An ultra-thick lightweight foamed ceramic and a method for preparing the same

Abstract

This invention belongs to the field of ceramic technology. It proposes an ultra-thick lightweight foamed ceramic and its preparation method. Expressed in oxide form, the chemical composition of the ultra-thick lightweight foamed ceramic, calculated by mass percentage, includes: 65-70% silicon, 17-20% aluminum, 3-6% potassium, and 2-4% sodium, wherein the silicon-to-aluminum ratio is 3.5 ≤ silicon-to-aluminum ratio ≤ 4.0, and the potassium-to-sodium ratio is ≥ 1.30. The foamed ceramic obtained by this invention has a thickness of 150-170 mm, uniform foaming without large bubbles, and exhibits advantages of low density and high compressive strength, achieving a lightweight and high-strength effect in ultra-thick foamed ceramics.

Description

Technical Field

[0001] This invention belongs to the field of ceramic technology, specifically relating to an ultra-thick lightweight foamed ceramic and its preparation method. Background Technology

[0002] In the field of foamed ceramics, based on firing equipment, processes can generally be divided into roller kiln technology and tunnel kiln technology. In actual production, both roller kiln and tunnel kiln processes have their advantages and disadvantages. Roller kilns are suitable for firing thin slabs with relatively short firing times. However, for thicker products, there is a problem with uniform foaming during firing, and the firing cycle lengthens as the product thickness increases. Tunnel kilns have a relatively longer firing cycle, but a larger loading capacity. With the same kiln length, tunnel kilns have a higher daily output and lower energy consumption.

[0003] Currently, there is a lack of foamed ceramic products with a thickness greater than 150 mm in the market. In terms of process selection, roller kilns are difficult to manufacture products with a thickness greater than 150 mm, so tunnel kilns are the only option. However, current ceramic formulations are not suitable for preparing thick foamed ceramic products, and various ceramic performance indicators of the resulting products cannot be simultaneously achieved. Even with the slow firing process using tunnel kilns, problems such as uneven foam pore size, low body strength, and easy breakage during cutting are still likely to occur.

[0004] Based on this, the present invention proposes a new method for preparing foamed ceramics to solve the above problems. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention aims to provide an ultra-thick lightweight foamed ceramic and its preparation method. The foamed ceramic has a thickness of 150~170 mm, uniform foaming without large bubbles, and the product has the advantages of low density and high compressive strength, achieving the effect of lightweight and high strength in thick foamed ceramic.

[0006] To achieve the above-mentioned objectives, the technical solution adopted by the present invention is as follows:

[0007] In a first aspect, the present invention provides an ultra-thick lightweight foamed ceramic with a thickness of 150-170 mm, expressed in oxide form. The chemical composition of the ultra-thick lightweight foamed ceramic, calculated by mass percentage, includes: 65-70% silicon, 17-20% aluminum, 3-6% potassium, and 2-4% sodium, wherein 3.5 ≤ silicon-aluminum ratio ≤ 4.0, and potassium-sodium ratio ≥ 1.30.

[0008] The preferred chemical composition of ultra-thick lightweight foamed ceramics includes: 65-70% silicon, 17-20% aluminum, 3-6% potassium, 2-4% sodium, 1-2% calcium, 1-3% magnesium, <3% iron and <3% titanium.

[0009] Preferably, the raw materials for preparing ultra-thick lightweight foamed ceramics, calculated by mass percentage, include 15-45% recycled materials, 20-40% feldspar materials, 5-30% plastic materials, 0-15% raw coke, 0-15% cooked coke, 0-5% flux, and 0.15-0.30% foaming agent. The recycled materials include one or more of stone cutting materials, tile polishing materials, and recycled solid waste. In the raw materials for preparing ultra-thick lightweight foamed ceramics, calculated by mass percentage, the raw materials include 0-10% stone cutting materials, 0-30% tile polishing materials, and 10-20% recycled solid waste, and the total mass percentage of stone cutting materials, tile polishing materials, and recycled solid waste is 15-45%. The amounts of raw coke, cooked coke, and flux are not all zero.

[0010] More preferably, the stone cutting material includes sawdust. More preferably, expressed in oxide form, the sawdust contains ≥70% silicon, ≥10% aluminum, and ≤1.5% iron by mass percentage.

[0011] More preferably, the tile polishing material includes polishing putty. More preferably, expressed in oxide form, the polishing putty contains 68-72% silicon, 14-16% aluminum, 5-8% potassium and sodium, and ≤1.5% iron and titanium by mass percentage.

[0012] More preferably, recycled solid waste refers to recyclable waste generated during the production of foamed ceramics, including one or more of the following: recycled blanks, cutting mud, and broken slag.

[0013] More preferably, the feldspar material includes one or more of stone powder, feldspar and white sand. In the raw materials for preparing ultra-thick lightweight foamed ceramics, the raw materials for preparing ultra-thick lightweight foamed ceramics include 10-30% stone powder, 0-20% feldspar, and 0-20% white sand by mass percentage, and the total mass percentage of stone powder, feldspar and white sand is 20-40%.

[0014] More preferably, based on the mass of the stone powder and expressed in oxide form, the stone powder contains 73-76% silicon, 12-15% aluminum, 7-10% potassium and sodium, and ≤1% iron and titanium by mass percentage.

[0015] More preferably, based on the mass of feldspar and expressed in oxide form, the feldspar contains 65-70% silicon, 15-18% aluminum, 8-12% potassium, 3-5% sodium, and ≤1.5% iron and titanium by mass percentage.

[0016] More preferably, based on the quality of the white sand and expressed in oxide form, the white sand contains 65-70% silicon, 18-20% aluminum, 8-12% potassium, 3-5% sodium, and ≤1% iron and titanium by mass percentage.

[0017] More preferably, the plastic material includes one or both of white clay and Zhucheng clay. In the raw materials for preparing ultra-thick lightweight foamed ceramics, the raw materials for preparing ultra-thick lightweight foamed ceramics include 0-20% white clay and 5-20% Zhucheng clay by mass percentage, and the total mass percentage of white clay and Zhucheng clay is 5-30%.

[0018] More preferably, based on the quality of the white clay and expressed in oxide form as a percentage by mass, the white clay contains 72-78% silicon, 13-16% aluminum, 6-10% potassium and sodium, and ≤1% iron and titanium.

[0019] More preferably, based on the quality of Zhucheng soil, expressed in oxide form and calculated as a percentage by mass, the silicon content in Zhucheng soil is 65-70%, the aluminum content is 13-16%, the potassium and sodium content is 3-6%, and the iron and titanium content is ≤3%.

[0020] In a second aspect, the present invention provides a method for preparing ultra-thick lightweight foamed ceramics, as follows:

[0021] S1. Weigh all raw materials according to the raw material formula of foamed ceramics;

[0022] S2. Mix all the raw materials together, add water and ball mill to make a slurry;

[0023] S3. Dry the slurry to obtain powder;

[0024] S4. The powdered fabric is piled up and fired at a final firing temperature of 1150~1200℃ for 9.5~12 hours to obtain the finished product.

[0025] Preferably, in step S4, the firing profile is as follows: heating from room temperature to 600°C for 60 min; heating from 600°C to 900°C for 30-60 min, and holding at that temperature for 30-60 min; heating from 900°C to 1080°C for 60-120 min, and holding at that temperature for 30-90 min; heating from 1080°C to 1120°C for 60-120 min, and holding at that temperature for 30-60 min; and heating from 1120°C to the final firing temperature for 30-90 min, and holding at that temperature for 30-60 min.

[0026] Beneficial effects:

[0027] This invention proposes a unique formula design that controls the silicon-aluminum ratio and the potassium-sodium ratio, resulting in foamed ceramics with a thickness of 150-170 mm. The foaming is uniform and free of large bubbles, and the product has the advantages of low density and high compressive strength, achieving a lightweight and high-strength effect in ultra-thick foamed ceramics. Detailed Implementation

[0028] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, specific implementation methods of the present invention will be described below. Obviously, the following descriptions are merely some embodiments of the present invention; those skilled in the art can obtain other implementation methods based on these embodiments without creative effort.

[0029] According to the standard "T / CBCSA12-2019 Foamed Ceramic Partition Board", the industry standard product thickness is 80 mm, 100 mm, and 120 mm. Thicker products are relatively rare in the industry due to production difficulties. This invention proposes an ultra-thick lightweight foamed ceramic with a thickness of 150-170 mm. This ultra-thick lightweight foamed ceramic has the advantages of being lightweight, high-strength, and having good cutting performance. In this invention, expressed in oxide form, the chemical composition of the ultra-thick lightweight foamed ceramic, calculated by mass percentage, includes: 65-70% silicon (i.e., silicon dioxide), 17-20% aluminum (i.e., aluminum oxide), 3-6% potassium (i.e., potassium oxide), and 2-4% sodium (i.e., sodium oxide), as well as calcium, magnesium, iron, and titanium, and may also contain trace amounts of unavoidable impurities. The silicon-to-aluminum ratio is 3.5 ≤ 4.0, and the potassium-to-sodium ratio is ≥ 1.30. The silicon-aluminum ratio refers to the mass ratio of silicon dioxide to aluminum oxide, and the potassium-sodium ratio refers to the mass ratio of potassium oxide to sodium oxide. This invention specifically defines the silicon-aluminum ratio and the potassium-sodium ratio, and based on a specific composition, produces foamed ceramic products with a thickness of 150-170 mm, uniform foaming, and high compressive strength, truly achieving ultra-high lightweight and high-strength performance in thick foamed ceramic products.

[0030] It should be noted that in this invention, ultra-thick foamed ceramics refer to foamed ceramics with a finished thickness of 150-170 mm. This is easily understood; if a thicker product can be produced, reducing the thickness allows for the production of a thinner product. The ultra-thick lightweight foamed ceramic product of this invention meets the requirements of existing foamed ceramics, and also satisfies the following: 3.5 ≤ silicon-alumina ratio ≤ 4.0, potassium-sodium ratio ≥ 1.30. This invention, based on specific dosages and element ratios, produces a high-thickness and lightweight foamed ceramic product.

[0031] Furthermore, the chemical composition of ultra-thick lightweight foamed ceramics includes: 65-70% silicon (i.e., silicon dioxide), 17-20% aluminum (i.e., aluminum oxide), 3-6% potassium (i.e., potassium oxide), 2-4% sodium (i.e., sodium oxide), 1-2% calcium (i.e., calcium oxide), 1-3% magnesium (i.e., magnesium oxide), <3% iron (i.e., ferric oxide), and <3% titanium (i.e., titanium dioxide).

[0032] Generally speaking, the chemical composition of the raw materials and finished products used to make ultra-thick lightweight foamed ceramics is similar. Materials that meet the above-mentioned requirements for the chemical composition of raw materials are suitable for this invention. That is, the raw materials used to make ultra-thick lightweight foamed ceramics should also conform to the above-mentioned chemical composition range. Furthermore, this invention proposes some suitable materials. For example, the raw materials for preparing lightweight foamed ceramics include recycled materials, feldspar materials, plastic materials, raw coke, cooked coke, flux, and foaming agents. The recycled materials include one or more of stone cutting materials, tile polishing materials, and recycled solid waste. This invention preferably uses waste generated in the industry, combined with feldspar raw materials, flux, and foaming agents, to produce foamed ceramic products with a thickness of 150-170 mm, thereby achieving the environmental protection goal of waste recycling and reducing production costs while ensuring product quality.

[0033] Furthermore, calculated by mass percentage, the raw materials for preparing foamed ceramics include 15-45% recycled materials, 20-40% feldspar materials, 5-30% plastic materials, 0-15% raw coke, 0-15% cooked coke, 0-5% flux, and 0.15-0.30% foaming agent, wherein the amounts of raw coke, cooked coke, and flux are not all zero. Preferably, the raw materials for preparing foamed ceramics, calculated by mass percentage, include 0-10% stone cutting material, 0-30% tile polishing material, and 10-20% recycled solid waste, and the total mass percentage of stone cutting material, tile polishing material, and recycled solid waste is 15-45%. It is easy to understand that, based on the chemical composition of this invention, the amount of each raw material can be adjusted according to production needs; therefore, some raw materials can be omitted, i.e., their amount is zero.

[0034] Processing and recycling waste refers to waste generated during the production process in this field, including stone cutting materials, tile polishing materials, and recycled solid waste. Therefore, the silicon content in processing and recycling waste is generally high, making it suitable as the main raw material. The amount of other raw materials is adjusted according to the silicon content, aluminum content, and other element content of the processing and recycling waste used to meet the chemical composition requirements of this invention.

[0035] Preferably, stone cutting material refers to solid waste generated during stone cutting and processing, such as sawdust. Preferably, expressed in oxide form, the sawdust contains ≥70% silicon, ≥10% aluminum, and ≤1.5% iron by mass percentage. The iron content requirement is low to avoid excessively dark product color; the same applies below.

[0036] Preferably, the ceramic tile polishing material refers to solid waste generated during the ceramic polishing process, such as polishing sludge. Preferably, expressed in oxide form, the polishing sludge contains 68-72% silicon, 14-16% aluminum, 5-8% potassium and sodium, and ≤1.5% iron and titanium by mass percentage.

[0037] Preferably, the recyclable solid waste refers to the recyclable waste generated during the production of foamed ceramics, including recycled blanks, cutting mud, and broken slag, etc., and its composition is similar to that of the finished product of foamed ceramics as described in this invention. This invention does not limit its components.

[0038] In the processing and recycling of waste materials, the use of various materials is based on the final product, and the amount of stone cutting materials, tile polishing materials and recycled solid waste materials used is not all zero at the same time.

[0039] Feldspar materials are materials that function as feldspar. For example, feldspar materials include one or more of stone powder, feldspar, and white sand. In the raw materials for preparing foamed ceramics, the raw materials for preparing foamed ceramics include 10-30% stone powder, 0-20% feldspar, and 0-20% white sand by mass percentage, and the total mass percentage of stone powder, feldspar, and white sand is 20-40%. Expressed in oxide form and calculated by mass percentage, preferably, the stone powder contains 73-76% silicon, 12-15% aluminum, 7-10% potassium and sodium, and ≤1% iron and titanium; more preferably, the stone powder can be Zhucheng stone powder. Preferably, the feldspar contains 65-70% silicon, 15-18% aluminum, 8-12% potassium, 3-5% sodium, and ≤1.5% iron and titanium; more preferably, the feldspar can be Zhangjia feldspar. The white sand contains 65-70% silicon, 18-20% aluminum, 8-12% potassium, 3-5% sodium, and ≤1% iron and titanium. This invention preferably uses feldspar materials with high potassium and sodium content, especially high potassium content, which is beneficial for broadening the firing temperature range of the product. If the product requires high whiteness, white sand can be appropriately selected to improve the whiteness after firing.

[0040] Plasticizing agents provide the necessary suspension for the slurry during the production process, preventing sedimentation. Plasticizing agents include one or both of white clay and Zhucheng clay. In the raw materials for preparing foamed ceramics, the raw materials, calculated by mass percentage, include 0-20% white clay and 5-20% Zhucheng clay, with the total mass percentage of white clay and Zhucheng clay being 5-30%. Expressed in oxide form, and calculated by mass percentage, preferably, the white clay contains 72-78% silicon, 13-16% aluminum, 6-10% potassium and sodium, and ≤1% iron and titanium; preferably, the Zhucheng clay contains 65-70% silicon, 13-16% aluminum, 3-6% potassium and sodium, and ≤3% iron and titanium. It is easy to understand that the plasticizing agent has a high silicon content, and its usage is determined according to the product design.

[0041] The purpose of raw coke and cooked coke is to increase the aluminum content in the formula, and the amount used is determined according to the product formula design. Expressed in oxide form and calculated as a percentage by mass, the preferred aluminum content in raw coke is 33-36%, for example, raw coke can be Shanxi raw coke; the preferred aluminum content in cooked coke is 48-52%.

[0042] Fluxes primarily serve to lower the firing temperature. Depending on their composition, they can also be used as raw materials to supplement the silicon and aluminum content of the product. Preferably, fluxes include talc, such as raw talc or calcined talc. More preferably, fluxes include talc with a magnesium content of ≥30%.

[0043] The foaming agent includes silicon carbide micro powder, preferably silicon carbide micro powder with a fineness of 2000 mesh.

[0044] Taking the aforementioned specific materials as an example, this invention proposes one applicable raw material formula. Calculated by mass percentage, the raw materials for preparing ultra-thick lightweight foamed ceramics include 0-10% sawdust, 10-30% Zhucheng stone powder, 0-30% polishing mud, 0-20% white sand, 0-20% white mud, 0-20% Zhangjiajie longite, 0-15% raw coke, 0-15% cooked coke, 0-5% talc, 5-20% Zhucheng soil, 10-20% recycled solid waste (one or more of recycled blanks, cutting mud, and broken slag), and 0.15-0.30% foaming agent.

[0045] Based on the above-mentioned ultra-thick lightweight foamed ceramic, this invention also proposes a feasible method for preparing ultra-thick lightweight foamed ceramic, preferably using a tunnel kiln for firing. The preparation method of this invention includes the following steps:

[0046] S1. Weigh all raw materials according to the raw material formula of foamed ceramics;

[0047] S2. Mix all the raw materials, add water and ball mill to make a slurry. The water content of the slurry is 31-33%, that is, the mass percentage of water in the slurry is 31-33%.

[0048] S3. Dry the slurry to obtain powder;

[0049] S4. The powdered fabric is piled up and fired at a final firing temperature of 1150~1200℃ for 9.5~12 hours to obtain the finished product.

[0050] Preferably, in step S4, the firing profile is as follows: from room temperature (e.g., 20~25℃) to 600℃, the heating time is 60 min; from 600℃ to 900℃, the heating time is 30~60 min, and the temperature is held for 30~60 min; from 900℃ to 1080℃, the heating time is 60~120 min, and the temperature is held for 30~90 min; from 1080℃ to 1120℃, the heating time is 60~120 min, and the temperature is held for 30~60 min; from 1120℃ to the final firing temperature, the heating time is 30~90 min, and the temperature is held for 30~60 min.

[0051] After firing, the finished product is obtained and, after complete cooling, is processed into ultra-thick foamed ceramic products of the required specifications according to industrial requirements.

[0052] The technical solution of the present invention will be described in detail below with specific embodiments.

[0053] In the following embodiments, the processed recycled materials include one or more of sawdust, polishing mud, and recycled solid waste; the feldspar materials include one or more of stone powder, feldspar, and white sand; and the plastic materials include one or two of white clay and Zhucheng soil.

[0054] The raw materials in the examples and comparative examples were weighed according to the mass percentage of each raw material in Table 1; Table 2 shows the overall chemical composition of the raw materials in the examples and comparative examples, with the remainder being impurities; Table 3 shows the silicon-aluminum ratio and potassium-sodium ratio of the formulations in the examples and comparative examples.

[0055] The weighed raw materials are ball-milled with water to obtain a slurry;

[0056] The slurry is dried and ground into powder to obtain the powder.

[0057] The powder particles are stacked and fired to obtain the finished blank. The firing profile is as follows: heating from room temperature to 600℃ for 60 minutes; heating from 600℃ to 900℃ for 60 minutes and holding for 60 minutes; heating from 900℃ to 1080℃ for 90 minutes and holding for 60 minutes; heating from 1080℃ to 1120℃ for 90 minutes and holding for 60 minutes; heating from 1120℃ to the final firing temperature (which varies slightly depending on the formula, for example, 1160℃) for 60 minutes and holding for 30 minutes.

[0058] Table 1. Raw material formulations for Examples 1-5 and Comparative Examples 1-5.

[0059] .

[0060] Table 2 Comparison of the chemical composition of the products in Examples 1-5 and Comparative Examples 1-5.

[0061] .

[0062] Table 3. Silicon-aluminum ratio and potassium-sodium ratio in the product formulations of Examples 1-5 and Comparative Examples 1-5.

[0063] .

[0064] The finished blanks were made into samples for testing, and the data obtained are shown in Table 4.

[0065] The specific gravity and compressive strength were tested according to the test methods specified in the standard "T / CBCSA12-2019 Foamed Ceramic Partition Board".

[0066] Table 4. Sample test data of Examples 1-5 and Comparative Examples 1-5.

[0067] .

[0068] As shown in Table 4, in this invention, the silicon-to-aluminum ratio and potassium-to-sodium ratio in the raw material formulation have a significant impact on the performance of the finished product. During the sintering process, when the silicon-to-aluminum ratio is high, the aluminum content is low while the silicon content is high, resulting in low high-temperature strength of the foamed ceramic skeleton structure. Under the above-mentioned firing temperature, the skeleton is prone to collapse and poor venting, leading to uneven foaming, as shown in Comparative Examples 1-3. When the silicon-to-aluminum ratio is low, the aluminum content is high while the silicon content is low, requiring a higher theoretical firing temperature. Under the above-mentioned firing temperature, the liquid phase is insufficient during sintering, which is insufficient to uniformly fill the gaps in the ceramic skeleton, resulting in uneven foaming, as shown in Comparative Examples 4-5.

[0069] During the sintering process, both potassium and sodium act as fluxes, with sodium having a relatively better fluxing effect, while potassium allows for a wider firing range, which is more conducive to the uniform foaming of foamed ceramics. This invention proposes a specific potassium-sodium ratio for thick products, taking into account both the fluxing effect and the promotion of uniform foaming.

[0070] Comparative Example 1 does not meet the silicon-aluminum ratio and potassium-sodium ratio requirements of the present invention. Comparative Examples 2-5 only meet the silicon-aluminum ratio requirement or the potassium-sodium ratio requirement, but do not simultaneously meet the silicon-aluminum ratio and potassium-sodium ratio requirements of the present invention. When thick foamed ceramics are made, the pore size is obviously uneven and the compressive strength of the finished product is significantly reduced.

[0071] According to the China Building Sanitary Ceramics Association group standard T / CBCSA12-2019, the density of type 400 products is 0.36~0.42 g / m³. 3 The minimum compressive strength of a single ceramic piece should be ≥4.0 MPa, and the average value should be ≥4.5 MPa. The finished products obtained in Examples 1-5 meet the density requirements, and the average compressive strength is ≥8.5 MPa, which is much greater than the standard requirements. Specifically, the ultra-thick and lightweight fine-pore foamed ceramic prepared by this invention has a height of 173~177 mm after firing, and a height of 150 mm after cutting. It is uniformly foamed, without large bubbles, with a pore size of 0.2~1.0 mm and a specific gravity of 400-420 kg / m³. 3 The compressive strength is 8.76-9.85 MPa, meeting the design requirements, and truly achieving the effect of lightweight and high strength in thick foamed ceramics.

[0072] The product obtained by this invention has good cutting performance. According to the standard T / CBCSA12-2019 "Foamed Ceramic Partition Board", the lateral bending is ≤L / 1000, where L is in millimeters (referring to the length of the product). When the 1800×3000mm product obtained by this invention is cut into a 10mm thick sheet, there is no chipping or corner breakage, and the lateral bending is less than 2mm (requirement ≤3, i.e. ≤3000 mm / 1000). This is achieved based on the unique formula structure of this invention. Combined with the firing curve of this invention, ultra-thick foamed ceramics can be prepared, while other sheets of the same specifications (with the same length, width and thickness as the product of this invention) have a lateral bending of 10~30mm.

[0073] The embodiments provided by the present invention have been described in detail above. Specific examples have been used to illustrate the principles and implementation methods of the present invention, and the descriptions of the embodiments above are only for the purpose of helping to understand the core ideas of the present invention. It should be noted that those skilled in the art can make several improvements and modifications to the present invention without departing from the principles of the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A type of ultra-thick lightweight foamed ceramic, characterized in that, The thickness of the foamed ceramic is 150~170 mm; Expressed in oxide form and calculated by mass percentage, the chemical composition of ultra-thick lightweight foamed ceramics includes: 65-70% silicon dioxide, 17-20% aluminum oxide, 3-6% potassium oxide, 2-4% sodium oxide, 1-2% calcium oxide, 1-3% magnesium oxide, <3% iron oxide, and <3% titanium dioxide. Among these, the silicon-to-aluminum ratio is 3.5 ≤ 4.0, and the potassium-to-sodium ratio is ≥ 1.

30. The silicon-to-aluminum ratio refers to the mass ratio of silicon dioxide to aluminum oxide, and the potassium-to-sodium ratio refers to the mass ratio of potassium oxide to sodium oxide. The raw materials are mixed and ball-milled with water to make a slurry. The dried slurry is then laid out as powder and fired. The final firing temperature is 1150~1200℃ and the firing time is 9.5~12 h.

2. The ultra-thick lightweight foamed ceramic according to claim 1, characterized in that, The raw materials for preparing ultra-thick lightweight foamed ceramics, calculated by mass percentage, include 15-45% recycled materials, 20-40% feldspar materials, 5-30% plastic materials, 0-15% raw coke, 0-15% cooked coke, 0-5% flux, and 0.15-0.30% foaming agent. The recycled materials include one or more of stone cutting materials, tile polishing materials, and recycled solid waste. Recycled solid waste refers to recyclable waste generated during the foamed ceramic production process, including one or more of recycled blanks, cutting mud, and slag. In the raw materials for preparing ultra-thick lightweight foamed ceramics, calculated by mass percentage, the raw materials include 0-10% stone cutting materials, 0-30% tile polishing materials, and 10-20% recycled solid waste, with the total mass percentage of stone cutting materials, tile polishing materials, and recycled solid waste being 15-45%. The amounts of raw coke, cooked coke, and flux are not all zero.

3. The ultra-thick lightweight foamed ceramic according to claim 2, characterized in that, Stone cutting materials include sawdust.

4. The ultra-thick lightweight foamed ceramic according to claim 2, characterized in that, Tile polishing materials include polishing putty.

5. The ultra-thick lightweight foamed ceramic according to claim 2, characterized in that, The plastic material includes one or both of white clay and Zhucheng clay. In the raw materials for preparing ultra-thick lightweight foamed ceramics, the raw materials for preparing ultra-thick lightweight foamed ceramics include 0-20% white clay and 5-20% Zhucheng clay by mass percentage, and the total mass percentage of white clay and Zhucheng clay is 5-30%.

6. A method for preparing ultra-thick lightweight foamed ceramic, characterized in that, The steps for preparing the ultra-thick lightweight foamed ceramic as described in any one of claims 1-5 are as follows: S1. Weigh all raw materials according to the raw material formula of ultra-thick lightweight foamed ceramic. S2. Mix all the raw materials together, add water and ball mill to make a slurry; S3. Dry the slurry to obtain powder; S4. The powdered fabric is piled up and fired at a final firing temperature of 1150~1200℃ for 9.5~12 hours to obtain the finished product.

7. The preparation method according to claim 6, characterized in that, In step S4, the firing profile is as follows: from room temperature to 600℃, the heating time is 60 min; from 600℃ to 900℃, the heating time is 30~60 min, and the temperature is held for 30~60 min; from 900℃ to 1080℃, the heating time is 60~120 min, and the temperature is held for 30~90 min; from 1080℃ to 1120℃, the heating time is 60~120 min, and the temperature is held for 30~60 min; from 1120℃ to the final firing temperature, the heating time is 30~90 min, and the temperature is held for 30~60 min.