Transforming Low-Value Quartz into Electronic-Grade Spherical SiO2 via a Morphology-Directed Hydrothermal Alkaline Process

The conventional production of electronic-grade, high-purity, spherical silicon dioxide (SiO2) faces challenges of high raw material costs and poor control over particle morphology. This study presents an alternative route using low-cost, powdered quartz as a starting material. The quartz was first purified by flotation to remove any associated minerals, such as talc. Subsequently, deep purification was achieved through a hydrothermal alkaline process, which leveraged the distinct leaching kinetics of SiO2 and impurity ions (Al3+, Ca2+, Fe3+) under precisely controlled hydrothermal conditions (10 mL/g liquid-to-solid ratio, 3 mol/L NaOH, 200 °C, 8 h). This step yielded a sodium silicate solution with a purity of 99.999%. Spherical SiO2 particles were then synthesized from solutions of varying moduli via chemical precipitation. The condensation kinetics of silicate anionic species (Qn) during acidification were investigated, revealing how the Qn distribution governs the final particle size and morphology. The optimal product exhibited excellent characteristics: a sphericity ≥ 0.98, a median particle size (D50) of 400–500 nm, and a narrow particle size distribution (polydispersity index, PDI of 0.178–0.192). These properties surpass the requirements for the QYG-H Type 002 grade specified in the Chinese National Standard GB/T 32661-2016 (“Spherical Silica Powder”) and meet the standard for electronic-grade spherical SiO2. This work provides a fundamental insight into morphology control and a feasible technical pathway for the value-added utilization of powdered quartz and the production of electronic-grade spherical SiO2 with a narrow particle size distribution.