BRPI1003984A2 - process for producing high purity metallurgical grade metal silicon from purification with metals and other compounds, followed by leaching - Google Patents

Abstract

PROCESS FOR THE PRODUCTION OF METALLIC SILICIUM METALLURGICAL DEGREE OF HIGH PURITY FROM PURIFICATION WITH METALS AND OTHER COMPOUNDS, FOLLOWED BY Leaching. The present patent presents a new production process of metallic silicon, in high purity metallurgical grade, by leaching the metallic silicon, followed by further purification steps. The Process, object of this Patent, when using the process of purification of metallic silicon from the introduction of metals and / or other compounds to the bath, and other techniques, followed by leaching, washing and drying, advances the State of the Art by allowing the obtaining the following advantages: 1. Significant reduction in the contents of contaminants and other metals, in silicon, 2. Economic viability in the production of metallic silicon, of high purity metallurgical grade, when compared to traditional processes; 3. Reduced number of process steps to obtain high purity metallurgical grade silicon; 4. Possibility of using low-cost products and / or substances for the formation and removal of contaminations or undesirable components. The present patent basically consists of four stages to obtain metallic Silicon, metallurgical grade of high purity, with individual contents of Boron and Phosphorus below 1ppm: First stage: - addition of alkaline and / or alkaline earth metals and / or other components such as : fluorite, silica, silicates, synthetic slag, before, during, or after the melting of metallic silicon. Second stage: simultaneous and / or consecutive injection of gases into the bath with high temperature, above the melting temperature of metallic silicon, such as argon, humidified argon, water vapor, oxygen, chlorine, hydrogen, hydroxides, etc. Maintenance of gas injection over the bath in turbulence for a sufficient time so that the entire volume / mass of the metal has contact with the gas mass directed to the bath. Third stage: - purification or not, of the aforementioned product, in a refining oven, plasma and / or inductive oven and / or electric oven, resistance oven, with simultaneous and / or consecutive use of various procedures. Fourth stage: - Metal silicon with individual levels of Boron and Phosphorus below 0.5 ppm - obtained as described above is subjected to the process of reflow and directional solidification, with or without the presence of thermal plasma and gas injection. These steps can occur simultaneously, in the order described above, but also with change or replacement in the order of occurrence, as well as frequency and number of repetitions of each step.

Description

"PROCESS FOR PRODUCTION OF METAL SILICON OF HIGH PURITY METALURGICAL DEGREE FROM PURIFICATION WITH METALS AND OTHER COMPOUNDS, FOLLOWING Leaching"

Fields of this Patent:

• Purification of metallurgical grade metallic silicon from the use of alkali, alkaline earth, halogen, silicate, synthetic slag, silica, fluoride and others.

• Process of injection or addition of metals during the metallurgical pan treatment of silicon metal to form boron and phosphorus based compounds.

• Process of injection or addition of metals during metallurgical treatment in the electric furnace itself, which may occur before or after the formation of the silicon metal bath, or melting of the metal.

• Metallurgical grade metallic silicon purification process, from the treatment of molten silicon, followed by cooling, solidification and final treatment by metal leaching and removal of impurities.

• Metallurgical grade metallic silicon purification process from consecutive treatment steps: addition of metals and / or specific compounds for Si-based alloy formation and segregation of impurities or contaminant metals, removal of acidic leach contamination from metallic silicon , plasma silicon metal treatment and / or gas injection induction for elimination and volatilization of residual boron compounds and directional solidification.

• Metallurgical grade metallic silicon purification process from the introduction of alkali metals, alkaline earth, halogens, silicates, synthetic slag, silica, fluorides and others to form phosphorus-based compounds, which are segregated in the slag. Simultaneously to the injection of gases in the bath at high temperature, for formation and volatilization of boron based compounds. Followed by scorification and elimination of deleterious elements to the preparation of solar cells.

The present invention relates to a process of producing high purity metallic silicon obtained from the addition of metals and / or other compounds to the liquid bath or even prior to melting; followed by further purification steps; thus obtaining silicon with very low levels of impurities.

State of the art.

The load used on each furnace loading for the production of metallic silicon consists of quartz and / or quartzite, charcoal, petroleum coke and / or charcoal, as well as wood chips and / or biomass. To obtain a good oven performance, the raw materials are previously gauged in certain particle size ranges. In order to obtain a high quality product, the raw material is rigorously selected, trying to avoid the presence of major impurities such as Iron, Calcium, Aluminum, Titanium, Tungsten, especially Boron and Phosphorus.

The production of metal silicon is obtained essentially by reducing the silica with carbon present in charcoal.

From a stoichiometric point of view, the relationship describing the process is as follows:

SiO2 (I) + 2C (S) = Si (i) + 2C0 .................................. ..............................(1)

However, this is only the final stoichiometric equation; The process of reducing silica by carbon is more complex than shown by equation (1), including several intermediate stages, as can be summarized below:

SiO2 (I) + 3C (S) = SiC (g) + 2C0 (g) ........................... ............ (2)

2SiC (g) + SiO2w = 3Si (i) + 2C0 (g) .............................. .................. (3)

2SiC (S) + 3Si02 (s) = Si (i) + 3SiO (g) + C0 (g) .......................... ............ (4)

In the absence of carbon the gases may react to generate condensed products, according to the reactions: SiO (g) + CO (g) = 2 Si (g) + SiC (g) .............. .......................... (5)

Si0 (g) + CO (g) = Si02 (g) + C .............................. ...... (6)

2SiO (g) = Si (I) + SiO2 (S) .................................... .... (7)

In the presence of carbon, the SiO + 2C = SiC + C0 (9) reaction is preferred above about 1500 ° C, and condensation reactions 5, 6 and 7 proceed at lower temperatures.

Proper control of the hanging load is required for proper furnace operation, avoiding high losses of silicon oxide in the gases and the formation of silicon carbonate which causes fouling and shortens the life of the furnace components.

The function of wood or biomass chips in an electric reduction furnace is to act as load conditioners and aims to improve porosity and reduce conductivity, as well as contributing as a carbon source.

The primary contribution of this chip in the charge composition of ferroalloy and silicon furnaces is to promote the stabilization and distribution of the gas flow evenly throughout the process by uniformly evolving gas throughout the layers. , providing a multitude of low pressure channels for exhaust gases. Uniform gas flow through the top of the furnace optimizes electrode penetration and thereby furnace performance and charge permeability.

Metallic silicon alloys and / or ferroalloys are similarly processed, but in addition to the use of quartz and / or quartzite as a raw material, other minerals such as hematite, calcite, etc. are also used.

The production of high purity metallurgical grade metallic silicon is conditioned more on the quality of its raw materials than on the process control itself. The sources of contamination can be endogenous or exogenous. Endogenous contaminations are characterized by being intrinsic to the raw materials, ie, they are part of their chemical composition (impurities). Exogenous contamination is all other sources.

High purity metallurgical grade silicon is a potential product for use in the photovoltaic industry. That is, it is a product capable of replacing electronic grade silicon in solar cell making with similar efficiency.

Among the major contaminations in high purity solar or metallurgical grade silicon are boron and phosphorus. These elements should ideally be null or less than 5ppm. Above this percentage, these elements impair the efficiency of the solar cell.

Both B and P are Si dopants, depending on the concentration present in the material can also function as impurities. The presence of these elements gives character to the blade, that is, the Si with higher concentration of Boron is of type p, and the Si or blade with higher concentration of Phosphorus is of type n. Resistivity and carrier life measurements along with chemical analysis are used to characterize the material. Slides with a low resistivity value of 0.08 ohm.cm indicate that the material still has many impurities, which may be metallic, or even have high levels of B and P.

The photovoltaic effect occurs in materials of nature called semiconductors that are characterized by the presence of energy bands where the presence of electrons (valence band) and another where totally "empty" (conduction band) is allowed. The most commonly used semiconductor is silicon. Their atoms are characterized by having four electrons that bind to their neighbors, forming a crystal lattice. By adding atoms with five bonding electrons, such as phosphorus, for example, there will be an excess electron that cannot be paired and will be "left over," loosely attached to its parent atom. This causes, with little thermal energy, this electron to break free, going into the conduction band. Thus it is said that phosphorus is an electron donor dopant and is called dopant η or impurity n. If, on the other hand, atoms with only three bonding electrons are introduced, such as boron, there will be a lack of one electron to satisfy the bonds with the silicon atoms in the network. This lack of electron is called a hole or gap and it occurs that with low thermal energy, an electron from a neighboring site can move to this position, causing the hole to move. Therefore, boron is said to be an electron acceptor or a dopant p.

If starting from pure silicon, boron atoms are introduced in one half and phosphorus in the other, the so-called pn junction will be formed. What happens at this junction is that free electrons from side η pass side ρ where they find the holes that capture them; This causes an accumulation of electrons on the p-side, making it negatively charged, and a reduction in electrons on the n-side, which makes it electrically positive. These trapped charges give rise to a permanent electric field that makes it difficult for more electrons to pass from side η to side p; This process achieves an equilibrium when the electric field forms a barrier capable of barring the remaining free electrons on the n side. If a pn junction is exposed to photons with energy greater than the gap, electron-gap pair generation occurs; if this happens in the region where the electric field is nonzero, the charges will be accelerated, thus generating a current through the junction; This shifting of charges gives rise to a potential difference we call the Photovoltaic Effect. If the two ends of the silicon "piece" are connected by a wire, there will be an electron circulation. This is the basis of the operation of photovoltaic cells.

For this reason, silicon used as a semiconductor should be as pure as possible, as any metallic contamination can steal electrons and impair the effect of current formation, especially the boron and phosphorus elements that are the donor / receptor metals and therefore should be doped homogeneously between the bedrings η and p. Otherwise, ie; present in the Si blade at random, they create resistance and significantly reduce the efficiency of the photoelectric effect. Among the raw materials used, charcoal is the main source of boron and phosphorus as silicon contaminants. And these elements are the most complex impurities or contaminants to remove and also most damaging to the solar cell, as they usually replace the silicon atom in the crystal structure. The boron content of coal may range from 5 to 30 ppm; and the ratio between the charge of charcoal per ton of metallic silicon is 1.2. Silica has about 1 to 20 ppm boron and its production ratio is 2.5 tons of quartz per ton of silicon produced. For wood chips, the boron concentration is around 3ppm and its ratio is 1.5 tons of chips per ton of metallic silicon. Thus, among the main constituents of the reaction, coal from biomass is the main contaminating agent or main source of undesirable components in the production of metallic silicon.

In a conventional process, the boron content and phosphorus content in the metallurgical grade silicon oscillate around 10 and 40 ppm, respectively. However, the world market requires concentrations of these elements below 1ppm, in some cases below 0.2ppm. This is a significant advance in the technology of processing and obtaining metallic silicon; which is significantly obtained today from the feedstock or tailings of the electronic grade silicon production process, so it has a high and often unviable production cost.

It is inferred that the photovoltaic industry has been growing rapidly and steadily, and it is pertinent to point out that the forecast demand for 2020 is 72,000t of solar grade silicon (SGS), whose purity content is 99.999%; and a potential power generation from solar panels around 40GW. Among the promising technologies, to achieve this expectation are the production of thin films, amorphous silicon and in particular the production of high purity metallurgical grade silicon.

Criticism of the State of the Art.

As in almost all chemical, metallurgical, pharmaceutical and biochemical processes in which products with purity levels greater than 99.999% are sought - or, from a different angle, contaminant content of less than 10 parts per million - experience indicates that The best technical and economical way is to use the highest possible raw materials.

In the case of contamination by Boron and Phosphorus of the main inputs for the production of Solar Grade Silicon - silica and wood - physical separation techniques such as flotation, magnetic separation, etc. They are generally ineffective for boron and phosphorus removal and may advantageously be replaced by leaching.

Innovations introduced by this patent in the prior art.

Nowadays there are constant and tireless search for new technologies in the production and cogeneration of renewable energy. Along the same path, it is verified that several projects are being developed in the fields of wind energy, solar energy, tidal energy, hydroelectric power plants, among others, as a source of clean and sustainable energy.

The present patent discloses a novel process of producing high purity metallurgical grade metal silicon by leaching the metallic silicon followed by further purification steps.

THE PROCESS FOR PRODUCING METAL SILICITY OF HIGH PURITY METALURGIC FROM PURIFICATION WITH METALS AND OTHERS FOLLOWED by this Patent when using the process of purifying metallic silicon from the introduction of metals and / or other compounds into the bath , and other techniques, followed by leaching, washing and drying advance the state of the art by enabling the following advantages to be obtained:

1. Significant reduction in the levels of contaminants and other metals in silicon;

2. Economic viability in the production of high purity metallurgical grade metallic silicon when compared to traditional processes; 3. Reduced number of process steps to obtain high purity metallurgical grade silicon;

4. Possibility of using low cost products and / or substances to form and remove unwanted contamination or components.

DESCRIPTION OF THE "PROCESS FOR PRODUCTION OF METAL SILICON OF HIGH PURITY METALURGICAL DEGREE FROM PURIFICATION WITH METALS AND OTHER COMPOSITIONS FOLLOWED BY Leaching", object of this Patent

The present patent consists basically of four steps to obtain high purity metallurgical grade metallic silicon with individual boron and phosphorus contents of less than 1ppm:

First step: - Addition of alkaline and / or alkaline earth metals and / or other components such as fluorite, silica, silicates, synthetic slag before, during or after melting of the metallic silicon.

• These substances may be added in the form of ground, pulverized, crushed material or even as grains, stones, etc.

• During the addition or feeding of one and / or some of these substances, the process can be optimized by shaking or moving the bath, aiming for better contact between reagents and greater homogenization of reactions. One can therefore use inert gas injection, such as argon; or even other purifying gases such as water vapor, hydrogen, oxygen, nitrogen, etc.

Second stage: - leaching of silicon in stones and / or after comminution process, using acid and oxidant reagents such as hydrochloric acid, hydrofluoric acid, nitric acid, sulfuric acid, sodium hypochlorite, sodium chlorate, hydrogen peroxide, among others.

• An optimized solution with high productivity, high heat release rate, high Gibbs energy can be represented by the reaction between metal silicon, hydrochloric acid and sodium chlorate.

• Among the products of this reaction are: high purity silicon, around 99.9999%; in addition to other by-products such as chlorides.

• In this case there is no generation or release of gaseous compounds, such as hydrogen, the process has low cost, high efficiency and high productivity.

• Reduction in individual levels of Boron and Phosphorus in silicon to values below 1ppm.

Third step: - Purification or otherwise of the above product in a refining oven, plasma and / or inductive oven and / or electric oven, resistance oven, with simultaneous and / or consecutive use of the following procedures:

• Injection of gases such as chlorine, oxygen, hydrogen, water vapor, and / or others;

• Simultaneous injection of reducing gases under the action of thermal plasma, aiming to achieve gas ionization, promoting a more reactive action in the formation of boron-based compounds, especially;

• Vacuum treatment for volatilization of phosphorus and boron compounds;

• After using the above technical resources, it is possible to produce metal silicon with individual Boron and Phosphorus contents below 0.5 ppm.

Fourth stage: - Metallic silicon with individual Boron and Phosphorus contents below 0.5 ppm - obtained as described above is subjected to the process of refluxing and directional solidification, with or without the presence of thermal plasma and gas injection.

• The results of the processes described above lead to the production of high purity metallurgical metal silicon, which is therefore suitable for use in the solar grade silicon industry and the production of solar panels.

The leaching process consists of the selective removal of one soluble component in solution from other non-soluble one (s). Mixing may occur by diffusion, dissolution, displacement or simple washing. Soluble constituents may be incorporated, absorbed, chemically combined or mechanically maintained in the porous structure of the insoluble material. The leaching mechanism, as described by Robert H. Perry (Chemical Engineers' Handbook), may involve a physical solution or dissolution activated by a chemical reaction. Therefore the rate of chemical reaction may affect the rate of leaching. The solution or flow containing the leachate solute is called overflow and the solution without the underflow solute. As these flows are not immiscible, the concept of equilibrium for leaching does not apply as with other mass transfer operations / separations. So in practice the leaching equilibrium is achieved when the concentrations between overflow and underflow are the same.

Leaching may occur in parallel and / or simultaneously, and may be through parallel, cross and / or counter current currents, in basic, neutral or acidic medium and in one or more stages.

During leaching a megasonic vibration system can be used, which assists in breaking Van der Waals bonds and in transporting impurities to the wood surface and solute / solvent interface. The dominant effect of this technique is the formation of cavitation in the wood volume, promoted by the bubbling of micro-gases, interfering and enhancing the removal of impurities in their original crystalline forms.

The present leaching technique proposed here is to immerse the metallic silicon in stones and / or gravel and / or ground, in a leaching tank, with stirring system for bath homogenization and possibility of injection of liquid and / or solid hydrogen peroxide. for temperature increase and consequent optimization of productivity and efficiency.

The proposed leaching technique presents practical, industrial results, with optimization proven by statistical analysis due to the conduction of consecutive events and statistical guidance, from several combinations of the following parameters:

• Residence time and / or contact between solute and solvent;

• Temperature and processing pressure; • Frequency of agitation and / or megasonic vibration during the leaching reaction.

Among the characteristics for definition of the solvent were observed or highlighted:

• Low cost,

• High saturation limit for solute (Boron and Phosphorus compounds)

• chemical stability,

• Low viscosity,

• Low vapor pressure,

• Low toxicity and flammability,

• Low density,

• Low surface tension,

• Possibility of reuse,

In the present invention patent the leaching process may occur in a countercurrent process as follows:

• Unreacted metal silicon is leached by a solution from the last leach;

• Metal silicon that has gone through all the leaching steps or sequences is finally leached by a new solution;

• The number of leaches is at the discretion of the quality, ie as many series can be made as necessary to achieve the desired purity standard;

• After each leaching step, the entire bath is routed to a separation system, which may be by means of a centrifuge, a filter press, a pressurized filter press, etc .;

• After this filtration, the solid or semi-dry material proceeds to the next leaching and the residual solution also proceeds to the next leaching, always in opposite directions, ie solution i in silicon i-1 and silicon i in solution i +. 1.

Claims (7)

1. "PROCESS FOR PRODUCING METAL SILICUM OF HIGH PURITY METALURGICAL FROM PURIFICATION WITH METALS AND OTHER COMPOUNDS, FOLLOWING Leaching", which has a significant reduction in the levels of contaminants and other metals in Silicon, economic viability in production high purity metallurgical grade metallic silicon compared to traditional processes; Reduced number of process steps to obtain high purity metallurgical grade silicon and the possibility of using low cost products and / or substances to form and remove unwanted contamination or components, with individual Boron and Phosphorus contents below 1ppm, characterized by basically consist of four steps: First step: - addition of alkaline and / or alkaline earth metals and / or other components such as fluorite, silica, silicates, synthetic slag before, during or after melting of the silicon; Second step: - Simultaneous and / or consecutive injection of gases into the high temperature bath, above the melting temperature of the metallic silicon, such as argon, humidified argon, water vapor, oxygen, chlorine, hydrogen, hydroxides, etc. Maintenance of gas injection into the turbulent bath for sufficient time so that all metal volume / mass has contact with the gas mass directed to the bath; Third step: - Purification or otherwise of the above product in refining oven, plasma and / or inductive oven and / or electric oven, resistance oven, with simultaneous and / or consecutive use of some procedures; Fourth stage: - Metallic silicon with individual Boron and Phosphorus contents below 0.5 ppm - obtained as described above is subjected to the process of refluxing and directional solidification, with or without the presence of thermal plasma and gas injection. These steps can occur simultaneously, in the order described above, but also with change or substitution in the order of occurrence, as well as frequency and number of repetitions of each step. 2. "PROCESS FOR PRODUCTION OF METALLIC SILENCE OF HIGH PURITY METALURGICAL FROM PURIFICATION WITH METALS AND OTHER COMPOUNDS, FOLLOWING Leaching" according to claim 1, characterized in that, in the first step, the substances are added as follows. ground, pulverized, crushed, grain, stone, etc. 3. "PROCESS FOR PRODUCTION OF METALLIC SILENCE OF HIGH PURITY METALURGICAL FROM PURIFICATION WITH METALS AND OTHER COMPOUNDS, FOLLOWING Leaching" according to claim 1, characterized in that in the first stage, during the addition or feeding of one and / or some of these substances, apply bath agitation or movement using inert gas injection such as argon or other purifying gases such as water vapor, hydrogen, oxygen, nitrogen, etc. 4. "PROCESS FOR PRODUCTION OF METALLIC SILENCE OF HIGH PURITY METALURGICAL FROM PURIFICATION WITH METALS AND OTHER COMPOUNDS, FOLLOWING Leaching" according to claim 1, characterized in that in the third stage it is used simultaneously and / or consecutive the following procedures: a. Injection of gases such as chlorine, oxygen, hydrogen, water vapor, and / or others; B. Simultaneous injection of reducing gases under the action of thermal plasma, aiming to achieve gas ionization, promoting a more reactive action in the formation of boron-based compounds, especially; ç. Vacuum treatment for volatilization of phosphorus and boron compounds; 5. "PROCESS FOR PRODUCTION OF METALLIC SILENCE OF HIGH PURITY METALURGICAL FROM PURIFICATION WITH METALS AND OTHER COMPOUNDS, FOLLOWING Leaching" according to claim 1, characterized in that the leaching process occurs in parallel and / or can be through parallel, cross and / or counter current currents, in basic, neutral or acidic medium and also in one or more stages, consisting basically in the immersion of metallic silicon in stones and / or gravel and / or ground , in a leach tank, with agitation system for bath homogenization and possibility of injection of liquid and / or solid hydrogen peroxide. 6. "METAL SILICON PRODUCTION PROCESS OF HIGH PURITY METALURGICAL DEGREE FROM METAL AND OTHER COMPOUND PURIFICATION, FOLLOWING Leaching" according to claim 5, characterized by the leaching process using the following parameters: a. Residence time and / or contact between solute and solvent; B. Processing temperature and pressure; ç. Frequency of agitation and / or megasonic vibration during the leaching reaction. 7. "PROCESS FOR PRODUCING METAL SILICON OF HIGH PURITY METALURGICAL DEGREE FROM METAL AND OTHER COMPOUND PURIFICATION, FOLLOWING Leaching" according to claim 5, characterized in that the leaching process occurs in a counter-current process as follows: : The. Unreacted metal silicon is leached by a solution from the last leach; B. Metallic silicon that has gone through all the leaching steps or sequences is finally leached by a new solution; ç. After each leaching step, the entire bath is routed to a separation system, which may be by means of a centrifuge, a filter press, a pressurized filter press, etc .; d. After filtration, the solid or semi-dry material proceeds to the next leaching and the residual solution also proceeds to the next leaching, always in opposite directions, ie solution i in silicon i-1 and silicon i in solution i + 1 .