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In high-end industrial fields such as photovoltaic glass, semiconductor and optical devices, quartz purity plays a decisive role in product performance. The data of global top 5 quartz manufacturers show that for every 0.01% increase in purity, the added value of the product can be increased by 12-18%. In this paper, we will analyze the core process chain of quartz purification and equipment innovation, to help you build an efficient purification system to enhance product competitiveness.
Intelligent crushing system adopts three-stage linkage process:
1. Jaw crusher roughly crushes massive quartz to 50-100mm.
2. Cone crusher further medium crushing to 10-30mm.
3. High-pressure roller mill for fine crushing to 0.5-2mm.
Combined with hydrocyclone, real-time control of grading accuracy through pressure sensors, energy saving of 23% compared with traditional equipment, particle size qualification rate increased to 98.6%. The precise particle size control lays a good foundation for the subsequent purification process.
The new spiral chute integrates a number of advanced technologies:
Multi-layer composite material liner, wear-resistant index increased 3 times.
Laser particle size monitoring system, real-time monitoring of particle size distribution.
Dynamic inclination adjustment device, automatically adjusting the inclination of the chute according to the slurry flow.
In a quartz mine in Australia, the system's iron impurity removal efficiency reached 82%, and processing capacity increased by 40%. Intelligent re-election technology significantly improves the separation effect of heavy minerals in quartz.
Permanent magnet - electromagnetic composite unit to achieve:
1. 0.1-1.6T adjustable magnetic field strength, to meet different magnetic mineral separation needs.
2. three-dimensional matrix magnetic pole layout, enhance the magnetic field gradient.
3. online magnetic media cleaning system to keep the magnetic separator running efficiently.
The removal rate of fine-grained (-0.045mm) hematite exceeds 91%, and the energy consumption is reduced to 67% of the traditional equipment. Gradient magnetic field technology effectively solves the problem of recovery of fine-grained magnetic minerals.
Intelligent flotation system has:
1. pH value automatic compensation device to maintain the best flotation pH environment.
2. precise dosing system of medicament, the error is less than 0.5%.
3. laser monitoring of foam layer thickness to optimize foam scraping timing.
After application in a quartz sand plant in the U.S., the feldspar separation efficiency was increased by 35% and the amount of trapping agent was reduced by 28%. Molecular level interface regulation technology significantly improves flotation selectivity and recovery.
Modular acid leaching device features:
1. corrosion-resistant titanium alloy reactor, resistant to HF concentration of 40%.
2. multi-stage counter-current leaching design, improve the efficiency of acid leaching.
3. acid mist recovery rate >99%, reduce environmental pollution.
The data of a project in Korea shows that after 48 hours of dynamic leaching, the Al₂O₃ content has been reduced from 1200ppm to 80ppm. The closed-loop reaction system realizes the high efficiency and environmental protection of the acid leaching process.
We designed a joint process for a customer in Indonesia:
1. high pressure roller milling + air flow classification, -200 mesh accounts for 85%.
2. High gradient magnetic separation, Fe₂O₃ <100ppm.
3. acid leaching - flotation combination, Al₂O₃ <150 ppm.
4. microwave calcination, whiteness increased to 92%.
The final product meets the standard of Grade I sand for PV glass, and the payback period is shortened to 2.3 years.EPCM+O solution provides customers with one-stop quartz purification service.
Contact our technical team for a customized purification solution that will enable your quartz products to exceed the 99.99% purity threshold and open up the market for high-end applications.
+86 13811510145