• Journal of the Korean Crystal Growth and Crystal Technology
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• v.29 no.6
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• pp.257-263
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• 2019

Lightweight geopolymers were fabricated with non-milled IGCC slag and Si sludge as a bloating material. The relationship between addition amount of Si sludge and physical/chemical properties of lightweight geopolymers was investigated. When the geopolymers were made by mixing IGCC slag, alkali activator, and more than 10 wt.% Si sludge, the temperature of the geopolymer pastes reached higher than 130℃ in a few minutes. This exothermic reaction accelerated the geopolymer reaction; however, it was difficult to make geopolymer specimens because of a rapid bloating reaction. Both compressive strength and density of the specimens tend to decrease with an addition of Si sludge; however, there was little difference in both compressive strength and density with addition of Si sludge more than 10 wt.%. Because there was a limit to get low density geopolymers by simply increasing the addition of Si sludge, the control of pore size and distribution of geopolymer is more important by controlling flow rate of the paste through the control of W/S ratio. Therefore, it is important to control process conditions, appropriate W/S ratio for the bloating than the control of Si sludge. The optimum W/S ratio was 0.20 for the addition of Si sludge less than 30 wt.% and W/S ratio should be more than 0.28 for the addition of Si sludge more than 30 wt.%, although there was no practical application in fact.

• Journal of Korea Foundry Society
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• v.30 no.2
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• pp.76-82
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• 2010

Effect of reaction time and sludge formation on the thickness of die soldering reaction layer has been studied in Al-9Si-0.3Mg casting alloy. Ternary ${\alpha}_{bcc}-Al_8Fe_2Si$ and ${\alpha}_{hcp}-Al_8Fe_2Si$ intermetallic compounds formed at the interface of SKD61 tool steel by interaction diffusion of Al, Fe and Si atoms after 0.5hr and 6hr immersion time, respectively. Binary ${\eta}-Fe_2Al_5$ additionally formed at the interface of SKD61 tool steel after 10hr immersion time. Thickness of soldering reaction layer in die surface increased as immersion time increased from 0.5hr to 24hr. Sludge formation was ascertained in the samples which were immersed in the melts more than 10hr. Reaction of die soldering after sludge formation was more accelerated than that of before sludge formation due to a decrease in Fe content, followed by higher diffusion rate of Al in the melt by sludge formation.

• Resources Recycling
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• v.26 no.6
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• pp.45-49
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• 2017

Most Waste slurry is produced in the process of silicon manufacturing for semiconductor industry, containing silicon (Si) and silicon carbide (SiC). Waste slurry is simply stored with solidifying by cement or buried. On the other hand, it was suggested in this study that the waste slurry should be used for heating source as supplementary material in steel making process. The waste slurry was refined and pulverized, which was recycled into SiC-based sludge briquette. Chemical composition for SiC-based sludge briquette was analyzed and the feature of heating source was observed in accordance with the injection time and input amount. As a result, SiC-based sludge briquette in terms of low cost and high efficiency had an effect on increasing liquid steel temperature in steel making plants.

• Proceedings of the Materials Research Society of Korea Conference
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• 1997.10a
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• pp.170-170
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• 1997

• Resources Recycling
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• v.31 no.6
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• pp.60-65
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• 2022

This study presents the carburization process for recycling sludge, which was formed during silicon wafer machining. The sludge used in the carburization process is a mixture of silicon and silicon carbide (SiC) with iron as an impurity, which originates from the machine. Additionally, the sludge contains cutting oil, a fluid with high viscosity. Therefore, the sludge was dried before carburization to remove organic matter. The dried sludge was washed by acid cleaning to remove the iron impurity and subsequently carburized by heat treatment under vacuum to form the SiC powder. The ratio of silicon to SiC in the sludge was varied depending on the sources and thus carbon content was adjusted by the ratio. With increasing SiC content, the carbon content required for SiC formation increased. It was demonstrated that substoichiometric SiC_x (x<1) was easily formed when the carbon content was insufficient. Therefore, excess carbon is required to obtain a pure SiC phase. Moreover, size reduction by high-energy milling had a beneficial effect on the suppression of SiC_x, forming the pure SiC phase.

• Resources Recycling
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• v.19 no.4
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• pp.51-57
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• 2010

As a recycling of Si sludge from Si wafer process, a Si-SiC-CuO-C composite material was synthesized and investigated as an anode material for lithium batteries. The Si sludge consisted of Si, SiC, machine oil, and metallic impurities. The oil and metal impurities was removed by organic washing, magnetic separation, and acid washing. The Si-SiC-CuO-C composite from the recovered Si-SiC mixture was prepared by high-energy mechanical milling. According to the electrochemical tests such as charge-discharge capacity and cycling behavior, it showed the improved cycle performance. The SiC and CuO-related phases were presumed to restrain the volume expansion of the anode and Fe, however, should be removed below 10 ppm prior to synthesis of the composite because it caused the capacity loss of the active material itself.

• Journal of the Korea Organic Resources Recycling Association
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• v.32 no.3
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• pp.57-66
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• 2024

In this study, silicon sludge from a semiconductor packaging process is recycled to fabricate silica coated silicon-sludge and applied as a filler for an epoxy molding compound(EMC). Silicon-sludge powder(S-sludge) is treated with acid to remove metallic impurities and then coated using the sol-gel method to synthesize silica coated silicon-sludge powder(SS-sludge). The as-synthesized SS-sludge is subsequently mixed with epoxy resin, a curing agent, and carbon black to create an EMC(SS-sludge EMC). The heat dissipation properties of the EMC were examined using an IR camera. IR camera analysis confirmed that the SS-sludge EMC exhibited the highest surface temperature of 58.5℃ compared to SiO₂-based EMC. This enhancement in heat dissipation using SS-sludge EMC is attributed to the excellent thermal conductivity(150W/mK) of the silicon substrate and the presence of the silica layer on the SS-sludge surface which effectively enhances the thermal property of the EMC. Therefore, this study successfully demonstrates the recycling of silicon sludge from a semiconductor packaging process by synthesizing silica coated silicon-sludge and suggests a novel application of this material in semiconductor packaging.

• Korean Journal of Materials Research
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• v.29 no.10
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• pp.592-602
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• 2019

Feasibility is investigated for reduction of chromium ore by Si sludge with mixed silicothermic and carbothermic reaction. The reduction behavior of chromium ore using Si sludge is investigated precisely to determine the effects of carbon addition, reaction time, and reaction temperature. The pellets are dropped into the furnace after temperature stabilized. As the amount of C addition increases, the amounts of CO and $CO_2$ gas generation increase. After the dropping of the pellets, the pellets are heated and the reaction starts at about 1,573 K or higher. The pellets maintain their shape until 10 min after the drop, and then melted. As the holding time increased, the size of the reduced metal particles increased. The chromium ore is rapidly reduced by the Si sludge, and the slag penetrated into the chromium ore and reduction progressed inside. As the reduction temperature increased, the reaction initiation time is shortened and the reaction fraction of the reduction reaction increased. As the reaction temperature increased, agglomeration of reduced ferrochrome metal is promoted.

• Journal of the Korea Organic Resources Recycling Association
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• v.30 no.3
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• pp.5-12
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• 2022

This study suggests the effective recycling method of sludge waste from various industrial fields to synthesize uniform colloidal silica nanoparticles. In detail, polymers are removed from the sludge waste to attain sludge-extracted silica (s-SiO₂) micron-sized particles, and ammonia assisted sonication is applied to s-SiO₂, which has effectively extracted the silanol precursor. The nano-sized silica (n-SiO₂) particles are successfully synthesized by a typical sol-gel method using silanol precursor. Also, the yield amounts of n-SiO₂ are determined by the function of s-SiO₂ etching time. Finally, n-SiO₂-based slurry is synthesized for the practical CMP application. As a result, rough-surfaced semiconductor chip is successfully polished by the n-SiO₂-based slurry to exhibit the mirror-like clean surface. In this regard, sludge wastes are successfully prepared as valuable semicondutor grade materials.

• Proceedings of the Korea Concrete Institute Conference
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• 1998.10c
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• pp.87-92
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• 1998

The purpose of this study is to use paper sludge ash as a material in manufacturing high strength admixture. The reactivity of paper sludge ash as iteself is low for the crystallized non-reactive $SiO_2$, but when the $SiO_2$ was removed, the phase component is mainly composed of glass phase which could react with cement hydrates. In this study, we manufactured high strength admixture using separated paper sludge ash, and examined the strength of mortar, spun concrete with and without this high strength admixture in steam curing. The strength of spun concrete with high strength admixture including paper sludge ash was more higher than that of spun concrete without admixture. As a result, it was found that paper sludge ash could be used to a pozzolanic material in manufacturing high strength admixture.