Chemical Handling for Wet Processing Equipment

Chemical Handling for Wet Processing EquipmentBecause wet processing of silicon wafers uses different types of chemicals, semiconductor manufacturing facilities need chemical handling equipment to store, deliver and dispose of the chemicals. A complete chemical handling system takes care of all aspects of chemical use and ensures chemicals are delivered to the process when and where needed.

For corrosive, toxic, or flammable chemicals, safe handling is critical. Most of the chemicals used in wet processing can’t be released into the environment without additional treatment. Neutralizing dangerous chemicals on site or storing them in safe containers until they can be transported to a treatment facility must be documented to comply with local regulations.

Since chemicals are often dangerous to the employees operating wet processing systems, the chemical handling equipment has to be designed to minimize spills and reduce employee exposure to chemicals and their fumes. A comprehensive chemical handling system can improve workplace safety, reduce spills and waste, and make chemical processes more efficient.

Chemical Delivery Systems Provides Your Process the Chemicals It Needs

Chemical delivery systems store the chemicals safely and then deliver the right quantities, mixtures, and concentrations directly to the production line. The amount of chemicals delivered has to be precise and repeatable. Successful wet processing often depends on the right mixture or concentration because etching, stripping, and cleaning can vary with the amount of chemicals in the bath. When processing batches, the amounts delivered must be precisely the same for each batch. With continuous processing, the chemicals delivered can’t vary over time.

Modutek has a complete range of chemical delivery equipment, from high volume systems for large continuous production lines to small batch operations. Chemicals can be stored remotely in large totes with a load cell interface or in 55-gallon drums near the wet process station. Modutek’s SolidWorks Simulation Professional and SolidWorks Flow Simulation applications can calculate the exact quantities of chemicals required, and the chemical delivery systems provide precisely the calculated amounts. These systems ensure that chemical handling and process repeatability are excellent.

Modutek’s Collection Systems Remove Used Chemicals from Processing Stations

Once a wet process such as cleaning, etching, or stripping is complete, the used chemicals must be removed from the process stations and collected. Chemicals can be stored in safe containers and sent to a company specializing in neutralizing and disposing of hazardous chemicals, or they may be neutralized on-site.

To collect the chemicals from processing stations, chemical lift stations can pump the chemical waste from the process tank to a storage container. Chemical carts, also called pump carts or collection carts, can be moved near the process tanks to empty smaller amounts of chemicals. Storage can range from small carboys to large collection tanks. For small volumes, waste chemicals can be pumped directly into a five-gallon DOT-approved carboy for subsequent shipping to an off-site neutralization facility.

Acid Neutralization Systems Ensure Compliance with Environmental Standards

Many wet process semiconductor manufacturing steps use strong acids in their process baths. The used acids must be disposed of safely without risks to employees, the general public, or the environment. Local regulations specify how acid waste must be treated to ensure that disposal meets these requirements.

As regulatory compliance becomes more complex, the costs of disposing of chemical waste off-site are increasing. Modutek can provide self-contained acid neutralization systems that are inexpensive to operate. These systems add neutralizing chemicals to the acid waste and track chemical use, waste pH, and discharge quantities. The systems can generate documentation for regulatory compliance and safely dispose of the neutralized waste.

Modutek Offers In-House Expertise for Selecting Chemical Handling Equipment

Modutek can help customers choose the right chemical handling equipment for their facility. In-house experts at Modutek can recommend equipment from a full line of chemical handling systems. Modutek can customize equipment for special applications and ensure that the systems meet customer needs. Contact Modutek today for t a free consultation to discuss your chemical handling needs.

How to Select an Acid Neutralization System to Reduce Chemical Disposal

When industrial processes such as semiconductor manufacturing use chemicals, the chemical waste needs to be treated before disposal. Chemical waste treatment can be handled on-site with an acid neutralization system or companies can use outside service providers to pick up the waste and properly dispose of it.

Modutek’s acid neutralization systems are designed for easy and flexible installation along with reliable operation and low chemical consumption. The systems make it easy for customers to avoid the costs of hiring disposal companies by treating chemical waste in-house. For many industrial processes, the chemical waste treated with an acid neutralization system is safe enough to drain into the local sewer system.

Continuous Flow Versus Batch Neutralization Systems

For most large industrial operations, a continuous flow acid neutralization system is the best solution. The waste chemicals from a process are produced continuously and they are automatically treated. A continuous flow of 5 to 100 gallons per minute (GPM) can be neutralized. Smaller industrial facilities often operate in batch mode where small quantities of used chemicals need to be disposed of. Modutek’s acid neutralization systems treat and neutralize chemicals using the continuous flow method.

Flexible Installation Means Modutek Systems Are Suited for Many Different Applications

To reduce chemical disposal via an outside service provider, an in-house neutralization system has to be flexible and easy to install. Cost-effective systems have to feature low chemical consumption for complete neutralization allowing disposal into a local sewer. Modutek’s acid neutralization systems satisfy these requirements and can save customers money by reducing chemical disposal costs.

Additional installation features for various service applications include the following:

  • Indoor or outdoor installation
  • Working volume up 4000 gallons
  • 110% Secondary containment tank for extra safety
  • Final discharge sample tank with pH probe and chart recorder for compliance purposes
  • Acidic or alkaline chemical waste treatment in two or three stages
  • Fully automatic operation with a touch screen monitor
  • Unitized construction with larger systems skid-mounted
  • Microprocessor-based pH controls with a comprehensive alarm system

Modutek’s acid neutralization systems are designed to fit into existing process lines with just a plumbing connection and electrical hookup. Once installed, the systems offer problem-free chemical waste neutralization and disposal.

Sensors, Meters, and Automation Help with Ease of Operation

Modutek acid neutralization systems are designed to work reliably in fully automated mode while sensing chemical waste composition and triggering alarms when key variables show abnormal values. Electronic chemical metering pumps supply the correct amounts of neutralizing chemicals while Signet pH probes and transmitters monitor the composition of the chemical waste. Signet paddle wheel flow sensors and signet 9900 flow meters/totalizers send their signals back to a PLC that controls alarms. The systems are designed to work independently while providing readouts for operators tracking the process. Chemical use, discharge pH, overall flow, and triggered alarms are recorded. Operators can make sure that discharged waste stays within the environmental regulatory framework and can use the recorded data to demonstrate compliance with proscribed values.

Modutek’s Expertise in Chemical Processing and Neutralization

By working closely with customers and industry partners, Modutek provides continuous innovative products to meet customer needs. Modutek has its own in-house expertise to evaluate specific applications and make recommendations. After identifying process requirements, Modutek can make suggestions and offer systems from its complete line of chemical handling equipment. For a free quote or consultation to discuss your chemical processing and neutralization requirements contact Modutek at 866-803-1533 or email [email protected].

Designing Chemical Delivery Systems to Meet Facility Requirements

Because semiconductor manufacturing facilities use a variety of chemicals to clean, etch and process silicon wafers, chemical delivery systems are critical for ensuring that operations run smoothly. Chemical handling equipment delivers or collects the required chemicals for the safe disposal of the chemical waste. Effective chemical delivery systems remove concerns about the availability and correct mixture of process chemicals and allow operators to focus on issues directly affecting silicon wafer fabrication, such as wafer cleaning, etch rates, and particle contamination. When chemical delivery systems exactly meet facility requirements, a focus on the fabrication processes lets operators optimize production and helps improve output.

Adapting Receiving and Storage of Chemicals to Facility Requirements

Chemical delivery depends on how many different chemicals a facility requires and the volume of the chemicals used. Chemical characteristics such as toxicity also have to be considered. For facilities using a variety of chemicals in varying quantities, a special area may be needed to centralize reception and storage functions.

For small volumes of chemicals, a standard drum located near the process may be the most convenient. For large volumes, receiving and storing chemical totes monitored with a load cell to track chemical use could be the best solution. For dangerous chemicals, containment of possible leaks and special safety measures may be required to ensure compliance with environmental and safety regulations. A competent manufacturer of chemical delivery and storage systems can evaluate these factors and make corresponding recommendations.

Ensuring Timely and Reliable Delivery of Chemicals to the Process

The key function of chemical delivery systems is to ensure that the required chemicals are provided in precise amounts as needed for the process. Silicon wafer fabrication steps clean and etch wafers with mixtures of chemicals that have to be delivered to process tanks. Each step requires precise quantities of chemicals delivered in sequence and at timed or process-dependent intervals. Each facility has different process steps and different chemical delivery requirements. A well-designed chemical delivery system will reliably provide exactly the right chemical in the specified volume at the correct time.

Collecting and Disposing of Used Chemicals Safely

Once a process step is complete, the chemical mixture that remains is often still chemically active, toxic and dangerous. The wafers will have been removed from the chemical bath and the used chemicals need to be safely treated or collected and disposed. For example, acids used in wafer etching are hazardous for operators, harmful for the environment and even the vapors may be dangerous.

Disposal of chemical waste has to be in accordance with local safety and environmental regulations. The chemical system can either drain the chemical waste and send it to an on-site chemical neutralization system for treatment, or to storage in a chemical collection container. Used chemicals in chemical collection containers can be picked up by service providers that specialize in chemical disposal. In either case, the chemical handling has to be carried out safely while containing any leaks or spills.

Modutek’s Expertise with Chemical Delivery Systems

Modutek has extensive experience designing and building customized chemical delivery systems. With in-house expertise in designing and supplying a full line of chemical handling equipment and systems, Modutek can evaluate a facility’s chemical delivery needs and make corresponding recommendations. If you need guidance on selecting the right chemical handling equipment and systems for your facility, contact Modutek for a free consultation.

Why Chemical Collection Carts are Needed for Chemical Handling

When high-volume chemical delivery systems are not needed because of small production volumes, chemical collection carts can provide safe chemical handling. Also known as chemical delivery carts or chemical pump carts depending on their role, these chemical carts can safely deliver chemicals to the process and remove them for disposal.

Safe handling of aggressive chemicals is especially important for small facilities that can benefit from the use of chemical collection carts. Labs, research centers and universities often have limited space and lack chemical treatment capability. Using chemical collection carts for the removal of used chemicals and safely delivering them to a specialized chemical treatment provider means small production sites don’t have to worry about adhering to disposal regulations.

Modutek’s Chemical Cart Characteristics and Features

Modutek’s chemical carts are designed for safety, ease of use, and flexibility. The incorporated on-cart holding tank can vary from 5 to 25 gallons and the carts can hold a 55-gallon drum in an optional configuration. The tanks are mounted on swivel casters with brakes and measure 18 inches wide, 36 inches long, and approximately 42 inches high.

With a three-eighths inch pneumatic pump and all-pneumatic operation, no electrical connection is required. Construction is white polypropylene with an all-Teflon fluid path and a stainless-steel option is available for solvent applications. The carts feature independent suction and discharge tubes and there is a high-level sensor with a pump interlock in the holding tank.

Operation of the carts for the dispensing of solvents, acids, or bases and the removal of waste chemicals is straightforward. The suction tube transfers chemicals from an external tank to the holding tank while the discharge tube drains holding tank chemicals and transfers them to an external container. A single pump cart can be used for multiple applications.

Chemical Collection Carts Are a Safe Way of Handling Chemicals

While still requiring manual operation, chemical pump carts can reduce the possibility of spills and accidents. With the use of carts, the transfer of chemicals between containers takes place in a controlled and structured fashion. Aggressive chemicals can be kept at a distance from the operators and workplace safety increases.

In normal use, the pump cart can be rolled up to the chemical processing station and can transfer the required chemicals. For chemical removal and disposal, for example, the suction tube of the cart can transfer the waste chemicals from the process tank to the cart holding tank. The cart can then be rolled out for chemical disposal.

Facilities that use chemicals for their production lines may have their own neutralization and disposal systems, but smaller facilities including universities and research labs often outsource chemical neutralization and disposal to specialized service providers. If the manufacturing facility neutralizes its own waste chemicals, the pump cart can transfer the collected waste from the holding tank into the neutralizing and disposal system. If an external service provider is used for chemical disposal, Modutek’s carts make it easy to ship the containers holding the waste.

The holding tanks on Modutek’s carts feature double containment for extra safety. If the waste chemicals are not neutralized on site, they are stored in a Department of Transport (DOT) approved container for pickup by the specialized chemical processing company. In this case, no in-house chemical neutralization processing is required.

Modutek designs and builds its own systems and equipment in-house. This means that the company can easily customize chemical collection carts to meet special customer requirements. Modutek works closely with customers to identify what they need and works and develops systems and equipment to meet their specific requirements. Contact Modutek for a free consultation and quote on equipment needed to support your chemical processing and disposal needs.

How On-Site Acid Neutralization Systems Provide Safe Chemical Disposal

How On-Site Acid Neutralization Systems Provide Safe Chemical DisposalWhen the right acid neutralization system is chosen, it can automatically add the required neutralizing chemicals to acid waste left over after a semiconductor manufacturing process step. Ideally such a system should use the least amount of chemicals while ensuring adequate neutralization of waste to comply with environmental standards. The system has to have enough capacity to handle the waste chemical flow and it must operate reliably, protecting against spills and documenting chemical use and discharge. With overall environmental standards tightening and local regulations becoming more stringent, semiconductor manufacturers need acid neutralization systems that provide safe and reliable disposal of chemical waste.

How to Choose Continuous Flow or Batch Acid Neutralization Systems

Acid neutralization systems can operate on a continuous basis or can neutralize individual batches of waste chemicals. For mass production of semiconductor parts, fabrication lines operate over extended periods, using fixed amounts of chemicals and producing uniform quantities of waste.

For these large-scale operations, a continuous flow acid neutralization system is the best choice. Because the nature of the waste chemicals is known and remains consistent over time, the neutralization process can add fixed amounts of low-pH chemicals to continuously neutralize the waste flow. Neutralization can be fine-tuned because the overall process doesn’t change.

Batch neutralization systems are better suited for the production of small quantities of semiconductor products. Typical applications are prototype production, production of small quantities for testing or the manufacture of special components. For these operations, the waste chemicals have to be neutralized in small volumes and each process is different. The batch acid neutralization system has to measure the pH of the waste chemicals, and determine what low-pH additions are appropriate. The neutralization is different for each batch as is each outflow.

Automation Can Play a Key Role in Effective Acid Neutralization Systems

Automated acid neutralization systems can help reduce chemical use, ensure regulatory compliance and reduce spills. The system automatically adds the required chemicals to the waste solution, tracks chemical use, measures outflow pH and records the results. Workplace safety is increased and human error is reduced. The records of chemical use and outflow pH can demonstrate that environmental standards are met.

Automating continuous flow systems is comparatively easy because the process parameters are known and they don’t change. The complete automation of batch neutralization systems can be challenging because key variables as well as the chemicals involved can vary from batch to batch.

For a continuous flow chemical acid neutralization system, the acid to be neutralized and the low-pH chemical to be used are known. The automation only has to add the required amount of neutralizing chemical on a continuous basis and record the resultant pH. For slight variations, a control loop can adjust the amount of neutralizing chemical to achieve the required output pH.

A fully automated batch neutralization system first has to measure the batch pH and add an amount of low-pH neutralizer. Depending on the chemicals involved, the automated system may have to add different neutralizing chemicals in several stages to achieve the required output. The automated system is complicated to program and difficult to set up. For batch neutralization systems, operator involvement to select the type of neutralization required can simplify the operation of the automated system and make it more effective.

Modutek Can Help Select the Right Acid Neutralization System

Modutek has a full line of chemical handling equipment, including acid neutralization systems. The company works closely with customers to determine their needs and can customize systems to meet special requirements. Once delivered, Modutek makes sure that the acid neutralization systems operate as specified and customers are completely satisfied. Contact Modutek for a free consultation to discuss the chemical disposal requirements needed at your facility.

Using Acid Fume Scrubbers to Maintain a Clean Work Environment

When semiconductor manufacturing process steps include etching or cleaning with acids, the process station exhaust can be harmful. Acid droplets in the discharge air can create health risks for workers and can corrode equipment. Worker safety standards and more stringent environmental regulations may set limits on the permissible acid droplet concentration.

To address these issues, semiconductor manufacturers need acid fume scrubbers to remove and neutralize acid droplets in the process discharge air. Once the acidic mist is passed through the scrubbers, the output air is clean enough to be discharged into the workspace or outside. Employees can work in a clean and safe work space and the outside environment is not contaminated with acid.

Acid Fume Scrubbers Can Remove up to 99 Percent of Acid Mist

Acid fume scrubbers work by passing the acid mist over a wet bed made up of special, large surface packing material. The scrubber has to be able to handle the flow volume from the process exhaust. Modutek’s scrubbers can remove up to 99% of acid mist and are available in sizes ranging from 500 to 25,000 CFM. This capacity range will satisfy the flow requirements from the smallest to the largest process volumes.

Modutek’s acid fume scrubbers use a high surface area packing material made by industry leader Lantec. The packing material is kept wet with a solution containing acid neutralizing chemicals. As the acid mist passes over the surface of the wet packing material, the acid droplets dissolve in the neutralizing solution. The acid droplets are almost completely removed from the process discharge air, resulting in a clean and non-corrosive air output. The acid in the neutralizing solution is rendered harmless and the solution can be discharged safely.

When Modutek’s high-efficiency acid fume scrubbers are used with the right flow capacity, the corrosive air output from wet process manufacturing stations can made safe for release into the work environment. This is especially important for semiconductor manufacturing operations that rely on a clean, particle-free process space.

Advantages of Modutek’s Fume Scrubbers

Modutek has built its fume scrubbers for a low total cost of ownership combined with design flexibility and ease of operation. The high efficiency resulting from careful design and the use of the Lantec packing material means that a higher percentage of acid fumes are removed and the resulting output air is cleaner and safer. The neutralizing solution from the packing material is recycled, reducing the use of water. A bottom drain makes maintenance easier and the scrubbers have a double containment system for extra safety.

The operator interface gives operators all the information they need for effective operation of the scrubbers. Pressure gauges and flow meters allow operators to get a complete picture of scrubber operation while water level indicators with discharge metering give operators control of neutralizing solution discharge. In addition to wet process station applications, acid fume scrubbers can be used with other chemical handling equipment Modutek offers to provide a safe working environment.

Benefits from Using Modutek Acid Fume Scrubbers

Modutek’s acid fume scrubbers allow facility managers to maintain a clean and safe work environment and neutralize acidic droplets that are discharged from wet process semiconductor manufacturing stations. Even when the use of fume scrubbers is not mandated by worker safety standards or environmental regulations, it often makes sense to install the scrubbers for the many benefits they provide. Benefits can include the following:

  • The high acid mist removal rate improves workplace air quality and results in higher employee job satisfaction.
  • Ease of use means operators don’t need extensive training and can reliably achieve operational targets.
  • Low cost of operation and maintenance allows for a quick return on investment.
  • The flexible design and wide range of capacities ensure that there is a system suitable for most applications.

Based on the needs of your facility Modutek can recommend specific acid fume scrubbers from its complete product line to ensure the installed unit meets application requirements.

How Chemical Carts Provide Safe Handling and Disposal of Chemicals

How Chemical Carts Provide Safe Handling and Disposal of ChemicalsChemical handling equipment is an important part of a semiconductor manufacturing operation because the aggressive chemicals used in etching and cleaning semiconductor wafers have to be stored, delivered to the process, and disposed of safely. Chemical carts, also referred to as chemical pump carts or chemical collection carts, are a convenient way to remove waste chemicals from process tanks and ready them for disposal. These carts are compact units that can be rolled up to the processing line to pump out processing tank contents. Carts have to be designed for safe pumping and containment of the chemicals and for moving them to a safe location for further treatment.

Chemical Cart Design Features

Modutek’s chemical carts allow operators to quickly remove used chemicals from a process line and let the process continue to the next step with a minimum of delay. The carts are easily rolled up to the process tank that contains the used chemicals and operators can safely transfer even toxic or corrosive chemicals. Modutek’s chemical carts have the following features:

  • Compact profile at 36 inches long, 18 inches wide, and 42 inches high
  • Made of white polypropylene resistant against acids; also available in stainless steel for solvent applications
  • Mounted on swivel casters that can be locked
  • Suction wand for emptying process tanks
  • Independent discharge tube for transfer of waste chemicals to a neutralization system
  • Pneumatic pump, three-eighths inch
  • On-cart five-gallon chemical tank with double containment that is Department of Transport approved
  • High-level sensor interlocked with pump for additional safety
  • All-Teflon piping

Once operators have pumped waste chemicals into the cart tank, the cart can be rolled out to a neutralization area or the waste can be shipped off-site for neutralization and disposal by a specialized company. In either case, the amount of chemicals and the treatment are recorded to ensure compliance with local environmental regulations.

Chemical Handling Equipment Increases Workplace Safety

Chemical handling equipment such as chemical carts allows operators to receive, store, deliver and discharge dangerous chemicals safely. Well-designed chemical handling equipment can reduce waste, deliver accurate dosages to the process and track chemical use. Containment of spills is an important safety and environmental issue that can be addressed by good design practices. Modutek’s extensive experience with wet process technology and the acids used to ensure that the company’s chemical handling systems operate in a completely safe and reliable manner.

Chemical Handling Functions Require Different Types of Equipment

While chemical carts used for the disposal of used chemicals fulfill one particular role, similar units can take on other functions. Chemical delivery systems handle chemical reception, storage, and delivery to the process. They can include remote bulk storage such as in large tote chemical containers that can supply high volumes of chemicals or 55-gallon drums located at the process. Chemical delivery systems can include software for dosage control and software can control the mixing of chemicals as well.

Chemical lift stations can fulfill a role similar to chemical carts but the units are permanently installed. They are sometimes located behind the wet process station they are serving, but Modutek has developed a space-saving design that allows an integration of the lift station in the process line. When chemical waste or waste water enters the lift station tank, the liquids are pumped to a neutralization area for further treatment.

Modutek’s product line of chemical handling equipment allows manufacturers to make their workplaces safer and save money. Chemical carts and other chemical handling equipment can be customized in terms of flow, capacity, and functionality to respond exactly to customer needs. Modutek can leverage its experience in semiconductor manufacturing equipment to help customers choose the right systems and ensure that the chosen systems perform as needed.

Selecting Chemical Handling Equipment for Solvents and Acids

When chemicals are used in a manufacturing process, chemical handling systems are Selecting Chemical Handling Equipment for Solvents and Acidscritical for accurate chemical delivery to the process equipment and the safe disposal of the chemical waste. Effective chemical handling systems are especially important for solvents and acids because of the corrosive nature and the dangers of unsafe handling of these chemicals. Finding the right chemical handling system for a manufacturing facility is often challenging because the applicable regulations have to be followed and worker safety has to be guaranteed. A competent manufacturer with extensive experience in chemical handling and a proven track record in chemical handling equipment can advise customers of the most appropriate system for their specific application.

Chemical Handling Equipment Functions and Features

Chemical handling equipment ensures the safe acquisition, use and disposal of hazardous chemicals used in manufacturing. Essential functions include the following:

  • Delivery: Chemicals have to be delivered to the process equipment in the quantities, mixtures and concentrations required. This requires accurate repeatability. We build all our delivery systems around your chemical drums. This includes single or double drums requirements.
  • Collection: Collection of hazardous chemicals takes place in a specially secured cabinet with containment and leak detection capabilities. Modutek’s systems are designed for use with Department of Transportation (DOT) approved drums for direct shipment for disposal.
  • Neutralization: This option is also available if chemical disposal becomes too expensive. Once chemical is neutralized properly chemicals can than drain directly to your main drain.

In addition to chemical handling equipment functionality, specific manufacturing applications may benefit from features that increase operational safety, reduce costs or improve manufacturing operations. For expensive chemicals, features that reduce chemical waste are important. Chemical handling equipment dealing with dangerous chemicals may have to include extra operator safety protections. Dangerous chemical waste is best neutralized next to the manufacturing process, but if that’s not possible, chemical collection systems can safely hold chemicals that will later be transported for off-site treatment. Chemical handling equipment often has to be customized to address the functions needed and make sure the required features are in place.

Modutek’s Line of Chemical Handling Equipment Can Meet Manufacturing Needs

Modutek can offer a complete line of chemical handling equipment that can customized for specific manufacturing needs. Modutek’s equipment line includes the following:

  • Acid neutralization systems. These compact systems add neutralizing chemicals to acid or alkaline waste. They feature low operating costs and either batch or continuous operation.
  • Chemical delivery systems. Chemicals are delivered to the process in exact quantities and at the right times. These systems reduce chemical waste and eliminate operator errors that cause spills.
  • Chemical lift stations. These stations pump chemicals directly from the process to the neutralization area. They can be incorporated into the process line and feature flow capacity adapted to process requirements.
  • Chemical collection systems. Chemicals are collected and stored locally near the process or remotely in large collection tanks. In the absence of neutralization, storage can be sized to process requirements and designed to permit transportation of the containers for off-site treatment.

Modutek’s chemical handling equipment is designed to ensure safe and precise handling of hazardous chemicals. Chemical use is lower due to reduced waste and workplace safety is increased. Neutralization and disposal of hazardous chemicals can be carried out in accordance with regulations and can be documented to demonstrate compliance. Modutek can offer solutions for the chemical handling needs of varied manufacturing operations and the company’s experience in the field and its in-house expertise lets it customize the equipment exactly as needed. Contact Modutek for a free consultation or quote on equipment for your specific manufacturing requirements.

Systems That Support Chemical Delivery and Disposal Requirements

Systems that Support Chemical Delivery and Disposal RequirementsWhen corrosive chemicals are used by manufacturers and research centers, they have to be stored safely, delivered to the process in precise quantities and neutralized prior to disposal. Chemical delivery systems that manage the use and disposal of chemicals have to be designed for high reliability and for compliance with local environmental regulations. Even for chemicals that are not hazardous, these systems can reduce waste and improve productivity. The varied requirements for chemical handling systems that fulfill these functions mean that a high degree of customization is necessary. Modutek offers a complete line of chemical handling products that support chemical delivery and disposal with extensive customization.

How Chemical Delivery Systems Improve Manufacturing Facility Performance

Effective chemical delivery systems make sure that chemicals are tracked from reception through storage to use in the manufacturing process. Low storage volume alarms let operators place orders to ensure a continuous supply. Bulk storage can take place in a separate storage area while smaller quantities can be stored close to the process. Sometimes chemicals have to be mixed or different chemicals added to the process at different times. Both storage and delivery to the process can be automated to varying degrees. Double containment and leak detection may be required. Such chemical delivery systems provide the following benefits:

  • Better process flow. Tracking chemical use and making sure there is enough supply lets the manufacturing process run more smoothly with a constant chemical consumption.
  • Higher output quality. Precise dosage and excellent repeatability results in reliable product quality over time.
  • Reduced waste. Chemical tracking, leak detection and reduced operator error mean there is less chemical waste.
  • Improved workplace safety. When operators don’t have to handle chemicals directly, they are less exposed to hazardous substances and the workplace becomes safer.

As a result of these benefits, chemical delivery systems can reduce costs and improve overall manufacturing and research facility performance.

How Chemical Disposal Systems Ensure Safety and Regulatory Compliance

When chemical disposal systems work properly, they ensure that all chemical waste is collected and disposed of safely in accordance with environmental regulations. Chemical disposal requires the use of Department of Transportation (DOT) approved containers. DOT approved containers provide added safety to prevent leaks during handling and transportation.

Modutek offers different chemical collection and disposal systems which include mobile chemical carts as well as larger volume chemical collection systems. Chemical carts (sometimes called chemical pump carts, chemical collection carts or chemical disposal carts) are units that can be easily rolled up to a process station to pump used chemicals into the DOT approved container within the cart. Modutek also provides chemical collection systems from 5 gallon carboy DOT approved containers to larger collection tanks and collection tank farms to support higher volume requirements. These systems incorporate the use of software controls to monitor chemical disposal levels, leak detection and data logging to keep your facility in continuous operation. With Modutek’s chemical collection systems and software interface there is no down time due to the “fill/empty” control system. Since Modutek designs all their Chemical Collection and Disposal Systems in house all the software and equipment is engineered and manufactured to meet a customer’s specific requirements.

Reliable Systems Customized for Volume, Process and Facility

Modutek has the experience and in-house expertise to customize all chemical handling systems for chemical delivery and disposal as needed. Factors such as chemical volumes used, types of chemical processes and facility layout all influence the system design. The degree of automation desired and the local regulatory environment are always different. Chemical delivery and disposal systems have to be adapted to meet these different requirements. Since Modutek builds its own systems, the company can adapt standard designs and automation to satisfy the unique needs of its customers. Contact Modutek for a free consultation to determine the right chemical delivery and disposal equipment that is needed to meet your requirements.

How Chemical Carts Support Chemical Disposal

How Chemical Carts Support Chemical DisposalWhen difficulties associated with chemical disposal and regulatory compliance increase, it’s time to think about either removing used chemicals for off-site disposal or using dedicated equipment for disposal according to official guidelines. Chemical carts can be rolled over to process stations and can pump used chemicals from the process tanks to a container on the cart. The used chemicals can then be turned over to a disposal company or can be neutralized and treated in an onsite facility. The manufacturing process can continue with a fresh batch of chemicals while documentation and handling of the used chemicals can be carried out according to local regulations.

Chemical Carts Remove Chemicals Quickly and Safely

Once the chemicals for a process step have fulfilled their function and the process step is complete, the used chemicals have to be drained from the process tank so that the next process batch can begin. The use of chemical handling equipment such as pump carts is a flexible solution allowing operators to remove used chemicals from the process tanks for different process steps.

An operator can roll the chemical pump cart to the tank that contains the used chemicals. A suction wand allows the operator to pump the chemicals out of the process tank. The used chemicals are pumped into a dedicated storage tank on the chemical pump cart and the cart can then be rolled out to a designated disposal area.

Depending on whether the company handles chemical neutralization and disposal in house or not, the chemicals can be transferred to a disposal system or turned over to an external chemical disposal specialist. In either case, documentation for the handling of chemicals according to local laws and regulations can be prepared before final disposal.

Modutek’s Chemical Carts Feature Ease of Use and Enhanced Safety

At 36″ long x 18″ wide x 42″ tall, Modutek’s chemical pump carts are compact and easy to roll out. Made of white polypropylene, the carts run on swivel casters with brakes and feature independent suction and discharge tubes. Pumping is with a 3/8th inch pneumatic pump. The five gallon chemical tank on the cart has a double containment system and is DOT (Department of Transportation) approved. A high level sensor on the tank is interlocked with the pump for additional safety. The plumbing is all Teflon and each cart can handle multiple applications.

As an option, chemical carts can be delivered in a stainless steel design for solvent applications. Other options include a pressure interlock safety switch, a large capacity tank and a double dump design. Modutek can help customers decide on the options they need and make sure that the chemical pump carts meet their requirements.

Modutek’s Chemical Handling Products Fulfill Manufacturing and Research Facility Needs

Modutek manufactures a complete line of chemical handling equipment to meet the needs of manufacturing plants and research facilities. In addition to chemical carts, Modutek’s chemical handling systems include chemical delivery systems, chemical collection systems and chemical lift stations. The systems can store chemicals, deliver them to process stations and remove them to neutralization areas. The chemical handling equipment is designed to interface with existing or new manufacturing lines and can be customized for almost any application. For example, storage in large tote containers with a load cell interface reduces drum changes and the lift station functions can be incorporated into a process station in a space-saving design. Throughout the design process, Modutek works closely with customers to identify production line issues and develop effective solutions. The company prioritizes customer satisfaction and delivers equipment of the highest quality with low operating costs and a low total cost of ownership. Contact Modutek for a free consultation or quote on selecting the right chemical handling equipment to meet your specific requirements.