A formula and method for preparing foamed ceramic by dry powdering

Abstract

The application discloses a formula and a method for preparing foamed ceramics by adopting a dry powder method, and relates to the technical field of foamed ceramics, and comprises perlite, foamed ceramic scraping slag, water mill tailings, polishing brick squeezing mud, talc, heavy magnesium oxide, aluminum ash and a foaming agent. The formula and the method for preparing foamed ceramics by adopting the dry powder method control the overall fluidity of the material by controlling the particle size of the powder granular material in the process of processing the raw material, so that the material does not need to be granulated again and then dried, and meanwhile, if the water content of the raw material is less than or equal to 5% in the production and processing process, the drying equipment does not need to be used to control the water content of the raw material, so that the energy consumption of the overall equipment is lower, the overall equipment is more energy-saving and environment-friendly, and meanwhile, the method can solve the problems of thick bubble walls and uneven pore diameters caused by the fact that the foaming agent cannot be perfectly combined with coarse particles for foaming, so that the overall uniform foaming can be achieved.

Description

Technical Field

[0001] This invention relates to the field of foamed ceramics technology, and in particular to a formula and method for preparing foamed ceramics using dry powder preparation. Background Technology

[0002] Foamed ceramics are a special type of ceramic material with a porous structure. By introducing air or other gases into the ceramic raw materials, a large number of tiny pores are formed, resulting in a lightweight and porous structure. The main characteristics of this material are low density, high porosity, good thermal insulation performance, and high mechanical strength.

[0003] Dry milling involves grinding raw materials according to a process formula to meet the requirements of the milling process, followed by water spraying and granulation to obtain powder particles with a moisture content of about 10%, and then drying to obtain powder with suitable moisture content.

[0004] The problems with the above dry grinding method are as follows: it requires a variety of raw materials, with mud accounting for about 20% of the entire formula, and the mud needs to be dried before dry grinding can be used. In addition, the raw materials are greatly affected by moisture. The powder after water spraying and granulation has poor flowability, and the uneven moisture content after drying has a significant impact on the pressing performance.

[0005] Therefore, it is necessary to propose a formula and method for preparing foamed ceramics using dry powder preparation to solve the above problems. Summary of the Invention

[0006] The main objective of this invention is to provide a formula and method for preparing foamed ceramics using dry powder preparation, which can effectively solve the problems in the background art.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A formula for preparing foamed ceramics using a dry powdering process includes perlite, leveling residue from foamed ceramics, water mill tailings, pressing mud from polished bricks, talc, heavy magnesium oxide, aluminum ash, and a foaming agent. The formula comprises, by weight, 27-45 parts perlite, 30-45 parts leveling residue from foamed ceramics, 0-25 parts water mill tailings, 2-16 parts pressing mud from polished bricks, 1-3 parts talc, 2-3.5 parts heavy magnesium oxide, 0-3 parts aluminum ash, and 0.2 parts foaming agent.

[0009] Preferably, the perlite and the leveling slag of the foamed ceramic are both self-foaming raw materials, used to compensate for the uneven pore size caused by the inability of the foaming agent to enter the interior of the raw materials. The raw talc is used to adjust the firing temperature of the foaming process. The foaming agent includes, but is not limited to, silicon carbide, dolomite, barium sulfate, carbon powder, bicarbonate, aluminum powder, and bicarbonate. The mesh size of the silicon carbide is in the range of 800-1500.

[0010] A method for preparing foamed ceramics using dry powder milling, employing the aforementioned formulation for preparing foamed ceramics using dry powder milling, includes the following operational steps:

[0011] S1: Coarse crushing: Prepare raw materials, including perlite, scraper residue of foamed ceramics, water mill tailings, pressing mud of polished bricks, talc, heavy magnesium oxide, aluminum ash, and silicon carbide. Use a loader to transport raw materials with a particle size greater than 5cm to a jaw crusher for preliminary crushing.

[0012] S2: Raw material homogenization: The raw materials that have been coarsely crushed are transported to the material yard for homogenization. After testing, the temperature deviation is within 5℃ to be considered qualified.

[0013] S3: Raw material drying: The homogenized raw materials are dried in a rotary kiln to a moisture content of less than 5%;

[0014] S4: Fine crushing: The dried raw materials are transported to a compound Raymond crusher for fine crushing. After crushing, the raw materials are sieved through an 80-mesh high-frequency vibrating screen and then sent to a special small powder box for storage.

[0015] S5: Secondary fine crushing: The raw material with a size greater than 80 mesh after crushing in step S4 is returned to the compound Raymond crusher via a belt for secondary fine crushing.

[0016] S6: Premixing of foaming agent: The foaming agent and finely crushed raw materials are weighed manually according to the formula ratio and then placed into the double cone mixer for thorough mixing before being sent to a special small powder box for storage.

[0017] S7: Raw material mixing: The raw materials in the small powder box are batched according to the formula ratio by a belt electronic scale and then fully mixed by an improved screw mixer before being sent to the powder silo in the raw material workshop;

[0018] S8: Aging process: Place the mixed raw materials in the powder silo and age for more than 24 hours;

[0019] S9: Raw material re-mixing: The raw material after the aging treatment in step S8 is discharged into the multi-powder silo, and after being re-mixed by a miniaturized improved spiral mixer, it is conveyed to the belt conveyor.

[0020] S10: Belt fabric: Evenly spread the powder material in the belt fabric equipment onto the belt of the belt fabric equipment;

[0021] S11: Calcination and molding: The powder raw material on the belt conveyor is evenly transferred into the refractory sagger and calcined in the foamed ceramic roller kiln at a high temperature of 1150-1250℃ to complete the preparation of foamed ceramics.

[0022] Preferably, the fine crushing in steps S4 and S5 is mainly used to fully crush the homogenized raw materials and make them reach the specified gradation, including the following steps:

[0023] S501: Raw material crushing: The raw material is conveyed to the compound Raymond crusher for the first coarse crushing. The fineness of the crushed raw material is close to 80 mesh before it is completely crushed.

[0024] S502: Drying: Drying the crushed raw materials to control their moisture content to below 5%;

[0025] S503: Screening: Screen out raw materials smaller than 80 mesh, and unqualified coarse particles are returned to the compound Raymond crusher for secondary crushing.

[0026] S504: Secondary crushing: The coarse particles in step S503 are subjected to secondary crushing to achieve the target gradation.

[0027] Preferably, the premixed foaming agent is used for refined management of the preparation process of foamed ceramics to ensure the stability of the foaming effect and the performance of the product, including the following steps:

[0028] S601: Selection and proportion of foaming agent: Select a suitable foaming agent according to the production requirements of foamed ceramics. When large-scale production of foamed ceramics is required, silicon carbide, dolomite, barium sulfate, carbon powder, bicarbonate, aluminum powder, and bicarbonate are selected as foaming agents. When the pore structure of foamed ceramics needs to be adjusted, dolomite and barium sulfate are selected as foaming agents. When the pore structure of foamed ceramics is required to be high, aluminum powder is selected as foaming agent.

[0029] S602: Mixing of foaming agent: Place the selected foaming agent and the finely crushed and qualified raw materials into a double cone mixer and mix them thoroughly and evenly.

[0030] S603: Testing of the mixture: The mixed raw materials are brought into the formula for trial firing to ensure that the amount of foaming agent added meets the requirements, including the concentration and uniformity of the foaming agent.

[0031] S604: Adjustment and Storage: Based on the test results, increase or decrease the amount of foaming agent added to the mixture that does not meet the requirements; increase the mixing time, and then store the adjusted mixture.

[0032] Preferably, the raw material mixing in step S6 is mainly used to mix the foaming agent and the raw materials generated in S4, including the following steps:

[0033] S605: Preparation of mixing equipment: The improved spiral mixer is equipped with spiral iron plates 5-10 cm high on all four sides inside to prevent powder from accumulating inside the roller;

[0034] S606: Raw material batching: The various raw materials, including the pre-mixed foaming agent, that have been finely crushed in the small powder box are precisely batched according to the formula using a belt electronic scale;

[0035] S607: Raw material mixing: The pre-mixed raw materials are conveyed by belt to the improved screw mixer for thorough mixing;

[0036] S608: Raw material sieving to remove iron: The well-mixed granular powder is sieved through a drum screen to remove iron.

[0037] Preferably, the belt fabric in S9 is used to transport the material while ensuring it is fully spread out, including the following steps:

[0038] S101: Belt conveyor speed control: Set the belt conveyor speed to less than 0.5m / s to ensure that the material can be spread stably and evenly during the conveying process;

[0039] S102: Stability detection of belt conveyor: The stability of the belt conveyor is monitored in real time by vibration sensors, and the belt is stopped and an alarm signal is transmitted in time when the belt stability is abnormal.

[0040] S103: Belt cleaning and maintenance: Clean and maintain the belt conveyor equipment to ensure its normal operation and prevent material contamination.

[0041] Compared with the prior art, the present invention has the following beneficial effects:

[0042] In this invention, during the processing of raw materials, the overall flowability of the material is controlled by controlling the particle size of the powdered granules, eliminating the need for further drying after granulation with water. Furthermore, if the moisture content of the raw materials is ≤5%, drying equipment is unnecessary to control the moisture content, resulting in lower overall energy consumption and greater energy efficiency and environmental friendliness. This method combines the raw materials with a foaming agent, solving the problems of thicker foam walls and uneven pore size caused by the foaming agent's inability to perfectly blend with coarse particles. This achieves uniform foaming and absorbs gas from the voids left by the particles during sintering, providing sufficient oxygen for the foaming agent to foam at high temperatures. Attached Figure Description

[0043] Figure 1 These are finished product images of GF-12 and GF-13 of the present invention after preparation in electric furnace #3;

[0044] Figure 2 These are images of the finished products prepared using GF-14 and GF-15 according to the present invention;

[0045] Figure 3 These are finished product images of GF-12 and GF-13 of the present invention after preparation in electric furnace #2;

[0046] Figure 4 These are images of the finished products prepared using GF-16 and GF-17 according to the present invention;

[0047] Figure 5 These are images of the finished products prepared using GF-17 and GF-12 according to the present invention;

[0048] Figure 6 This is a picture of the finished product prepared by GF-18 and GF-19 of the present invention. Detailed Implementation

[0049] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] Example 1:

[0051] A formula for preparing foamed ceramics using a dry powdering process includes perlite, leveling residue from foamed ceramics, water mill tailings, pressing mud from polished bricks, talc, heavy magnesium oxide, aluminum ash, and a foaming agent. The formula comprises, by weight, 27-45 parts perlite, 30-45 parts leveling residue from foamed ceramics, 0-25 parts water mill tailings, 2-16 parts pressing mud from polished bricks, 1-3 parts talc, 2-3.5 parts heavy magnesium oxide, 0-3 parts aluminum ash, and 0.2 parts foaming agent.

[0052] Perlite and the leveling slag of foamed ceramics are both self-foaming raw materials, used to compensate for the uneven pore size caused by the inability of foaming agent to enter the interior of the raw material. Raw talc is used to adjust the firing temperature of foaming. Foaming agents include, but are not limited to, silicon carbide, dolomite, barium sulfate, carbon powder, bicarbonate, aluminum powder, and bicarbonate. The mesh size of silicon carbide ranges from 800 to 1500.

[0053] A method for preparing foamed ceramics using dry powder milling, employing the aforementioned formulation for preparing foamed ceramics using dry powder milling, includes the following operational steps:

[0054] S1: Coarse crushing: Prepare raw materials, including perlite, scraper residue of foamed ceramics, water mill tailings, pressing mud of polished bricks, talc, heavy magnesium oxide, aluminum ash, and silicon carbide. Use a loader to transport raw materials with a particle size greater than 5cm to a jaw crusher for preliminary crushing.

[0055] S2: Raw material homogenization: The raw materials that have been coarsely crushed are transported to the material yard for homogenization. After testing, the temperature deviation is within 5℃ to be considered qualified.

[0056] S3: Raw material drying: The homogenized raw materials are dried in a rotary kiln to a moisture content of less than 5%;

[0057] S4: Fine crushing: The dried raw materials are transported to a compound Raymond crusher for fine crushing. After crushing, the raw materials are sieved through an 80-mesh high-frequency vibrating screen and then sent to a special small powder box for storage.

[0058] S5: Secondary fine crushing: The raw material with a size greater than 80 mesh after crushing in step S4 is returned to the compound Raymond crusher via a belt for secondary fine crushing.

[0059] The fine crushing in steps S4 and S5 is mainly used to fully crush the homogenized raw materials and bring them to the specified gradation, including the following steps:

[0060] S501: Raw material crushing: The raw material is conveyed to the compound Raymond crusher for the first coarse crushing. The fineness of the crushed raw material is close to 80 mesh before it is completely crushed.

[0061] S502: Drying: Drying the crushed raw materials to control their moisture content to below 5%;

[0062] S503: Screening: Screen out raw materials smaller than 80 mesh, and unqualified coarse particles are returned to the compound Raymond crusher for secondary crushing.

[0063] S504: Secondary crushing: The coarse particles in step S503 are subjected to secondary crushing to achieve the target gradation.

[0064] S6: Premixing of foaming agent: The foaming agent and finely crushed raw materials are weighed manually according to the formula ratio and then placed into the double cone mixer for thorough mixing before being sent to a special small powder box for storage.

[0065] Raw material mixing is mainly used to mix the foaming agent and the raw materials generated in S4, including the following steps:

[0066] S605: Preparation of mixing equipment: The improved spiral mixer is equipped with spiral iron plates 5-10 cm high on all four sides inside to prevent powder from accumulating inside the roller;

[0067] S606: Raw material batching: The various raw materials, including the pre-mixed foaming agent, that have been finely crushed in the small powder box are precisely batched according to the formula using a belt electronic scale;

[0068] S607: Raw material mixing: The pre-mixed raw materials are conveyed by belt to the improved screw mixer for thorough mixing;

[0069] S608: Raw material screening for iron removal: The well-mixed granular powder is screened through a drum screen to remove iron.

[0070] The premixed formulation of the foaming agent is used for the refined management of the preparation process of foamed ceramics, ensuring the stability of the foaming effect and the performance of the product, including the following steps:

[0071] S601: Selection and proportioning of foaming agent: Select a suitable foaming agent according to the production requirements of foamed ceramics. When large-scale production of foamed ceramics is required, silicon carbide, dolomite, barium sulfate, carbon powder, bicarbonate, aluminum powder, and bicarbonate are selected as foaming agents. When the pore structure of foamed ceramics needs to be adjusted, dolomite and barium sulfate are selected as foaming agents. When the pore structure of foamed ceramics is required to be high, aluminum powder is selected as foaming agent.

[0072] S602: Mixing of foaming agent: Place the selected foaming agent and the finely crushed and qualified raw materials into a double cone mixer for thorough and uniform mixing.

[0073] S603: Testing of the mixture: The mixed raw materials are brought into the formula for trial firing to ensure that the amount of foaming agent added meets the requirements, including the concentration and uniformity of the foaming agent.

[0074] S604: Adjustment and Storage: Based on the test results, increase or decrease the amount of foaming agent added to the mixture that does not meet the requirements; increase the mixing time, and then store the adjusted mixture.

[0075] S7: Raw material mixing: The raw materials in the small powder box are batched according to the formula ratio by a belt electronic scale and then fully mixed by an improved screw mixer before being sent to the powder silo in the raw material workshop;

[0076] S8: Aging process: Place the mixed raw materials in the powder silo and age for more than 24 hours;

[0077] S9: Raw material re-mixing: The raw material after the aging treatment in step S8 is discharged into the multi-powder silo, and after being re-mixed by a miniaturized improved spiral mixer, it is conveyed to the belt conveyor.

[0078] S10: Belt fabric: Evenly spread the powder material in the belt fabric equipment onto the belt of the belt fabric equipment;

[0079] The belt fabric is used to transport materials while keeping them fully spread out, and includes the following steps:

[0080] S101: Belt conveyor speed control: Set the belt conveyor speed to less than 0.5m / s to ensure that the material can be spread stably and evenly during the conveying process;

[0081] S102: Stability detection of belt conveyor: The stability of the belt conveyor is monitored in real time by vibration sensors, and the belt is stopped and an alarm signal is transmitted in time when the belt stability is abnormal.

[0082] S103: Belt cleaning and maintenance: Clean and maintain the belt conveyor to ensure its normal operation and prevent material contamination;

[0083] S11: Calcination and molding: The powder raw material on the belt conveyor is evenly transferred into the refractory sagger and calcined in the foamed ceramic roller kiln at a high temperature of 1150-1250℃ to complete the preparation of foamed ceramics.

[0084] Example 2:

[0085] The raw material composition of the leveling slag and perlite in foamed ceramics is shown in the table below:

[0086]

[0087]

[0088] Example 3:

[0089] An experiment was conducted on the scraping residue of foamed ceramics. The experimental results are shown in the table below:

[0090]

[0091]

[0092] Example 4:

[0093] Based on Example 3, further experiments were conducted on the foamed ceramic formulation. Here, silicon carbide was selected as the foaming agent. The formulation table below is as follows:

[0094]

[0095] Preparation experiments were conducted according to the preparation method in Example 1. Here, silicon carbide was selected as the foaming agent. GF-12 and GF-13 were manually passed through a 60-mesh sieve (silicon carbide passed through an 80-mesh sieve) and fired into an electric furnace No. 3. The temperature curve was maintained for 30 minutes at 0-352℃ (30 min)-1062℃ (60 min)-1192℃ (120 min). GF-14 and GF-15 were prepared according to the formula and ball-milled at a material ball ratio of 400:600 for 25 minutes. They were then fired into an electric furnace No. 2 and maintained for 30 minutes at a temperature curve of 0-350℃ (30 min)-1050℃ (60 min)-1180℃ (120 min).

[0096] The finished products of GF-12 and GF-13 are as follows Figure 1 As shown, the pore sizes of GF-12 and GF-13 are not uniform, and the reaction at the bottom of the sample is incomplete. Following the formulation of GF-12 and GF-13, they were recalcined in electric furnace #2. Figure 3 As shown, it was found that the previous uneven pore size was due to the electric furnace, and the pore size of the GF-12 formula was relatively uniform.

[0097] Finished products of GF-14 and GF-15, such as Figure 2 As shown, GF-14 and GF-15 have uniform pore sizes, with GF-14 having a larger pore size than GF-15. However, the content of perlite and scraping residue in the formula is too high, so the formula needs to be modified further.

[0098] Preparation experiments were conducted according to the preparation method in Example 1. Silicon carbide was selected as the foaming agent. Formulas 16 and 17 were obtained by reducing the content of perlite and leveling slag in the formula. The raw materials were fired in an electric furnace (No. 2) and held at a temperature of 0-350℃ (30 min) - 1050℃ (60 min) - 1180℃ (120 min) for 30 min. The following is Formula Table 2:

[0099]

[0100] like Figure 4 It can be seen that the apertures of GF-16 and GF-17 are relatively uniform, with no obvious large apertures, and the apertures of GF-17 are smaller.

[0101] Preparation experiments were conducted according to the preparation method in Example 1. Silicon carbide was selected as the foaming agent, specifically formulations GF-12 and GF-17. The mixture was fired in a roller kiln in the workshop, maintaining a temperature of 0-350℃ (30 min) - 1050℃ (60 min) - 1180℃ (120 min) for 30 minutes. Figure 5 As shown, GF-12 and GF-17 have relatively uniform pore sizes, but the pore sizes are too large, and the firing temperature is too low. It is necessary to add some high-temperature materials to raise the temperature of the formula and reduce the pore size. Based on GF-12 and GF-17, the formula was adjusted to obtain GF-18 and GF-19, which were then fired in a roller kiln in the workshop, holding at a temperature curve of 0-350℃ (30min)-1055℃ (60min)-1185℃ (120min) for 30 minutes. The following is the formula table three:

[0102]

[0103] like Figure 6 It can be seen that the pore size is significantly reduced after adding a certain amount of water-milled tailings, and the optimal formulations are denoted as GF-18 and GF-19.

[0104] The above conclusions clearly show that the scraping residue can be mixed well with the foaming agent. By controlling the sieve residue of the scraping residue and the amount of foaming agent, it is possible to produce foamed ceramics with uniform and fine pore size.

[0105] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A formula for preparing foamed ceramics using a dry powder-making process, characterized in that: The product includes perlite, leveling residue from foamed ceramics, water mill tailings, pressing mud from polished bricks, talc, heavy magnesium oxide, aluminum ash, and foaming agent. By weight, it includes 27-45 parts perlite, 30-45 parts leveling residue from foamed ceramics, 0-25 parts water mill tailings, 2-16 parts pressing mud from polished bricks, 1-3 parts talc, 2-3.5 parts heavy magnesium oxide, 0-3 parts aluminum ash, and 0.2 parts foaming agent. The perlite and the leveling slag of the foamed ceramic are both self-foaming raw materials, used to compensate for the uneven pore size caused by the inability of the foaming agent to enter the interior of the raw materials. The talc is used to adjust the firing temperature of the foaming process. The foaming agent is silicon carbide, and the mesh size of the silicon carbide is in the range of 800-1500. A method for preparing foamed ceramics using dry powder preparation includes the following steps: S1: Coarse crushing: Prepare raw materials, including perlite, scraper residue of foamed ceramics, water mill tailings, pressing mud of polished bricks, talc, heavy magnesium oxide, and aluminum ash. Use a loader to transport raw materials with a particle size greater than 5cm to a jaw crusher for preliminary crushing. S2: Raw material homogenization: The raw materials that have been coarsely crushed are transported to the material yard for homogenization. After testing, the temperature deviation is within 5℃ to be considered qualified. S3: Raw material drying: The homogenized raw materials are dried in a rotary kiln to a moisture content of less than 5%; S4: Fine crushing: The dried raw materials are transported to a compound Raymond crusher for fine crushing. After crushing, the raw materials are sieved through an 80-mesh high-frequency vibrating screen and then sent to a special small powder box for storage. S5: Secondary fine crushing: The raw material with a size greater than 80 mesh after crushing in step S4 is returned to the compound Raymond crusher via a belt for secondary fine crushing. S6: Premixing of foaming agent: The foaming agent and finely crushed raw materials are weighed manually according to the formula ratio and then placed into the double cone mixer for thorough mixing before being sent to a special small powder box for storage. S7: Raw material mixing: The raw materials in the small powder box are batched according to the formula ratio by a belt electronic scale and then fully mixed by an improved screw mixer before being sent to the powder silo in the raw material workshop; S8: Aging process: Place the mixed raw materials in the powder silo and age for more than 24 hours; S9: Raw material re-mixing: The raw material after the aging treatment in step S8 is discharged into the multi-powder silo, and after being re-mixed by a miniaturized improved spiral mixer, it is conveyed to the belt conveyor. S10: Belt fabric: Evenly spread the powder material in the belt fabric equipment onto the belt of the belt fabric equipment; S11: Calcination and molding: The powder raw material on the belt conveyor is evenly transferred into the refractory sagger and calcined in the foamed ceramic roller kiln at a high temperature of 1150-1250℃ to complete the preparation of foamed ceramics. The fine crushing in steps S4 and S5 is mainly used to fully crush the homogenized raw materials and make them reach the specified gradation, including the following steps: S501: Raw material crushing: The raw material is conveyed to the compound Raymond crusher for the first coarse crushing. The fineness of the crushed raw material is close to 80 mesh before it is completely crushed. S502: Drying: Drying the crushed raw materials to control their moisture content to below 5%; S503: Screening: Screen out raw materials smaller than 80 mesh, and unqualified coarse particles are returned to the compound Raymond crusher for secondary crushing. S504: Secondary crushing: The coarse particles in step S503 are subjected to secondary crushing to achieve the target gradation. The premixed formulation of the foaming agent is used for refined management of the preparation process of foamed ceramics, ensuring the stability of the foaming effect and the performance of the product, including the following steps: S601: Selection and proportioning of foaming agent: Silicon carbide is selected as the foaming agent; S602: Mixing of foaming agent: Place the selected foaming agent and the finely crushed and qualified raw materials into a double cone mixer and mix them thoroughly and evenly. S603: Testing of the mixture: The mixed raw materials are brought into the formula for trial firing to ensure that the amount of foaming agent added meets the requirements, including the concentration and uniformity of the foaming agent. S604: Adjustment and Storage: Based on the test results, increase or decrease the amount of foaming agent added to the mixture that does not meet the requirements; increase the mixing time, and then store the adjusted mixture. The raw material mixing in step S6 is mainly used to mix the foaming agent and the raw materials generated in S4, including the following steps: S605: Preparation of mixing equipment: The improved spiral mixer is equipped with spiral iron plates 5-10 cm high on all four sides inside to prevent powder from accumulating inside the roller; S606: Raw material batching: The various raw materials, including the pre-mixed foaming agent, that have been finely crushed in the small powder box are precisely batched according to the formula using a belt electronic scale; S607: Raw material mixing: The pre-mixed raw materials are conveyed by belt to the improved screw mixer for thorough mixing; S608: Raw material screening for iron removal: The well-mixed granular powder is screened through a drum screen to remove iron. The belt conveyor in S10 is used to transport the material while ensuring it is fully spread out, and includes the following steps: S101: Belt conveyor speed control: Set the belt conveyor speed to less than 0.5m / s to ensure that the material can be spread stably and evenly during the conveying process; S102: Stability detection of belt conveyor: The stability of the belt conveyor is monitored in real time by vibration sensors, and the belt is stopped and an alarm signal is transmitted in time when the belt stability is abnormal. S103: Belt cleaning and maintenance: Clean and maintain the belt conveyor equipment to ensure its normal operation and prevent material contamination.

2. A method for preparing foamed ceramics using dry powder milling, employing the formulation for preparing foamed ceramics using dry powder milling as described in claim 1, characterized in that: The following steps are included: S1: Coarse crushing: Prepare raw materials, including perlite, scraper residue of foamed ceramics, water mill tailings, pressing mud of polished bricks, talc, heavy magnesium oxide, and aluminum ash. Use a loader to transport raw materials with a particle size greater than 5cm to a jaw crusher for preliminary crushing. S2: Raw material homogenization: The raw materials that have been coarsely crushed are transported to the material yard for homogenization. After testing, the temperature deviation is within 5℃ to be considered qualified. S3: Raw material drying: The homogenized raw materials are dried in a rotary kiln to a moisture content of less than 5%; S4: Fine crushing: The dried raw materials are transported to a compound Raymond crusher for fine crushing. After crushing, the raw materials are sieved through an 80-mesh high-frequency vibrating screen and then sent to a special small powder box for storage. S5: Secondary fine crushing: The raw material with a size greater than 80 mesh after crushing in step S4 is returned to the compound Raymond crusher via a belt for secondary fine crushing. S6: Premixing of foaming agent: The foaming agent and finely crushed raw materials are weighed manually according to the formula ratio and then placed into the double cone mixer for thorough mixing before being sent to a special small powder box for storage. S7: Raw material mixing: The raw materials in the small powder box are batched according to the formula ratio by a belt electronic scale and then fully mixed by an improved screw mixer before being sent to the powder silo in the raw material workshop; S8: Aging process: Place the mixed raw materials in the powder silo and age for more than 24 hours; S9: Raw material re-mixing: The raw material after the aging treatment in step S8 is discharged into the multi-powder silo, and after being re-mixed by a miniaturized improved spiral mixer, it is conveyed to the belt conveyor. S10: Belt fabric: Evenly spread the powder material in the belt fabric equipment onto the belt of the belt fabric equipment; S11: Calcination and molding: The powder raw material on the belt conveyor is evenly transferred into the refractory sagger and calcined in the foamed ceramic roller kiln at a high temperature of 1150-1250℃ to complete the preparation of foamed ceramics. The fine crushing in steps S4 and S5 is mainly used to fully crush the homogenized raw materials and make them reach the specified gradation, including the following steps: S501: Raw material crushing: The raw material is conveyed to the compound Raymond crusher for the first coarse crushing. The fineness of the crushed raw material is close to 80 mesh before it is completely crushed. S502: Drying: Drying the crushed raw materials to control their moisture content to below 5%; S503: Screening: Screen out raw materials smaller than 80 mesh, and unqualified coarse particles are returned to the compound Raymond crusher for secondary crushing. S504: Secondary crushing: The coarse particles in step S503 are subjected to secondary crushing to achieve the target gradation. The premixed formulation of the foaming agent is used for refined management of the preparation process of foamed ceramics, ensuring the stability of the foaming effect and the performance of the product, including the following steps: S601: Selection and proportioning of foaming agent: Silicon carbide is selected as the foaming agent; S602: Mixing of foaming agent: Place the selected foaming agent and the finely crushed and qualified raw materials into a double cone mixer and mix them thoroughly and evenly. S603: Testing of the mixture: The mixed raw materials are brought into the formula for trial firing to ensure that the amount of foaming agent added meets the requirements, including the concentration and uniformity of the foaming agent. S604: Adjustment and Storage: Based on the test results, increase or decrease the amount of foaming agent added to the mixture that does not meet the requirements; increase the mixing time, and then store the adjusted mixture. The raw material mixing in step S6 is mainly used to mix the foaming agent and the raw materials generated in S4, including the following steps: S605: Preparation of mixing equipment: The improved spiral mixer is equipped with spiral iron plates 5-10 cm high on all four sides inside to prevent powder from accumulating inside the roller; S606: Raw material batching: The various raw materials, including the pre-mixed foaming agent, that have been finely crushed in the small powder box are precisely batched according to the formula using a belt electronic scale; S607: Raw material mixing: The pre-mixed raw materials are conveyed by belt to the improved screw mixer for thorough mixing; S608: Raw material screening for iron removal: The well-mixed granular powder is screened through a drum screen to remove iron. The belt conveyor in S10 is used to transport the material while ensuring it is fully spread out, and includes the following steps: S101: Belt conveyor speed control: Set the belt conveyor speed to less than 0.5m / s to ensure that the material can be spread stably and evenly during the conveying process; S102: Stability detection of belt conveyor: The stability of the belt conveyor is monitored in real time by vibration sensors, and the belt is stopped and an alarm signal is transmitted in time when the belt stability is abnormal. S103: Belt cleaning and maintenance: Clean and maintain the belt conveyor equipment to ensure its normal operation and prevent material contamination.

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