Making reusable reaction-bonded silicon nitride crucibles for silicon casting from kerf-loss silicon waste

Silicon kerf loss during wafer slicing and the broken quartz crucibles after silicon casting are two major solid wastes from photovoltaic (PV) industry. Especially, the recycle of kerf-loss silicon has become an urgent issue because near 100 000 t of solid wastes are generated every year. One of the most meaningful recycle routes of the kerf-loss silicon is to make silicon nitride crucibles to replace the quartz crucibles. In this study, we demonstrated how this is feasible through acid leaching refining, slip casting, and nitridation. The reaction-bonded silicon nitride (RBSN) crucibles after oxidation were found pure enough for silicon ingot growth. More importantly, they could be reused after ingot growth. With the present examples, the potential of using the kerf-loss silicon for fine ceramics is prominent.