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Separation of quartz and feldspar is the core link of glass, ceramics and photovoltaic industry chain. The traditional process faces three major pain points: low recovery rate (<75%), high chemical pollution, and uncontrolled operation cost. This paper analyzes the cutting-edge technology of combined flotation-acid leaching process, and shows how a quartz sand project in Brazil realized 99.9% purity and 28% reduction of operation cost through intelligent EPCM+O mode.
Similar physical and chemical properties: density (quartz 2.65g/cm³ vs feldspar 2.56-2.76g/cm³), electrical and magnetic differences are tiny
High environmental pressure: Hydrofluoric acid method produces 200-300L of fluorinated wastewater per ton of ore (EPA limit <10mg/L).
Economic bottleneck: the cost of traditional flotation chemicals accounts for more than 40% of the total cost of separation.
1.Ion reverse flotation--accurate capture of feldspar particles
(1) Pharmacy system innovation:
Capture agent: dodecylamine + sodium petroleum sulfonate composite formula (selectivity increased by 35%)
Inhibitor: modified starch to inhibit quartz uplift (dosage reduced by 50%)
(2) Process parameter optimization:
pH value 2.5-3.5 (sulfuric acid adjustment)
Concentration of slurry 25-35
Flotation time 8-12 minutes
(3)Comparison of benefits:
| Process Type | Quartz Purity | Feldspar Removal Rate | Ton Cost(USD) |
|---|---|---|---|
| Conventional Flotation | 98.2% | 82% | 15.6 |
| Ion Reverse Flotation | 99.5% | 94% | 12.8 |
2. Fluorine-free acid leaching process--Win-win for environmental protection and efficiency
(1) Technical route:
Crushing and grinding → flotation pre-separation → hydrochloric acid leaching (instead of hydrofluoric acid) → washing and drying
(2)Breakthrough Advantage:
Fluoride emissions reduced by 99% (meeting ISO 14001 standard).
Feldspar dissolution rate increased to 91
(3)Equipment package:
Titanium alloy reactor (hydrochloric acid corrosion resistant)
Vacuum belt filter (washing efficiency increased by 3 times)
3. Photoelectricity sorting - pretreatment reduction of 40%
(1) Working principle:
Using X-ray transmission to identify quartz (low atomic number) and feldspar (containing K/Na elements)
(2) Economic value:
Pre-throwing waste rate of 35-45%, reducing the subsequent processing load
Sorting speed up to 10t/h, suitable for coarse particles of raw ore
1. Background of the project
Raw ore composition: quartz 62%, feldspar 28%, kaolin 10%.
Target product: quartz sand for photovoltaic glass (SiO₂>99.9%, Fe₂O₃<0.01%)
2. Solution
(1)Pre-treatment:
Optical sorting to remove 50% feldspar coarse particles
High pressure roller grinding to -0.3mm
(2)Core process:
Two-stage ion reverse flotation → two-stage hydrochloric acid leaching → magnetic separation to remove iron
3.Operation results:
Quartz Concentrate: SiO₂ 99.92%, Fe₂O₃ 0.008
Feldspar recovery rate: 91.3
Water recycling rate: 95%
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