Step-by-Step Production Process of 1101 Silicon Metal

1101 Silicon Metal is a high-purity grade of silicon metal with low levels of iron (Fe), aluminum (Al), and calcium (Ca). It is primarily used in the chemical industry for producing silicone compounds, electronic applications, and polysilicon for solar and semiconductor industries.

Step-by-Step Production Process of 1101 Silicon Metal

1. Raw Material Selection & Preparation

• Quartz (SiO?): High-purity silica (≥99%) is sourced as the primary raw material.
• Carbonaceous Reducing Agents:Low-ash petroleum cokeHigh-purity wood chipsLow-sulfur coal
• Purity Requirement: All raw materials must have low Fe, Al, and Ca content to ensure the final silicon metal meets the 1101-grade specification.

2. Smelting in a Submerged Arc Furnace (SAF)

• The raw materials are mixed in specific ratios and loaded into a submerged arc furnace (SAF).
• High temperatures (1600-2000°C) are applied, and carbon reacts with SiO? to reduce silica into liquid silicon metal.
• Chemical Reaction:SiO2+C→Si+CO2↑SiO_2 + C → Si + CO_2 ↑SiO2+C→Si+CO2↑
• Impurities such as Fe, Al, and Ca are minimized by controlling the furnace temperature and refining additives.

3. Refining & Impurity Removal

• Oxidation Refining: Oxygen or other refining agents are introduced to remove aluminum (Al) and calcium (Ca) as oxides.
• Slag Removal: The impurities float to the surface and are skimmed off from the molten silicon.
• Multiple Refining Stages: High-purity silicon undergoes repeated melting and slag removal to achieve 1101 purity levels.

4. Casting & Solidification

• The molten silicon is poured into molds or casting beds to cool and solidify into silicon metal ingots.
• Proper cooling control prevents contamination and ensures uniform crystal structure.

5. Crushing & Sieving

• The solidified silicon metal is crushed into lumps or powder according to the required size for different applications.
• Magnetic separation is used to remove any residual iron impurities.
• Final sieving ensures uniform particle size distribution.

6. Quality Control & Testing

• Chemical Composition Analysis: Using ICP-OES (Inductively Coupled Plasma Optical Emission Spectrometry) to check Fe, Al, and Ca levels.
• Physical Inspection: Checking for uniformity, proper size, and absence of contamination.
• Batch Certification: Each batch of 1101 silicon metal is certified before shipment.

Final Product & Applications

1101 Silicon Metal is delivered in lumps, granules, or powder form and used in: ? Silicone Production (Silicone oils, rubbers, and sealants) ? Polysilicon Manufacturing (Solar and semiconductor industries) ? High-Purity Chemical Applications

The production of 1101 silicon metal requires strict quality control at every stage, from raw material selection to refining and final testing. Its high purity and low impurity content make it an essential material for advanced industrial applications.

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