Silicon Refining by Solidification from Liquid Si–Zn Alloy and Floating Zone Method

Abstract

This study evaluated the refining ability of a proposed production process for solar-grade silicon utilizing the electrolytic reduction of SiO₂ on a liquid zinc electrode in molten salt. The distribution behaviors of impurity elements during the precipitation of solid silicon from a liquid Si–Zn alloy were studied by thermodynamic calculations at 923 K. In the precipitation experiment, silicon granules were recovered from a liquid Si–Zn alloy, which was prepared from metallurgical-grade silicon. The impurity removal ratios exceeded 99% for C, Al, and Ca, and 90% for Fe. High removal ratios were attained for B and O as well. As the post-processing, a silicon ingot was produced from the precipitated silicon granules by the floating zone method. The Zn residue in the precipitated silicon was completely evaporated during the floating zone refining. The total content of metallic elements (Al, Ca, Fe, Ti, and Zn) was lower than 0.2 ppmw, even though metallurgical-grade silicon was used as the starting material.