water usage in the semiconductor industry
TRANSCRIPT
Water Usage in the Semiconductor Industry
Jeff Hanson, P.E.Facilities Engineering ManagerTexas Instruments, Inc.May 13th, 2009
Texas Instruments
• Businesses– Semiconductors
• Analog• Digital Signal Processors• Wireless• DLP Technology• DLP Technology
– Education Technology
Semiconductors
Sensor & ControlsEducational &
Productivity Solutions$0.5B
Texas Instruments
Sensors &Controls
Educational &Productivity Solutions
Texas Instruments
Sustainability - The Triple Bottom Line
SocialSustainabilityCultural Identity
Environmental SustainabilityEcosystem IntegrityCarrying CapacityBiodiversity Environment
The balance of People,Profit, and the Planet
Cultural IdentityEmpowermentAccessibilityStabilityEquity
EconomicSustainabilityGrowthDevelopmentProductivity
SocietyEconomy
Human Well-Being
A sustainable system delivers services without exhausting resources. It uses all resources efficiently both in an environmental and economic sense.
Water Optimization Strategy
• Leverage industry associations for best practices and consumption data
• Utilize semiconductor manufacturing equipment data to drive improvements
• Leverage internal consumption data toLeverage internal consumption data to understand gaps and close
• Water Systems Team– Facilities organization which works with fab(s) to
optimize consumption and reduce cost
Industry Facts• Semiconductor Industry Association (SIA)
– Industry trade association representing over 70 US companies– Profile of the U.S. Semiconductor Industry
• U.S. 2008 Sales = $120 Billion • Worldwide 2008 Sales = $249 Billion • 2008 World Market Share = 48 percent of $249 Billion Market • U.S. Jobs = 216,400 • Percent of Sales Outside U S Market = 77 PercentPercent of Sales Outside U.S. Market 77 Percent • Capital Equipment = $13 Billion, 11 Percent of Sales • R&D Investment = $20 Billion, 17 Percent of Sales
• SEMATECH– Industry consortium that reduces the time from device research to
a manufactured product• International subsidiary ISMI (International SEMATECH Manufacturing
Initiative)
• 6 DielectricDeposition Steps
• 12 DielectricEtch Steps
• 6 Ta/Cu PVD Steps• 6 Cu Plating Steps• 6 Cu CMP Steps• 1 W CMP Step• 12 Wet Clean Steps
Interconnect130nm microprocessor
Wafer Processing Technology
Ion Implantation
W-CMPCopper DepositionPVD + ECPDielectric
DepositionDielectric
EtchCopper
CMPMetal
DepositionPVD + WCVD
DielectricEtch
DielectricDeposition
Shallow TrenchIsolation Etch
Shallow TrenchIsolation CMP
Gate OxideGrowth
Poly SiliconDeposition
Poly SiliconGate EtchShallow Trench
Isolation DielectricDeposition
Silicon Wafer • 16 Thermal Steps• 11 Implant Steps• 5 Etch Steps• 2 CMP Steps• 38 Wet Clean Steps
Transistor
Semiconductor Factory Water Consumption
Source: 2006 ISMI Water Balance Survey
Semiconductor Factory Water Production
Source: 2006 ISMI Water Balance Survey
Normalized Water Used
Gallons per cm2 Wafer Outs
Industry Average = 3 91 gal/cm2 wafer outs6
7
8
9
10
Industry Average = 3.91 gal/cm2 wafer outs
0
1
2
3
4
5
1442
2544
9749
5738
9471
3927
6395
3858
5155
7324
8656
3996
3238
3148
2467
3532
3500
5636
1352
5474
3389
6593
2824
3017
8345
8736
8299
7337
3665
5061
5037
4879
4289
Source: Semiconductor Industry Association
Normalized UPW UsedGallons per cm2 Wafer Outs
5
6
7
8
Industry Average = 2.53 gal/cm2 wafer outs
0
1
2
3
4
9471
5738
3927
1442
3858
2544
3532
3148
5155
7324
6395
5636
1352
3500
2467
6593
2824
9749
7337
4879
3389
8656
3996
8736
3238
3017
8345
5061
4289
5474
5037
8299
3665
Source: Semiconductor Industry Association
Equipment Vendor UPW Consumption Data
• Common wet clean hood recipe data shown
• Comparison of UPW rinse time across many companies
• Large variations present
0
100
200
300
400
500
600
Post
SC
1 R
inse
Ti
me
(sec
)
A B C D E F G H I J TI L M
• Large variations present for same process
0
100
200300
400
500
600
Post
SC
2 R
inse
Ti
me
(sec
)A B C D E F G H I TI K
Facilities Water Systems Team• World wide team with members from all major
manufacturing sites• Focus is on cost reduction and learning new water
technologies• Forum for best practice sharing
Develops strategy for recycle and reuse of “waste”• Develops strategy for recycle and reuse of waste streams– 1st cut → Spent rinse water– 2nd cut → “clean” acid waste water– Others
• RO reject• Water system instrumentation consumption
Typical Wet Process Tool Setup
PREFURNACE HOOD
SC-1 1OO:1HF
SC-2IPA
DRYER UPWRinse
SC-1 SC-2IPA
DRYERSC-1
RECYCLE IWW
SOLVENT
RESIST STRIP HOOD
UPWRinse
UPWRinse
UPWRinse
UPWRi
UPWRi
UPWRi
UPWRi
DRAIN TYPE
SC 1 SC 2 DRYERSC 1
IPASPIN
DRYERIPA
SOLVENT HOOD
SOLVENT
IWW
SOLVENT
IWW
Rinse Rinse Rinse Rinse
UPWRinse
UPWRinse
OrganicSolvent
OrganicSolvent
OrganicSolvent
Two Main Water Sources:City
WaterSpentRinseWater
Poor Quality High Quality
Spent Ultrapure Rinsewater
Two Main Water Users: CoolingTowers
UPWPlant
HighestQuality
Requirement
MinimumQuality
Requirement
Which source to send to which user?
DI Recycle System Schematic
R aw Water
S torag e Tank
P rim aryT rea tm ent
R .O. Wate r
S torage Tank
Ion E xchangeTrea tm ent
P olishing Trea tm e nt
P oint of Us e
D.I. R eturn
Recyc le
Rec yc le
Recyc le
Ult rap ure W ater
S to rage
O ther R ec la im
IW
IW
IW
IW
Spent Rinsewater Recycle Benefits:•Improved final UPW quality
• Less demand on the municipal water supply and waste water treatment systems
•Reduced chemical usage for ion exchange regenerations and waste treatment
• Less risk of municipal water supply variations
Risk Analysis
Reward
• City Water Offset• Chemical Savings• Increased savingsby recycling to low
#4
#3
#7
#2
#6
#1
$300,000
$400,000
$500,000
$600,000
Risk
by recycling to low end users• Improve water
quality
• Bio-fouling• Dumping Chemical
other than organics •Project not succeeding
• FAB impact• Equipment Malfunction• Project not succeeding
#5#8
$-
$100,000
$200,000
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
Review of Water Demand – 1st Pass
A = 850
B = 1705
City Water Demand
C = 315
A DI R = 250
Internal Re-use
Cooling
DIW Plant
B Brine Recovery = 270
A = 300
D = 150
D DI R = 125
F IWW Re-use = 280
E IWW Re-use = 150
% Water Re-used = 29%
TPU andScrubbers
gTowers
A = 50
D = 125
A Brine = 200
A DI R = 150
Total City Demand = 3495 Total H2O Demand = 4920 Total Internal Re-use = 1425*All values in gpm
Review of Water Demand– 2nd Pass
A = 850
B = 1705
City Water Demand
C = 25
A DI Recycle = 250
Internal Re-use
Cooling
DIW Plant
B Brine Recovery = 270
D DI R = 115A Brine = 130
DIW Plant
D = 35
D IWW Re-use = 250
F IWW Re-use = 280E IWW Re-use = 150
% Water Re-used = 46%
TPU andScrubbers
TowersA = 50
A DI Reclaim =150
Total City Demand = 2665 Total H2O Demand = 4920 Total Internal Re-use = 2255*All values in gpm
E DIR = 175
KFAB DIR = 185
A IWW Re-use = 300
RO Brine Recovery“Winner 2001 “Winner 2001 AWWA Bob AWWA Bob Derrington Derrington Award”Award”
Water Recovered 216 GPMYearly Water Savings $295,000Installation Cost $142,000Yearly Operating Cost $33,500
Conclusion
• The semiconductor industry is actively searching for more ways to optimize water consumption
• Benchmarking with industry and internal data will continue to drive industry water consumption down
• The “low hanging fruit” has been picked; new ideas are needed for existing water reuse barriers (reduce risk)