CN112759417A - 一种利用花岗岩锯泥为基料制备的发泡陶瓷以及制备方法 - Google Patents
一种利用花岗岩锯泥为基料制备的发泡陶瓷以及制备方法 Download PDFInfo
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- CN112759417A CN112759417A CN202011564600.2A CN202011564600A CN112759417A CN 112759417 A CN112759417 A CN 112759417A CN 202011564600 A CN202011564600 A CN 202011564600A CN 112759417 A CN112759417 A CN 112759417A
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- foamed ceramic
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- granite
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- 239000000919 ceramic Substances 0.000 title claims abstract description 76
- 239000010438 granite Substances 0.000 title claims abstract description 26
- 239000000463 material Substances 0.000 title claims description 22
- 238000002360 preparation method Methods 0.000 title claims description 10
- 239000011230 binding agent Substances 0.000 claims abstract description 21
- 238000000034 method Methods 0.000 claims abstract description 21
- 239000000843 powder Substances 0.000 claims abstract description 21
- 239000000945 filler Substances 0.000 claims abstract description 20
- 239000006260 foam Substances 0.000 claims abstract description 17
- 238000005187 foaming Methods 0.000 claims abstract description 17
- 239000003381 stabilizer Substances 0.000 claims abstract description 16
- 230000008569 process Effects 0.000 claims abstract description 12
- 238000005245 sintering Methods 0.000 claims abstract description 10
- 239000010451 perlite Substances 0.000 claims abstract description 8
- 235000019362 perlite Nutrition 0.000 claims abstract description 8
- 239000007767 bonding agent Substances 0.000 claims abstract description 3
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims abstract 2
- 239000002994 raw material Substances 0.000 claims description 27
- 239000004088 foaming agent Substances 0.000 claims description 16
- 238000001035 drying Methods 0.000 claims description 15
- 239000000203 mixture Substances 0.000 claims description 15
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 12
- 238000005469 granulation Methods 0.000 claims description 12
- 230000003179 granulation Effects 0.000 claims description 12
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 238000001238 wet grinding Methods 0.000 claims description 12
- 239000005995 Aluminium silicate Substances 0.000 claims description 11
- 235000012211 aluminium silicate Nutrition 0.000 claims description 11
- 239000003795 chemical substances by application Substances 0.000 claims description 11
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 9
- 238000003825 pressing Methods 0.000 claims description 9
- 239000011248 coating agent Substances 0.000 claims description 8
- 238000000576 coating method Methods 0.000 claims description 8
- 239000012744 reinforcing agent Substances 0.000 claims description 8
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 7
- 239000000126 substance Substances 0.000 claims description 7
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 claims description 6
- 238000010304 firing Methods 0.000 claims description 6
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 claims description 6
- 238000002156 mixing Methods 0.000 claims description 6
- 239000002245 particle Substances 0.000 claims description 6
- 239000002002 slurry Substances 0.000 claims description 6
- 239000011787 zinc oxide Substances 0.000 claims description 6
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 claims description 5
- 239000010453 quartz Substances 0.000 claims description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 5
- 239000002904 solvent Substances 0.000 claims description 5
- 229910001570 bauxite Inorganic materials 0.000 claims description 4
- 239000004927 clay Substances 0.000 claims description 4
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 4
- 229910021532 Calcite Inorganic materials 0.000 claims description 3
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 claims description 3
- 229910052656 albite Inorganic materials 0.000 claims description 3
- 238000000498 ball milling Methods 0.000 claims description 3
- 229910021418 black silicon Inorganic materials 0.000 claims description 3
- WUKWITHWXAAZEY-UHFFFAOYSA-L calcium difluoride Chemical compound [F-].[F-].[Ca+2] WUKWITHWXAAZEY-UHFFFAOYSA-L 0.000 claims description 3
- 238000005520 cutting process Methods 0.000 claims description 3
- 238000007688 edging Methods 0.000 claims description 3
- 239000010433 feldspar Substances 0.000 claims description 3
- 239000010436 fluorite Substances 0.000 claims description 3
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 claims description 3
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 claims description 3
- 229910052629 lepidolite Inorganic materials 0.000 claims description 3
- 238000003754 machining Methods 0.000 claims description 3
- 239000000395 magnesium oxide Substances 0.000 claims description 3
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 claims description 3
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 claims description 3
- 229940072033 potash Drugs 0.000 claims description 3
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Substances [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 claims description 3
- 235000015320 potassium carbonate Nutrition 0.000 claims description 3
- 238000000926 separation method Methods 0.000 claims description 3
- 239000007921 spray Substances 0.000 claims description 3
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- 239000000454 talc Substances 0.000 claims description 3
- 229910052623 talc Inorganic materials 0.000 claims description 3
- 229910052593 corundum Inorganic materials 0.000 claims description 2
- 239000010431 corundum Substances 0.000 claims description 2
- 239000011449 brick Substances 0.000 abstract description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 238000010521 absorption reaction Methods 0.000 description 3
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- 238000005265 energy consumption Methods 0.000 description 3
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- 239000011819 refractory material Substances 0.000 description 2
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
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- 230000007547 defect Effects 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
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- 239000011707 mineral Substances 0.000 description 1
- 235000010755 mineral Nutrition 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 238000005192 partition Methods 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 229910052573 porcelain Inorganic materials 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000004321 preservation Methods 0.000 description 1
- 230000000750 progressive effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 239000002910 solid waste Substances 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
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Abstract
一种利用花岗岩锯泥为基料制备的发泡陶瓷以及制备方法，所述发泡陶瓷由若干薄片叠烧而成，所述薄片的基料为花岗岩锯泥、含有氧化铝的稳泡剂以及轻质填充剂，在各薄片之间设置有薄片结合剂，所述薄片结合剂包括珍珠岩粉。本申请的发泡陶瓷采用多片叠烧方式进行高温发泡，薄片与薄片之间通过坯体结合剂促进薄片间相互反应，并且通过轻质填充剂降低生坯体比重使发泡陶瓷发泡膨胀率减小，并利用稳泡剂使发泡陶瓷在发泡过程中能够均匀膨胀并保持一定的形状，防止发泡陶瓷坯体在发泡过程中产生巨大变形而塌陷，满足发泡陶瓷在无模框条件下高温发泡。
Description
技术领域
本申请涉及一种利用花岗岩锯泥为基料制备的发泡陶瓷以及制备方法。
背景技术
发泡陶瓷一般以珍珠岩尾矿、抛光瓷渣、花岗岩锯泥和金尾矿等固体废物作为主要原料，引入适量无机物，采用先进的生产工艺经高温发泡而成。发泡陶瓷因其封闭孔的结构特点，常温状态下具有保温隔热、隔音降噪、防水防潮的功能。
国内现有的发泡陶瓷生产技术一般在以堇青石-莫来石或碳化硅等耐火材料作为底板和挡板构成的模框内填充发泡陶瓷造粒粉，并通过硅酸铝耐火纤维纸将造粒粉与模框隔离，模框带着造粒粉一拼进入窑炉内进行烧制，使用的模框窑具比重高、重量大，在烧成过程中将吸收大量的热量，其比例占总消耗热量的一半以上，传统工艺单位质量的发泡陶瓷烧成需天然气约为100-110m3，能源消耗量巨大，导致生产成本居高不下。
发明内容
为了解决上述问题，本申请一方面提出了一种利用花岗岩锯泥为基料制备的发泡陶瓷，所述发泡陶瓷由若干薄片叠烧而成，所述薄片的基料为花岗岩锯泥、含有氧化铝的稳泡剂以及轻质填充剂，在各薄片之间设置有薄片结合剂，所述薄片结合剂包括珍珠岩粉。本申请的发泡陶瓷采用多片叠烧方式进行高温发泡，薄片与薄片之间通过坯体结合剂促进薄片间相互反应，并且通过轻质填充剂降低生坯体比重使发泡陶瓷发泡膨胀率减小，并利用稳泡剂使发泡陶瓷在发泡过程中能够均匀膨胀并保持一定的形状，防止发泡陶瓷坯体在发泡过程中产生巨大变形而塌陷，满足发泡陶瓷在无模框条件下高温发泡。
优选的，所述薄片的原料包括如下质量份数的物质：花岗岩锯泥：40-60 份；轻质填充剂：15-25份；稳泡剂：15-35份；助熔剂：5-15份；发泡剂：0.2-1 份，坯体增强剂：0.01-0.1份。
优选的，所述薄片结合剂的原料包括如下质量份数的物质：珍珠岩粉： 60-80份；钾长石：5-20份；石英：1-5份；高岭土：5-15份；发泡剂：0.2-1 份。
优选的，所述稳泡剂为星子高岭土或焦宝石或铝矾土中的一种或者两种以上的任意配比。稳泡剂的一个重要作用是提供氧化铝，提高发泡陶瓷高温熔体粘度，使发泡陶瓷能够均匀膨胀并保持一定形状，因此其他可以提供氧化铝的矿物也可以作为本发明的稳泡剂，也可本发明的保护范围之内。
优选的，所述轻质填充剂为玻化微珠、发泡陶瓷边角料颗粒中的一种或者两种的任意配比。轻质填充剂的一个重要作用是降低发泡陶瓷坯体比重，减小发泡陶瓷的膨胀率，同时轻质填充剂能在发泡过程中与发泡陶瓷充分反应并熔为一体，且不影响发泡陶瓷气孔的结构，因此其他具有该作用的轻质材料也可以作为本发明的轻质填充剂，也可本发明的保护范围之内。
优选的，所述助熔剂为钾长石、钠长石、滑石、方解石、萤石、锂云母、氧化锌、氧化镁、氧化铁和氧化锰的一种或者两种以上的任意配比，所述助熔剂中含有氧化锌。
优选的，所述发泡剂为黑碳化硅、绿碳化硅中的一种或者两种的任意配比，所述发泡剂的粒度不低于1000目。
优选的，所述坯体增强剂为CMA、HPMC、PVA中的一种或者两种以上的任意配比。
一种利用花岗岩锯泥为基料的发泡陶瓷的制备方法，包括如下步骤：
S1.配料：发泡陶瓷原料按重量份数取如下原料：花岗岩锯泥：40-60份；稳泡剂：15-35份；助熔剂：5-15份；发泡剂：0.2-1份，坯体增强剂：0.01-0.1 份；坯体结合剂原料按重量份数取如下原料：珍珠岩粉：60-80份；钾长石：5-20 份；石英：1-5份；高岭土：5-15份；发泡剂：0.2-1份；
S2.球磨机湿磨：按如下质量比，原料：球：水＝1：2：0.6的比例分别将发泡陶瓷和坯体结合剂原料入球磨罐，混合料经球磨机湿磨，细度控制万孔筛余不大于5.0wt％；
S3.造粒：将发泡陶瓷湿磨后的混合料，喷雾造粒得到造粒粉，粒径控制在 40目-80目不低于80wt％，干燥后含水率不超过7wt％；坯体结合剂湿磨后的浆料入浆池，备用；
S4.二次混料：按质量比，将15-25份轻质填充剂均匀平铺在发泡陶瓷造粒粉传送皮带上，通过二次滚筒筛将轻质填充剂与造粒粉均匀混合得到混合料；
S5.干压成型：发泡陶瓷混合料，经皮带输送机，斗式提升机输送至压机，采用干压成型的方法压制成15-25mm的薄片；
S6.坯体干燥：薄片在干燥辊道窑内干燥，干燥周期80-240min，干燥温度不超过220℃，干燥后的薄片含水率不高于0.5wt％；
S7.坯体叠加：在干燥后薄片的上表面淋一层坯体结合剂，将多个薄片相互叠加组成坯体；
S8.烧成：将得到的坯体底部涂耐火涂料进辊道窑，采用无模裸烧高温发泡烧成发泡陶瓷毛坯；
S9.冷加工：包括切割、磨边、倒角、开槽等，冷加工后的产品经分色、分级、包转入库。本申请得到的发泡陶瓷抗压强度大于5MPa，容重300～500kg/m3，吸水率小于1％，耐火极限大于1h，导热系数0.1～0.14w/(m.k)，烧成段单位产品天然气消耗量为40～60m3。
本申请能够带来如下有益效果：现有技术烧成发泡陶瓷一般在耐火材料组成的模框内布置一定厚度的粉料而得到，模框的存在吸收大量的热量，并影响发泡陶瓷退火时散热速率，延长了发泡陶瓷退火时间。本发明利用轻质填充剂降低坯体的比重，减小发泡陶瓷发泡膨胀率，利用星子高岭土或焦宝石或铝矾土为配方提供氧化铝作为稳泡剂，提高发泡陶瓷高温熔体的粘度及表面张力，发泡陶瓷在发泡过程中均匀膨胀并使坯体保持形状，通过引入相似化学成分的坯体结合剂促进相同化学组成的薄片相互反应，从而将多个薄片高温熔成一个整体，薄片之间结合牢固，无力学缺陷。本发明，减少窑具吸热，同时缩短发泡陶瓷的退火时间，将烧成段发泡陶瓷能耗降至传统工艺的60％左右，发泡陶瓷各项性能满足使用要求，从而提高以花岗岩锯泥为主要原料生产发泡陶瓷产品的经济效益。
具体实施方式
为能清楚说明本方案的技术特点，下面通过具体实施方式，对本申请进行详细阐述。
本申请本身包括一个配方，一个制备方法，但是由于生产方法是基于配方所产生的，因此下面从制备方法的角度进行本申请的阐明，本申请的发泡陶瓷的合成包括如下步骤：
S1.配料：发泡陶瓷原料按重量份数取如下原料：花岗岩锯泥：40-60份；稳泡剂：15-35份；助熔剂：5-15份；发泡剂：0.2-1份，坯体增强剂：0.01-0.1 份；坯体结合剂原料按重量份数取如下原料：珍珠岩粉：60-80份；钾长石：5-20 份；石英：1-5份；高岭土：5-15份；发泡剂：0.2-1份；所述稳泡剂为星子高岭土或焦宝石或铝矾土中的一种或者两种以上的任意配比；所述轻质填充剂为玻化微珠、发泡陶瓷边角料颗粒中的一种或者两种的任意配比；所述助熔剂为钾长石、钠长石、滑石、方解石、萤石、锂云母、氧化锌、氧化镁、氧化铁和氧化锰的一种或者两种以上的任意配比，所述助熔剂中含有氧化锌；所述发泡剂为黑碳化硅、绿碳化硅中的一种或者两种的任意配比，所述发泡剂的粒度不低于1000目；所述坯体增强剂为CMA、HPMC、PVA中的一种或者两种以上的任意配比。
S2.球磨机湿磨：按如下质量比，原料：球：水＝1：2：0.6的比例分别将发泡陶瓷和坯体结合剂原料入球磨罐，混合料经球磨机湿磨，细度控制万孔筛余不大于5.0wt％；
S3.造粒：将发泡陶瓷湿磨后的混合料，喷雾造粒得到造粒粉，粒径控制在40目-80目不低于80wt％，干燥后含水率不超过7wt％；坯体结合剂湿磨后的浆料入浆池，备用；
S4.二次混料：按质量比，将15-25份轻质填充剂均匀平铺在发泡陶瓷造粒粉传送皮带上，通过二次滚筒筛将轻质填充剂与造粒粉均匀混合得到混合料；具体的发泡陶瓷原料以及胚体结合剂的原料配比见表1；
表1：
S5.干压成型：发泡陶瓷混合料，经皮带输送机，斗式提升机输送至压机，采用干压成型的方法压制成15-25mm的薄片；
S6.坯体干燥：薄片在干燥辊道窑内干燥，干燥周期80-240min，干燥温度不超过220℃，干燥后的薄片含水率不高于0.5wt％；
S7.坯体叠加：在干燥后薄片的上表面淋一层坯体结合剂，将多个薄片相互叠加组成坯体；所述坯体结合剂的厚度是：0.1-0.5mm；
S8.烧成：将得到的坯体底部涂耐火涂料进辊道窑，采用无模裸烧高温发泡烧成发泡陶瓷毛坯；所述发泡陶瓷毛坯的厚度是：80-150mm，所述耐火涂层由氧化铝、刚玉和高岭土的一种或两种以上的任意比例组成；
S9.冷加工：包括切割、磨边、倒角、开槽等，冷加工后的产品经分色、分级、包转入库。
S10.对于得到的材料进行产品表征，具体参数以及测量数据见表2。
表2：
注意：在表2的抗压强度中大于等于某个数值，表示其测量值在该数值以及该数值+1之间。
由此可见，采用本发明的方法，利用花岗岩锯泥为主要原料制备的发泡陶瓷，容重低、强度高，满足隔墙板使用要求，具有使用价值，避免了窑具的吸热，可以明显降低产品能耗。
本说明书中的各个实施例均采用递进的方式描述，各个实施例之间相同相似的部分互相参见即可，每个实施例重点说明的都是与其他实施例的不同之处。尤其，对于系统实施例而言，由于其基本相似于方法实施例，所以描述的比较简单，相关之处参见方法实施例的部分说明即可。
以上仅为本申请的实施例而已，并不用于限制本申请。对于本领域技术人员来说，本申请可以有各种更改和变化。凡在本申请的精神和原理之内所作的任何修改、等同替换、改进等，均应包含在本申请的权利要求范围之内。
Claims (10)
1.一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述发泡陶瓷由若干薄片叠烧而成，所述薄片的基料为花岗岩锯泥、含有氧化铝的稳泡剂以及轻质填充剂，在各薄片之间设置有薄片结合剂，所述薄片结合剂包括珍珠岩粉。
2.根据权利要求1所述的一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述薄片的原料包括如下质量份数的物质：花岗岩锯泥：40-60份；轻质填充剂：15-25份；稳泡剂：15-35份；助熔剂：5-15份；发泡剂：0.2-1份，坯体增强剂：0.01-0.1份。
3.根据权利要求1所述的一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述薄片结合剂的原料包括如下质量份数的物质：珍珠岩粉：60-80份；钾长石：5-20份；石英：1-5份；高岭土：5-15份；发泡剂：0.2-1份。
4.根据权利要求1所述的一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述稳泡剂为星子高岭土或焦宝石或铝矾土中的一种或者两种以上的任意配比。
5.根据权利要求1所述的一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述轻质填充剂为玻化微珠、发泡陶瓷边角料颗粒中的一种或者两种的任意配比。
6.根据权利要求1所述的一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述助熔剂为钾长石、钠长石、滑石、方解石、萤石、锂云母、氧化锌、氧化镁、氧化铁和氧化锰的一种或者两种以上的任意配比，所述助熔剂中含有氧化锌。
7.根据权利要求1所述的一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述发泡剂为黑碳化硅、绿碳化硅中的一种或者两种的任意配比，所述发泡剂的粒度不低于1000目。
8.根据权利要求1所述的一种利用花岗岩锯泥为基料制备的发泡陶瓷，其特征在于：所述坯体增强剂为CMA、HPMC、PVA中的一种或者两种以上的任意配比。
9.一种利用花岗岩锯泥为基料的发泡陶瓷的制备方法，其特征在于：包括如下步骤：
S1.配料：发泡陶瓷原料按重量份数取如下原料：花岗岩锯泥：40-60份；稳泡剂：15-35份；助熔剂：5-15份；发泡剂：0.2-1份，坯体增强剂：0.01-0.1份；坯体结合剂原料按重量份数取如下原料：珍珠岩粉：60-80份；钾长石：5-20份；石英：1-5份；高岭土：5-15份；发泡剂：0.2-1份；
S2.球磨机湿磨：按如下质量比，原料：球：水＝1：2：0.6的比例分别将发泡陶瓷和坯体结合剂原料入球磨罐，混合料经球磨机湿磨，细度控制万孔筛余不大于5.0wt％；
S3.造粒：将发泡陶瓷湿磨后的混合料，喷雾造粒得到造粒粉，粒径控制在40目-80目不低于80wt％，干燥后含水率不超过7wt％；坯体结合剂湿磨后的浆料入浆池，备用；
S4.二次混料：按质量比，将15-25份轻质填充剂均匀平铺在发泡陶瓷造粒粉传送皮带上，通过二次滚筒筛将轻质填充剂与造粒粉均匀混合得到混合料；
S5.干压成型：发泡陶瓷混合料，经皮带输送机，斗式提升机输送至压机，采用干压成型的方法压制成15-25mm的薄片；
S6.坯体干燥：薄片在干燥辊道窑内干燥，干燥周期80-240min，干燥温度不超过220℃，干燥后的薄片含水率不高于0.5wt％；
S7.坯体叠加：在干燥后薄片的上表面淋一层坯体结合剂，将多个薄片相互叠加组成坯体；
S8.烧成：将得到的坯体底部涂耐火涂料进辊道窑，采用无模裸烧高温发泡烧成发泡陶瓷毛坯；
S9.冷加工：包括切割、磨边、倒角、开槽，冷加工后的产品经分色、分级、包转入库。
10.根据权利要求9所述的一种利用花岗岩锯泥为基料的发泡陶瓷的制备方法，其特征在于：所述发泡陶瓷毛坯的厚度是：80-150mm；
所述坯体结合剂的厚度是：0.1-0.5mm；
所述耐火涂层由氧化铝、刚玉和高岭土的一种或两种以上的任意比例组成。
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