Recovery of cutting fluids and silicon carbide from slurry waste

Preparation of Porous Composite Materials through Silicon Component Foaming and Special Heat Treatment

This study proposes a foaming method along with calcination to produce silica-based porous materials. The high-silicon-content waste residue reacts with sodium hydroxide for hydrogen evolution foaming reactions. Then, the foaming green bodies are embedded and calcined in the calcination powder consisting of silicon, silicon carbide, graphite, and activated carbon at 1200 °C. The calcination powder creates a reducing atmosphere and prevents adhesion of the foaming green bodies to the crucible during calcination. Furthermore, the addition of activated carbon and calcination improve the macroporosity issue of the prepared sample through a gas-liquid-solid transformation. The BET surface area measurement is 64.197 m2/g, and the mercury intrusion porosimetry measurement indicates a porosity of 56.48%, with an average pore diameter of 396.48 nm. The porous composite materials exhibit the capability to adsorb methylene blue in solution. The porous materials possessing functional groups suggest promising potential for future development and application prospects.

Purification and preparation of pure SiC with silicon cutting waste

Recycling silicon cutting waste (SCW) plays a pivotal role in reducing environmental impact and enhancing resource efficiency within the semiconductor industry. Herein SCW was utilized to prepare SiC and ultrasound-assisted leaching was investigated to purify the obtained SiC and the leaching factors were optimized. The mixed acids of HF/H2SO4 works efficiently on the removal of Fe and SiO2 due to that HF can react with SiO2 and Si and then expose the Fe to H+. The assistance of ultrasound can greatly improve the leaching of Fe, accelerate the leaching rate, and lower the leaching temperature. The optimal leaching conditions are HF-H2SO4 ratio of 1:3, acid concentration of 3 mol/L, temperature of 50 °C, ultrasonic frequency of 45 kHz and power of 210 W, and stirring speed of 300 rpm. The optimal leaching ratio of Fe is 99.38%. Kinetic analysis shows that the leaching process fits the chemical reaction-controlled model.

Efficient recycling of silicon cutting waste for producing high-quality Si-Fe alloys

A tremendous amount of silicon cutting waste (SCW) is being produced during slicing Si ingots, which leads to a great waste of resources and serious environmental pollution. In this study, a novel method that recycling SCW to produce Si-Fe alloys was proposed, which not only provides a process with low energy consumption, low cost, and short flow for producing high-quality Si-Fe alloys but also achieves a more effective recycling of SCW. The optimal experimental condition is investigated to be a smelting temperature of 1800 °C and a holding time of 10 min. Under this condition, the yield of Si-Fe alloys and the Si recovery ratio of SCW were 88.63% and 87.81%, respectively. Compared with the present industrial recycling method that uses SCW to prepare metallurgy-grade Si ingot by an induction smelting process, this Si-Fe alloying method can achieve a higher Si recovery ratio of SCW at a shorter smelting time. The promoting mechanism of Si recovery by Si-Fe alloying is mainly expressed as follows: (1) facilitating the separation of Si from SiO₂-based slag; (2) reducing the oxidization and carbonization loss of Si by accelerating the heating of raw materials and reducing the exposed area of Si.

Polydimethylsiloxane-decorated magnetic cellulose nanofiber composite for highly efficient oil-water separation

Developing three-dimensional porous hydrophobic and oleophilic materials (3D-PHOMs) for efficient and selective oil-water separation is important to clean up oil spills and organic pollutants. However, 3D-PHOMs are still confined to lab-scale research due to several crucial drawbacks. Herein, a hydrophobic oil-water separation composite, containing cellulose nanofiber (delignificated porous wood, PW) substrate, magnetic nickel (Ni) layer and hydrophobic polydimethylsiloxane (PDMS) coating, is prepared using electroless deposition (ELD) and surface modification techniques. Owing to the porosity, hydrophobicity (>130° of water contact angle), lipophilicity, convenient magnetic collection and high cycle compressibility, the as-fabricated PDMS-Ni-PW exhibits excellent oil adsorption capacity (>60% of the volumetric absorption capacity) and outstanding cyclic stability (>80% of the adsorption capacity after 200 cycles). Thanks to the low surface energy and rough surface structure, the adsorbent demonstrates superior oil-retention ability (>80% at 200 rpm). Also, the oil-collecting apparatus is successfully designed to continuously separate various oils, e.g., n-hexane and dichloromethane, from water due to the unidirectional liquid transport of the adsorbent. These excellent properties make PDMS-modified cellulose nanofiber a promising candidate for oil-water separation.

Precision micro-milling process: state of the art

Micro-milling is a precision manufacturing process with broad applications across the biomedical, electronics, aerospace, and aeronautical industries owing to its versatility, capability, economy, and efficiency in a wide range of materials. In particular, the micro-milling process is highly suitable for very precise and accurate machining of mold prototypes with high aspect ratios in the microdomain, as well as for rapid micro-texturing and micro-patterning, which will have great importance in the near future in bio-implant manufacturing. This is particularly true for machining of typical difficult-to-machine materials commonly found in both the mold and orthopedic implant industries. However, inherent physical process constraints of machining arise as macro-milling is scaled down to the microdomain. This leads to some physical phenomena during micro-milling such as chip formation, size effect, and process instabilities. These dynamic physical process phenomena are introduced and discussed in detail. It is important to remember that these phenomena have multifactor effects during micro-milling, which must be taken into consideration to maximize the performance of the process. The most recent research on the micro-milling process inputs is discussed in detail from a process output perspective to determine how the process as a whole can be improved. Additionally, newly developed processes that combine conventional micro-milling with other technologies, which have great prospects in reducing the issues related to the physical process phenomena, are also introduced. Finally, the major applications of this versatile precision machining process are discussed with important insights into how the application range may be further broadened.

Recycling of silicon from silicon cutting waste by Al-Si alloying in cryolite media and its mechanism analysis

More than 40% of the crystalline silicon has been wasted as silicon cutting waste (SCW) during the wafer production process. This waste not only leads to resource wastage but also causes environmental burden. In this paper, SCW produced by the diamond-wire sawing process was recycled by Al-Si alloying process. Cryolite was introduced to the reaction system to dissolve the SiO₂ layer existed on the surface of the Si particles in SCW. Alloys with 12.02 wt% of Si were prepared and the mechanism of the alloying process was investigated in detail. The Si-Al-cryolite system and SiO₂-Al-cryolite system were studied individually to analyze the reaction process and transferring behavior of Si and SiO₂ in SCW. The SiO₂ shell was firstly transformed into Si-O-F ions. Then the Si-O-F ions diffused to the reaction interface by the effect of the concentration gradient and were reduced to Si by the aluminothermic reduction reaction: 4Al (l) + 3SiO₂ (dissolved in the melt) = 3Si (Al)+ 2Al₂O₃ (dissolved in the melt). Then the internal Si particles were released into cryolite after the dissolution of SiO₂ and transferred to the reaction interface by the effect of gravity. The influences of the mass ratio of Al/SCW and agitation modes on the Si content of the alloys and the Si recovery ratio in SCW were investigated. With the increase of the mass ratio of Al/SCW from 2.2 to 6.5, the Si recovery ratio in SCW increased from 44.08% to 69.05%, but the silicon content of the alloys decreased from 16.06 wt% to 8.83 wt%. Agitation can effectively improve the smelting effect during smelting by which the silicon content of the alloys and the Si recovery ratio in SCW increased from 12.02 wt% and 64.25% to 13.17 wt% and 69.46%, respectively.