Separation Time of Aluminothermic Reduction Products for Sustainable Silicon Production

<ns3:p>Background This work was carried out within the framework of the SisAl Pilot project, which is devoted to the environmentally friendly production of silicon. This new method relies on the aluminothermic reduction of quartz in slag, offering a more sustainable alternative to the traditional reduction of silica with carbon in submerged arc furnaces. Methods The process takes place in a rotary kiln producing silicon (Si) and alumina slag (actually, a CaO – Al2O3 slag), which must be separated at the end to extract the silicon. This separation process is analyzed through mathematical modelling and numerical simulation, as it is of industrial interest to know how much time it takes for Si and CaO – Al2O3 slag to separate once the process has ended. Generally, a multiphase flow model is used to estimate the separation time of the two components once aluminothermic reduction has ended. Results Several scenarios are considered for the numerical simulation of the separation time, namely different initial configurations and material properties of both fluids are covered. Moreover, the separation times obtained with two distinct multiphase flow models -VOF (volume of fluid) and Eulerian- are compared. Conclusions The separation times resulting from simulations using the multiphase Eulerian model are more realistic compared to those from the VOF model, which clearly tends to underestimate separation times. Furthermore, apart from the selected multiphase flow model, the density difference between silicon and alumina slag plays a critical role in determining the separation time.</ns3:p>