-inspired foamed ceramic in Example 1 includes the following steps:

[0074] (1) Preparation of foamed ceramic powder: The above-mentioned foamed ceramic base material is prepared into base powder by ball milling and spray granulation, and then pore-forming material is added and mixed evenly; the process parameters of the base powder are: bulk density ≥0.87g / mL, powder moisture content 5.5~6.0%, 1~2% above 20 mesh sieve, 45~70% of 20~40 mesh, 80~97% of 20~60 mesh, and ≤1.5% below 100 mesh sieve. By controlling the above conditions, the green body strength can be higher than 1.3MPa.

[0075] (2) Spread the foamed ceramic powder in the refractory kiln furniture to a thickness of 65mm and scrape it flat;

[0076] (3) The product is placed in a kiln and fired at a temperature of 1160℃ for a period of 13.5 hours.

[0077] (4) After cooling and removing the kiln furniture, the imitation volcanic rock foamed ceramic is obtained.

[0078] The performance of the volcanic rock-like foamed ceramic prepared in Example 1 was tested, and the testing methods and standards are shown in the table below:

[0079]

[0080] Note: The pore size of foamed ceramics is measured directly using a length measuring tool.

[0081] The test results are shown in Table 1:

[0082] Table 1

[0083]

[0084] As shown in Table 1, the reference embodiment is a conventional foamed ceramic, and the pore size range produced by uniform foaming is relatively uniform, within the range of 0.5–0.8 mm. The foamed ceramic obtained in Example 1, due to the addition of a pore-forming material, can obtain pores of various sizes including 0.5–0.8 mm, 0.8–1.2 mm, and 2–3 mm, achieving a decorative effect similar to volcanic rock. In Comparative Example 1, because the silicon carbide content of the pore-forming material is 0.2%, the difference between the silicon carbide content in the pore-forming material and the base material is less than 0.2%, it cannot form a good large-pore effect, only having two pore sizes: 0.5–0.8 mm and 0.8–1.2 mm. The difference in pore size is not significant, resulting in a poor volcanic rock imitation effect.

[0085] Example 2

[0086] To further improve the density and compressive strength of foamed ceramics, the formulation system of the foamed ceramic base material was adjusted. The raw material components, by mass percentage, are shown in the table below:

[0087]

[0088] Note: Silicon carbide, manganese oxide, liquid deflocculant, and preform reinforcement are introduced by external means.

[0089] In this scheme, waste ceramic fiber paper is used. In practice, other ceramic fibers, such as alumina fiber, can be selected as needed.

[0090] Add a pore-forming material to the above base material. The raw material composition of the pore-forming material, by mass percentage, is shown in the table below:

[0091]

[0092] Note: Silicon carbide, manganese oxide, liquid deflocculant, and preform reinforcement are introduced by external means.

[0093] The addition ratio of base material to pore-forming material is shown in the table below:

[0094]

[0095] The preparation method of the volcanic rock-inspired foamed ceramic in Example 2 includes the following steps:

[0096] (1) Preparation of foamed ceramic powder: The above-mentioned foamed ceramic base material A, base material B and pore-forming material 1 are mixed and then ball-milled into slurry and spray-granulated to prepare base powder. Pore-forming material 2 with a granulation particle size of 8-10 mesh is added and mixed evenly in proportion. The process parameters of the base powder are: bulk density ≥0.87g / mL, powder moisture content 5.5-6.0%, 1-2% above 20 mesh sieve, 45-70% of 20-40 mesh, 80-97% of 20-60 mesh, and ≤1.5% below 100 mesh sieve. Under the above conditions, the green body strength can be higher than 1.3MPa.

[0097] (2) Spread the foamed ceramic powder in the refractory kiln furniture to a thickness of 65mm and smooth it out;

[0098] (3) The product is placed in a kiln and fired at a temperature of 1160℃ for a period of 13.5 hours.

[0099] (4) After cooling and removing the kiln furniture, the imitation volcanic rock foamed ceramic is obtained.

[0100] The performance of the volcanic rock-like foamed ceramic prepared in Example 2 was tested, and the test results are shown in Table 2:

[0101] Table 2

[0102]

[0103] As shown in Table 2, the compressive strength of the foamed ceramic prepared in Example 2 was significantly improved after adjusting the formulation of the foamed ceramic base material. Furthermore, the pore size range of the foamed ceramic prepared in Example 2 included 0.5–0.8 mm, 2–3 mm, and 4–5 mm, exhibiting greater pore size variation, which resulted in a better imitation volcanic rock decorative effect. (Refer to...) Figure 1 .

[0104] Example 3

[0105] The formulation system of the foamed ceramic base material was adjusted, and the raw material components, by mass percentage, are shown in the table below:

[0106]

[0107] Note: Silicon carbide, manganese oxide, liquid deflocculant, and preform reinforcement are introduced by external means.

[0108] Add a pore-forming material to the above base material. The raw material composition of the pore-forming material, by mass percentage, is shown in the table below:

[0109]

[0110] Note: Silicon carbide, manganese oxide, liquid deflocculant, and preform reinforcement are introduced by external means.

[0111] The addition ratio of base material to pore-forming material is shown in the table below:

[0112]

[0113] The preparation method of the volcanic rock-inspired foamed ceramic in Example 3 includes the following steps:

[0114] (1) Preparation of foamed ceramic powder: The above-mentioned foamed ceramic base material A, base material C and pore-forming material are mixed and then ball-milled into slurry and spray-granulated to prepare base powder. Then, pore-forming material with a particle size of 8-10 mesh is added and mixed evenly in proportion. The process parameters of the base powder are: bulk density ≥0.87g / mL, powder moisture content 5.5-6.0%, 1-2% above 20 mesh sieve, 45-70% of 20-40 mesh, 80-97% of 20-60 mesh, and ≤1.5% below 100 mesh sieve. Under the above conditions, the green body strength can be higher than 1.3MPa.

[0115] (2) Spread the foamed ceramic powder in the refractory kiln furniture to a thickness of 70 mm and smooth it out;

[0116] (3) The product is placed in a kiln and fired at a temperature of 1160℃ for a period of 13.5 hours.

[0117] (4) After cooling and exiting the kiln, the refractory kiln furniture is removed to obtain the imitation volcanic rock foamed ceramic.

[0118] The performance of the volcanic rock-like foamed ceramic prepared in Example 3 was tested, and the test results are shown in Table 3:

[0119] Table 3

[0120]

[0121] As shown in Table 3, due to the addition of base material C containing attapulgite, the foamed ceramic prepared in Example 3 not only has large pore sizes of 2-3 mm and 4-5 mm, but also a main structure with small pore sizes within 0.5 mm, exhibiting a good imitation volcanic rock decorative effect (such as...). Figure 2 (As shown) At the same time, it significantly improves the compressive strength, with foamed ceramics reaching 800-1000 kg / m³. 3 Within a certain density range, the compressive strength can reach 30MPa.

[0122] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A method for preparing volcanic rock-inspired foamed ceramic, characterized in that, Includes the following steps: (1) Preparation of foamed ceramic powder: The known foamed ceramic base material with silicon carbide as foaming agent is ball-milled into slurry and spray-granulated to prepare base powder. Then, pore-forming material is added and mixed evenly. The mass ratio of the base powder to the pore-forming material is 70-85:15-30, and the particle size range of the pore-forming material is 6-30 mesh. (2) Spread the foamed ceramic powder in the refractory kiln furniture according to the preset thickness and scrape it level; (3) The product is placed in a kiln for firing at a temperature of 1160-1170℃ for a period of 8-13.5 hours. (4) After cooling and exiting the kiln, the refractory kiln furniture is removed to obtain the imitation volcanic rock foamed ceramic; In step (1), the silicon carbide content in the pore-forming material raw material component is greater than the silicon carbide content in the foamed ceramic base material raw material component by mass percentage. The difference between the silicon carbide content in the pore-forming material and the silicon carbide content in the foamed ceramic base material is ≥0.2% by mass percentage. By mass percentage, the pore-forming material contains 0.15-0.5% silicon carbide, and the foamed ceramic base material contains 0.05-0.4% silicon carbide. The raw materials for the pore-forming material, by weight percentage, include the following components: 50-80% sand and mud tailings, 25-50% waste clinker, and 0-10% magnesia clay, totaling 100%; with 0.15-0.5% silicon carbide introduced externally. By weight percentage, the foamed ceramic base material raw material includes at least two of the following three formulation systems: Component A: Sodium sand 5-15%, pressed mud 40-65%, waste ceramic fiber 0-3%, talc 5-10%, frit 0-8%, potassium feldspar 8-18%, cordierite 0-5%, wollastonite 0-3%; Component B: 10-30% mine tailings, 10-25% pressed mud, 0-10% glass tailings, 5-40% waste clinker, 0-10% sand, 10-20% waste soil, and 4-6% magnesia clay; Component C: tailings 10-45%, waste clinker 5-15%, attapulgite 45-65%; The process parameters of the basic powder are: bulk density ≥ 0.87 g / mL, powder moisture content 5.5~6.0%, 1~2% above 20 mesh sieve, 45~70% of 20~40 mesh, 80~97% of 20~60 mesh, ≤1.5% below 100 mesh sieve, and green body strength higher than 1.3 MPa.

2. The method for preparing a volcanic rock-like foamed ceramic as described in claim 1, characterized in that, Based on the total amount of raw materials in the pore-forming material, the raw materials in the pore-forming material further include: 0.15-0.5% silicon carbide, 0-0.3% manganese oxide, 1.0-2.0% liquid desizing agent, and 0-0.35% preform reinforcement, with silicon carbide, manganese oxide, liquid desizing agent, and preform reinforcement introduced externally.

3. The method for preparing a volcanic rock-like foamed ceramic as described in claim 1, characterized in that, Based on the total amount of raw materials in the foamed ceramic base material, the raw materials in the foamed ceramic base material also include: 0.05-0.4% silicon carbide, 0-0.5% manganese oxide, 1.0-2.0% liquid debinding agent, and 0-0.35% green body reinforcing agent.

4. A type of volcanic rock-inspired foamed ceramic, characterized in that, It is prepared by the method for preparing a volcanic rock-like foamed ceramic according to any one of claims 1 to 3.

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