A new strategy for de-oxidation of diamond-wire sawing silicon waste via the synergistic effect of magnesium thermal reduction and hydrochloric acid leaching

Silicon Extraction from a Diamond Wire Saw Silicon Slurry with Flotation and the Flotation Interface Behavior

Diamond wire saw silicon slurry (DWSSS) is a waste resource produced during the process of solar-grade silicon wafer preparation with diamond wire sawing. The DWSSS contains 6N grade high-purity silicon and offers a promising resource for high-purity silicon recycling. The current process for silicon extraction recovery from DWSSS presents the disadvantages of lower recovery and secondary pollution. This study focuses on the original DWSSS as the target and proposes flotation for efficiently extracting silicon. The experimental results indicate that the maximal recovery of silicon reached 98.2% under the condition of a dodecylamine (DDA) dosage of 0.6 g·L-1 and natural pH conditions within 24 min, and the flotation conforms to the first-order rate model. Moreover, the mechanism of the interface behavior between DWSSS and DDA revealed that DDA is adsorbed on the surface of silicon though adsorption, and the floatability of silicon is improved. The DFT calculation indicates that DDA can be spontaneously adsorbed with the silicon. The present study demonstrates that flotation is an efficient method for extracting silicon from DWSSS and provides an available option for silicon recovery.

Hematite tailings to high-purity silica: Mechanistic studies and life cycle assessment analysis

This study aimed to recover high-purity silica from hematite tailings (HTs) using superconducting high-gradient magnetic separation (S-HGMS) technology. This process involved converting silica into a silicone-rich concentrate and subsequently employing a fluorine-free mixed acid to leach the silicon-rich concentrate to remove impurities and achieve refinement and purification. The optimization of the S-HGMS process was conducted using the "Box-Behnken Design" method, resulting in the following optimal conditions: a pulp concentration of 50 g/L, a magnetic velocity ratio of 0.076 T s/m, and a pulp velocity of 500 mL/min. These conditions yielded a silica grade range of 61.905% in the HTs to 91.818% in the silicon-rich concentrate, with corresponding recovery rates of 53.031%. Under the optimized leaching process, this resulted in an increase in the silica content from 91.818% in the silicon-rich concentrate to 99.938% in high-purity silica. Additionally, by analyzing the production process of 1 kg of high-purity silica from HTs using the process LCA method, environmental hotspots were identified, and corresponding solutions were proposed. This approach is vital for efficient utilization of HTs as a resource. This process has low energy consumption and is environmentally friendly, enabling the reduction of hematite tailings. It has a wide range of applications and offers substantial economic benefits, rendering it a promising candidate for industrial applications.

Preparation of high-purity SiO2 by S-HGMS coupled with mixed-acid leaching: A case study on hematite tailings from Ansteel, China

Hematite tailings (HTs) are rich in silica and are used as replacements for fine aggregates in the preparation of construction materials. However, there is scope for a more effective utilization of the valuable elements present in HTs. In this paper, a process for preparing high-purity SiO2 using HTs procured from Ansteel (China) is proposed. HTs were treated using the superconducting high-gradient magnetic separation (S-HGMS) technology, where the silica as part of the nonmagnetic fraction was obtained in the form of a high-silica concentrate, which was then subjected to mixed-acid leaching to dissolve impurities to achieve refined purification. The optimum process conditions for S-HGMS were determined, and the response surface methodology was applied to optimize the process parameters of the mixed-acid leaching process. The process indicators of the mixed-acid leaching step included the leaching time, leaching temperature, and molar ratio of the mixed acids. The optimum process conditions for S-HGMS were as follows: the magnetic strength-to-velocity ratio in the weak magnetic separation stage was set to 0.034 T·s/m whereas it was maintained at 0.076 T·s/m in the strong magnetic separation stage; the pulp concentration was 40 g/L, the pulp velocity was 500 mL/min, and the dispersant concentration was 1 mg/g. Under these conditions, the high-silica pulp was processed. The corresponding SiO2 grade increased from 71.788 % to 95.260 %, and its recovery and yield reached 56.330 % and 42.450 %, respectively. The SiO2 content in the sample increased from 95.260 % to 99.961 %. Further, the mechanisms of the S-HGMS and mixed-acid leaching were revealed. The proposed process is environmentally friendly and operationally inexpensive. It can reduce the amount of HTs by 42.450 %, and the obtained high-purity silica product has high economic value and good industrialization prospects.

Recycling of kerf loss silicon: An optimized method to realize effective elimination of various impurities

Photovoltaic solid waste, particularly diamond-wire sawing silicon powder (DWSSP), has emerged as a significant concern in the industry. Consequently, the recycling and reuse of such waste have become a prominent research focus. In this study, focusing on achieving direct recycling and reuse of DWSSP, the key driving factors for effective purification were identified. It was found that simply increasing the melting temperature and time was insufficient to completely remove volatile impurities, and the migration process in the melt had to be taken into consideration. Additionally, this study focused on analyzing the instability model of inter-granular grain growth and its impact on the stable migration of impurities, with particular attention to the microstructure of inter-granular micro-regions. The thermal control directional solidification technique focused on controlling the temperature gradient during the melt solidification process. This approach helped stabilize the microstructure, enhance impurity migration, and ultimately led to a more effective purification of DWSSP.

Oxygen removal and silicon recovery from polycrystalline silicon kerf loss by combining vacuum magnesium thermal reduction and hydrochloric acid leaching

With the strengthened awareness of environmental protection and the growing interests of wastes recycling, silicon recovery from polycrystalline silicon kerf loss (PSKL) has drawn extensive attentions all over the world. In this paper, an efficient and environmental friendly approach for oxygen removal and silicon recovery from PSKL by combining vacuum magnesium thermal reduction (VMTR) and hydrochloric acid leaching was proposed. The effects of temperature, duration and particle size on the reduction of PSKL were investigated thoroughly. It is proved that the amorphous SiO₂ in PSKL can be reduced by magnesium vapor at 923 K to generate MgO, and then the produced MgO can be dissolved by hydrochloric acid to eliminate the impurity oxygen. The oxygen removal fraction and the silicon recovery efficiency attained 98.43% and 94.46%, respectively, under the optimal conditions, indicating that a high efficiency recovery of silicon from PSKL was achieved. Compared to the existing PSKL deoxidation technologies, e.g., the high temperature process and the hydrofluoric acid leaching method, this method requires a relatively lower temperature and the waste acid can be easily recovered. Additionally, by taking into accounts the fact that the MgCl₂ in leaching liquor can be recycled for cyclic utilization with a molten salt electrolysis method, it should be suggested that an efficient and environmental friendly process for PSKL recycling was obtained, which shows good prospects for commercial application.