industrial pretreatment technology 2006 pacific northwest pretreatment conference – sept. 28, 2006...
TRANSCRIPT
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Industrial Pretreatment Technology
2006 Pacific Northwest Pretreatment Conference –
Sept. 28, 2006
By Stephen G. Edward, PE
For Printed Circuit Board Manufacturing at Merix Corporation
in Forest Grove, Oregon
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Merix Corporation -Industrial Pretreatment Technology
AGENDA
1. Merix Corporation
2. Circuit Board Manufacturing
3. Industrial Wastewater Pretreatment
4. Lessons Learned and Keys to a Successful
Compliance Program
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History• Merix’ Forest Grove facility built in 1982 as the Circuit Board Division
of Tektronix.
• Market changed from captive to merchant providing small to medium volumes of high quality / high tech boards in test, internet server, and communications equipment.
• Spun off into separate entity as Merix Corporation in 1994.
• Started up a new mass lam facility in Wood Village in 2002.
• In 2004, added an ultra-short lead time facility in California.
• In 2005, added five commodity facilities in Asia.
Merix Corporation -Industrial Pretreatment Technology
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Merix Corporation Today
Merix Corporation -Industrial Pretreatment Technology
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Merix Corporation Today
Merix is a leading manufacturer of technologically advanced, multilayer, rigid printed circuit boards for use in sophisticated electronic equipment. Merix provides quick-turn prototype, pre-production and volume board production to its customers.
Principal markets served by Merix include data communications and wireless telecommunications, automotive, high-end computing, and test and measurement end markets in the electronics industry.
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing• Each design custom – Design Review
• Laminate / Prepreg
• Imaging Processes
• Mechanical Processes
• Plating Processes
• Finishing Processes
• Typical Bare Printed Circuit Board Assay
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Manufacturing
Merix Corporation -Industrial Pretreatment Technology
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Printed Circuit Board Business Challenges
• Global Competition
• Rapid Evolution of products and processes.
• Typical Oregon Products
– Order Size: 1-20 Panels
– Copper Layers: < 40
– Mixed Dielectrics
– Blind and Buried Vias
– Embedded passives
– Heat Sinks
Merix Corporation -Industrial Pretreatment Technology
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Wastewater Characteristics• Heavy Metals (Copper, Nickel, Tin, Lead, Silver, Gold, Manganese)
• Chelators and Complexers
• Acids
• Bases
• Cyanide
• Soluble Photoresist Polymers
• COD / BOD
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment• Effective Technologies
– Neutralization (pH)
– Chemical Precipitation (Metals & Photoresist)
– Clarification (Separation of Metals & Photoresist)
– Ion Exchange (Metals, including gold cyanide complex)
– Reverse Osmosis (Small dissolved solids)
– Ultrafiltration (Polymers)
• For efficiency, Use Appropriate Wastewater Segregation
Merix Corporation -Industrial Pretreatment Technology
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Merix – FG Permit Requirements• Daily Flow Proportional Sampling and Analysis for:
– Metals: Ag, Cd, Cr, Cu, Mn, Pb, Ni, Zn.
– Chemical Oxygen Demand.
• Continuous analysis of pH.
• Weekly analysis for CN.
• Semi-annual analysis for Sulfate.
• Periodic analysis for TTO.
Merix Corporation -Industrial Pretreatment Technology
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Merix – FG Wastewater Pretreatment Facility
Merix Corporation -Industrial Pretreatment Technology
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Merix – FG Wastewater Pretreatment Facility
Merix Corporation -Industrial Pretreatment Technology
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Merix – FG Wastewater Pretreatment Facility
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment Example 1 for Copper
• Wastewater Description:
– [Cu] = 50 mg/L
– Not chelated or complexed
• Treatment Technology:
– Adjust pH to 8.9
– Add polymer and/or flocculant
– Clarify
• Results:
– [Cu] < 0.5 mg/L Complies with Permit Limits
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment Example 2 for Copper
• Wastewater Description:
– [Cu] = 50 mg/L
– Chelated or complexed
• Treatment Technology:
– Adjust pH to 8.9
– Add polymer and/or flocculant
– Clarify
• Results:
– [Cu] > 5 mg/L Exceeds Permit Limits
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment Example 3 for Copper
• Wastewater Description:
– [Cu] = 50 mg/L
– Chelated or complexed
• Treatment Technology:
– Add Ferrous Sulfate or Sulfide Chemistry
– Adjust pH to 8.9
– Add polymer and/or flocculant
– Clarify
• Results:
– [Cu] < 2 mg/L Complies with Permit Limits
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment Example 4 for Copper
• Wastewater Description:
– [Cu] = 50 mg/L
– Chelated or complexed
• Treatment Technology:
– Pass through Ion Exchange Resin
• Results:
– [Cu] < 0.2 mg/L Complies with Permit Limits
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment Example 5 for Copper
• Wastewater Description:
– [Cu] = 50 mg/L
– Chelated or complexed
– Contains Dissolved Photoresist Polymer
• Treatment Technology:
– Pass through Ion Exchange Resin
• Results:
– Initial: [Cu] < 0.2 mg/L Complies with Permit Limits
– Later: [Cu] = 50 mg/L Exceeds Permit Limits
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment Example 6 for Copper
• Wastewater Description:
– [Cu] = 50 mg/L, Chelated or complexed
– Contains Dissolved Photoresist Polymer
• Treatment Technology:
– Lower pH < 5.5
– Add Ferrous Sulfate or Sulfide Chemistry
– Raise pH to 8.9
– Add polymer and/or flocculant and Clarify
• Results:
– [Cu] < 2 mg/L Complies with Permit Limits
Merix Corporation -Industrial Pretreatment Technology
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Industrial Pretreatment Keys• Segregation Strategies
• Unplanned chelation or complexing.
• Unanticipated Photoresist impacts
– Clogging of pumps and filters.
– Coating of probes and other critical control devices.
– Coating of resin.
• Human Beings
– Flexible, but, subject to Errors.
Merix Corporation -Industrial Pretreatment Technology
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How Are We Doing?• 2002: Zero Violations.
• 2003: Zero Violations.
• 2004: Three minor Permit Limit exceedances.
• 2005: Zero Violations.
• 2006 to date: One paperwork Violation.
Merix Corporation -Industrial Pretreatment Technology
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Plan for Success• Unless there is no chance for an upset, applied IP Technology
should be flexible. Think stable and forgiving!
• Use effective administrative programs: Chemical pre-screening.
• Recruit and Retain quality personnel.
• Continuously improve education of personnel.
• Recognize and reward superior performance.
• Wastewater segregation strategy should anticipate potential upsets and errors.
Merix Corporation -Industrial Pretreatment Technology
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Ease of Control & Monitoring
Merix Corporation -Industrial Pretreatment Technology
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Ease of Control & Monitoring
Merix Corporation -Industrial Pretreatment Technology
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Storage for Segregation & Equalization
Merix Corporation -Industrial Pretreatment Technology
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Plan for Success (cont.)• Benchmark to identify unknown options.
– Share environmental successes with competitors and learn from them.
– Enhanced industry performance helps minimize negative public perceptions.
• Institutionalize successful methods.
– Properly implemented, an EMS will enhance compliance systems.
– Merix uses the ISO 14001 International Standard as model for site Environmental Management Systems.
Merix Corporation -Industrial Pretreatment Technology
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Summary• Must understand the manufacturing operations and its
requirements.
• Need to understand the limitations of the specific IP Technology in the context of its application.
• Implement Systems that minimize surprises and the opportunity for errors.
• Select and retain the right quality of employees.
• Institutionalize continuous improvement.
Merix Corporation -Industrial Pretreatment Technology
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Questions?
Merix Corporation -Industrial Pretreatment Technology