Purification of metallurgical silicon using iron as an impurity getter part I: Growth and separation of Si

The purification of metallurgical grade silicon (MG-Si) using a combination of solvent refining and physical separation is studied. MG-Si was alloyed with iron and solidified under different cooling rates in order to grow pure Si dendrites from the alloy. The Si dendrites were then separated using a gravity-based method. The separation method relies on the significantly different densities of Si and FeSi2, and it uses a heavy liquid with specific gravity between the two phases to float the light Si particles to the surface of the liquid, while the heavy iron silicide sinks. The effects of the particle size and cooling rate on the yield and separation efficiency of the Si phase were investigated by quantifying the fraction of Si in the sinks and floats. The results demonstrate that the crushing size of the particles prior to separation should be approximately the same as the width of the dendrites in order to maximize the separation efficiency while simultaneously lowering the grinding cost.