Eco-friendly strategy for preparation of high-purity silica from high-silica IOTs using S-HGMS coupling with ultrasound-assisted fluorine-free acid leaching technology

Iron ore tailings (IOTs), a typical hazardous solid waste, seriously threaten human health and the ecological environment. However, the abundance of quartz, particularly in high-silica IOTs, renders them useful. Yet, state-of-the-art technologies have rarely reported the preparation of high-purity silica from high-silicon IOTs. Thus, this study proposed an eco-friendly technology for producing high-purity silica from high-silica IOTs through the coupling of superconducting high gradient magnetic separation (S-HGMS) preconcentration with leaching followed by the use of ultrasound-assisted fluorine-free acid solution. Following an analysis of the separation index and chemical composition, the optimum conditions for the quartz preconcentration were determined as a magnetic flow ratio of 0.068 T s/m, a slurry flow velocity of 500 mL/min, and a pulp concentration of 40 g/L. Consequently, the SiO2 grade increased from 69.32% in the raw sample to 93.12% in quartz concentrate following the application of S-HGMS, with the recovery reaching 45.24%. X-ray diffraction, vibrating sample magnetometer, and scanning electron microscope analyses indicated that quartz was effectively preconcentrated from the tailings by S-HGMS. Subsequently, employing the "ultrasound-assisted fluorine-free acid leaching process," impurity elements were removed and high-purity silica was produced. Under optimal leaching conditions, the SiO2 purity of silica sand increased to 97.42%. Following a three-stage acid leaching process with 4 mol/LHCl +2 mol/LH2C2O4, the removal efficiency of Al, Ca, Fe, and Mg exceeded 97% for all cases, and the SiO2 purity in high-purity silica reached 99.93%. Thus, this study proposes a new strategy for the preparation of high-purity quartz from IOTs, which facilitated the effective realization of the high-value utility of the tailings. Furthermore, it provides a theoretical basis for the industrial application of IOTs, which is of great scientific significance and practical application value.