Electrochemical Reduction of Solid Silica to Form Silicon in Molten Salts

Abstract

Nowadays, Silicon is the most critical element in solar cells and/or solar chips. Silicon having 98 to 99% Si as being metallurgical grade, requires further refinement/purification processes such as zone refining [1,2] and/or Siemens process [3] to upgrade it for solar applications. A promising method, based on straightforward electrochemical reduction of oxides by FFC Cambridge Process [4], was adopted to form silicon from porous SiO2 pellets in molten CaCl2 and CaCl2-NaCl salt mixture [5]. It was reported that silicon powder contaminated by iron and nickel emanated from stainless steel cathode, consequently disqualified the product from solar applications. SiO2 pellets sintered at 1300oC for 4 hours, were placed in between pure silicon wafer plates to defeat the contamination problem. Encouraging results indicated a reliable alternative method of direct solar grade silicon production for expanding solar energy field.[1] P.R. Mei, S.P.Moreira, E.Cardoso, A.D.S.Cortes, F.C.Marques, “Purification of metallurgical silicon by horizontal zone melting”, Sol. Energ. Mat. Sol., 98 (2012), 233-239. [2] P. Siffert, E.F. Krimmel, eds. Silicon: Evolution and future of a technology. Berlin,Springer (2004). [3] Siemens & Halske: BRD Patents 1.102.117 and 1.140.1594 filed 1954, issued 1956 [4] G.Z. Chen, D. J. Fray, T. W. Farthing, “Direct Electrochemical Reduction of Titanium Dioxide to Titanium in Molten Calcium Chloride”, Nature, 407 (2000), 361-364. [5] E. Ergül, İ. Karakaya, M. Erdoğan, “Electrochemical decomposition of SiO2 pellets to form silicon in molten salts” Journal of Alloys and Compounds, 509 (2011), 899-903.