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Chips in the desert - Water Use in the Semiconductor Industry

Chips in the desert - Water Use in the Semiconductor Industry. Laurie Reemeyer – MBA 2010 Vivek Narayanan – ChemE 2010 Andrew Slocombe – EHS 2010 Ping Hay Lam – ChemE 2010. Intel is largest manufacturer and industry leader.

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Chips in the desert - Water Use in the Semiconductor Industry

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  1. Chips in the desert - Water Use in the Semiconductor Industry Laurie Reemeyer – MBA 2010 Vivek Narayanan – ChemE 2010 Andrew Slocombe – EHS 2010 Ping Hay Lam – ChemE 2010

  2. Intel is largest manufacturer and industry leader. Major high value industry, developed in Texas and California in 1960s. Now Korea, Japan, Taiwan and USA are largest manufacturers. Major point source water users and historical polluters. Need high quality water in process. Some plants in arid regions of the world. Main issues – sourcing good quality, reducing water use, reuse and recycling. Limited supply in some locations, competing needs e.g. residential. Semi-conductor Industry

  3. Water Withdrawal rates in the US

  4. Semiconductor Fabrication Locations in USA • Source: http://www.10stripe.com/include/flashmap/world/world.swf?data_file=/featured/map/fabs.xml

  5. Total freshwater = 349 billion gal / day Major uses – cooling for electricity generation, agriculture Trends – Overall use has leveled off, conservation growing. Water much more scarce in SW USA. USGSEstimated Use of Water in the United States in 2005:

  6. Increasing Population and Decreasing Water Availability in SW Increasing temperatures due to climate change mean decreased snow packs in the Sierra Nevadas and Rocky Mountains. Source: US census bureau. http://www.census.gov/population/www/projections/projectionsagesex.html

  7. Process flowchart for semiconductor assembly First Level Assembly Die Preparation Die Attach Wastewater Treatment DI Water Production Semiconductor Product Wafer Flux Clean Mold/Post Mold Solder Plate/ Post Solder Clean Final Test, Mark, Pack

  8. Mass balance of water flow IC cutting cooling water IC platting water Wastewater Treatment 800 Loss 65 Effluent 800 Process & AC cooling water 230 DI Water 950 DI Water 665 Effluent 155 Reject 285 Evaporation 75 Tap Water 1550 Toilet 55 Effluent 300 Office 155 Sewage 300 Tap Water 600 Process flush water 200

  9. AZ Case Study: Ocotillo Water Conservation Internal Water Recycling Wastewater Treatment DI Water FAB City RO Treatment Unit Operations Aquifer Recharge Reclaimed Water Public Treatment Works

  10. Significant point users of water for chip manufacture Need very high purity de-ionized water for cutting and plating operations. Need high quality input water and energy to purify (RO). Priorities – reduce, reuse, recycle. Some conventional water conservation opportunities (e.g. toilets, cooling towers etc). Greater R&D and technology based solutions needed for some manufacturing steps. Water discharge quality – manage heavy metals, F, ammonia. Water issues in semiconductor manufacture

  11. Intel Case Study - New Mexico • 1993 – Intel approves manufacturing facility at Rio Rancho after negotiating significant tax breaks. Employs 4000 people, major economic stimulus. • Environmentalists raise concerns about water. • Mayor & City Council shuns any concerns

  12. 1993 – Albuquerque residents consuming 250 gallons of water per person per day, drawing down local aquifer net 95000 acre-ft/yr Aquifer capacity severely underestimated. Estimates say that water resources will last 20 years Intel sets up its first manufacturing plant in Rio Rancho The Rio Rancho Story:

  13. Why New Mexico? • 57 million USD in tax abatements • 36 million USD in waived new-equipment sales taxes • 20 million USD in manufacturing tax credits • Floating a 2 BILLION dollar bond issue for Intel

  14. The Intel Effect • Manufacturing facility is setup at Rio Rancho • Intel employs 4000 people • Average salary of Intel employee is more than double the average salary of New Mexico • With increasing affluence, increase in demand for recreational activities

  15. Arguments against Intel • Consumed about 6 million gallons of water a day • Neighboring suburbs complained of foul emissions causing skin and respiratory diseases • Depletion of the aquifer and reduction in the water table

  16. Arguments in favor of Intel • Created more than 10,000 jobs in NM • Consumed a lot of water, but nothing compared to agriculture • Presence of a 200 ft solid layer underground prevented any possible contamination between waste water and aquifer • Intel returned 85 percent of water to Rio Grande

  17. Comparative Water use Product Gallons of Water • Glass of Milk - 65 • 1 Steak - 2,607 • Ton of Alfalfa - 13,500 • 1 Egg - 120 • Pair of jeans - 1,800 • Sunday newspaper - 150 • Wheat for 2 lb loaf of bread - 1,000 • Core 2 Duo - <10 Source: Intel & EPA Office of Water

  18. Water management - Intel: • Tailor solutions to local issues • Corporate Industrial Water Management Group established to develop and implement programs to improve water use efficiency at major manufacturing sites. • Focus on communication of water issues internally and externally

  19. Intel recognized the need to show leadership in water conservation. Applied innovation and technology, invested in capital, collaborated with other stakeholders. Received EPA Water Efficiency Leader Award, 2007. Intel recognized as a water leader in the SW, in a strong position to influence other water users. Has shared information on its initiatives and failures to build trust in water user community. Intel learnings for the future

  20. Chandler’s Total Water Use

  21. Chandler’s Total Water Use: Non-residential sector • Intel uses about half the industrial metered Non-resident water

  22. Technology. Adapt existing technologies (membrane bioreactor). Develop new low water processes, e.g. electrocoagulation flotation to remove fluorine. Key issue – lead time to research, prove and implement new technologies. Process control and measurement to minimize over-rinsing. University of Arizona – researching alternative ways to polish chip surface, e.g. gas phase cleaning Future technology trends Semi-conductor Industry

  23. Membrane Bioreactor (MBR) Potentially successful application of alternative WWT technology – aids water recycling and recharge. Biomass Recirculation Anoxic Reactor Aerobic Reactor Membrane Tank Inflow Outflow Air Excess Sludge

  24. Risk and site selections. Better assess water resources at new site locations needed to avoid repeat of New Mexico dilemmas. Industry and stakeholder collaboration. Integrated water management with water treatment facilities and potential water reusers (e.g. golf courses). Other future considerations Semi-conductor Industry

  25. Semiconductor industry has taken major strides to improve water efficiency and quality, while under significant scrutiny from stakeholders. Technology very important. Major inhouse R&D supported by external institutions. Both adaptation of existing technologies into new semi-conductor applications and development new semi specific technologies. Long term commitment to semis manufacture in arid regions. Collaboration within firm and with other water users and stakeholders has and will continue to be critical to ensure continuity of operations. Conclusions

  26. Thank You! Questions?

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