Tips on Selecting an Acid Neutralization System for your Application

Tips on Selecting an Acid Neutralization System for your ApplicationAcid neutralization systems are essential for various industrial processes such as semiconductor fabrication and research facilities that produce acidic effluents. These cannot legally be discharged directly into public sewer systems; instead, they need to first be processed in legally prescribed ways. Altering the pH of acidic waste by-products to legally acceptable pH ranges of between 6 and 9 can be a major challenge, however.

As process engineer or semiconductor facility manager, what do you look for in an acid neutralization system? The best solution is a system that is easy to use, has a low operating cost and complies with all laws and regulations. Managers tend to see waste treatment as an operation that is difficult to administer and control costs in. The use of an effective system that provides automation would be the best option.

Automation frees up resources and lowers costs for businesses. When equipment is properly maintained to manufacturer-recommended specifications, a business can easily manage the process to meet specific criteria.

Acid neutralization systems treat acidic effluents using either continuous-flow processing or batch processing.

Considering a Continuous-flow Neutralization System

Continuous flow neutralization — where a stream of influent is treated while in flow through a pipeline system, prior to discharge — tends to work well in applications where there is a high rate discharge of mild acid or alkali. Continuous flow systems tend to be practical as long as the pH of influents remain stable from one moment to another.

Most systems offer a two-stage handling process; these can be effective for processes that produce moderately acidic effluent. Three-stage processes work well for processes that produce especially polluted effluents.

An automated, continuous-flow neutralization system is designed to provide acid neutralization within the confines of a compact unit, and can process streams as high as 500 gallons per minute.

With microcomputer-controlled monitoring at every stage, there is a high level of reliability to ensure compliance.

Considering a Batch Neutralization System

Acid neutralization systems that handle influent waste acid in batches can be effective in certain applications. Unlike continuous flow systems, batch systems are able to effectively deal with complex, highly acidic influents. Batch systems are suitable in the treatment of processes that cannot be relied upon to produce effluents of stable character. When acidic content tends to change, batches of waste need to be collected and treated separately. Batch neutralization systems also excel in the treatment of influents that are complex in nature — ones that contain heavy metal and fluorides.

These systems come with excellent automation benefits that include:

  • The automation of chlorination and pH adjustment for removal of bacteria.
  • The programming of operational sequences where different reagents and polymer flocculants are fed in.

The Benefits of Choosing an Automated Solution

With an automated acid neutralization system in place, manufacturers are able to get by with a minimal amount oversight to this side of operations. Fully automated from end to end, these systems offer intelligent, sensor-based checks at every point to alert staff of any need for attention, should it arise. Operators can be assured that problems will not go unnoticed.

Modutek Can Help You Choose the Right System for Your Requirements

Modutek, a leading provider of equipment solutions for semiconductor manufacturers, offers a full range of neutralization technologies with different configurations. These are highly cost-effective systems both to install and operate. Modutek can assist process engineers and managers at manufacturing facilities to select the right equipment to meet their specific requirements.

Modutek At Semicon Conference in China

Modutek At Semicon Conference in ChinaModutek, a leading provider of leading-edge wet benches and wet process equipment, will have a factory representative at the Semicon Conference in Shanghai China from March 15-17, 2016. Modutek will be with their China Rep Laserwort located in Hall N3 at booth 3401. Information about the Semicon Conference can be referenced at http://www.semiconchina.org/ and details on Modutek’s attendance at the conference can be referenced at: Modutek at Semicon Conference in China

Stop by the Modutek /Laserwort booth to get information and answer any questions you have about Automated, Semi-Automated and Manual Wet Process Stations used for acid/base, solvent and ozone cleaning or photo resist strip. Modutek also provides IPA vapor drying and Megasonic cleaning equipment to support your manufacturing applications. In addition environmentally friendly acid neutralization systems and air scrubbers are available with all their equipment.

Additional details on some of Modutek’s products are listed below:

  • Fully-automated Wet Bench Equipment
    • Benefits include:
      • Full automation control with touch screen
      • SolidWorks Simulation Professional software
      • SolidWorks Flow Simulation software
      • Servo motor automation
      • All robotics and software designed in house
      • Complete design, assembly and test done according to your specifications
  • Semi-automated Wet Bench Equipment:
    • Benefits include:
      • Automation control with touch screen
      • SolidWorks Simulation Professional software
      • SolidWorks Flow Simulation software
      • Servo motor automation
      • All robotics and software designed in house
      • Complete design, assembly and test done according to your specifications
  • Manual Wet Bench Equipment:
    • Benefits include:
      • High end manual equipment at competitive pricing
      • Meets or exceeds all current safety standards
      • Designed to meet any process requirements
      • Can accommodate custom designs and processes
      • Low cost of ownership
      • Equipment designed for future expansion

Our fully-automated, semi-automated and manual wet bench equipment supports the following applications:

  • KOH Etching
  • Quartz cleaning
  • Ozone Etching
  • Ozone Cleaning
  • SC1 & SC2 featuring Megasonic Cleaning
  • BOE (Buffered Oxide Etching)
  • MEMs processing
  • Plating
  • All solvent applications
  • Hot phosphoric (Nitride Etching)
  • SPM Cleaning
  • Precision Part Cleaning
  • IPA Vapor Dryer
    • Benefits include:
      • Very low IPA consumption
      • No moving parts inside drying chamber which eliminates wafer breakage
      • Most drying cycles completed within 10-15 minutes
      • No watermarks
      • Drying technology can be easily designed into your wet bench eliminating one transfer step
    • The IPA Vapor Dryer supports the following applications:
      • Ozone Cleaning
      • Wafer Drying

Modutek has over 35 years of experience developing and building wet bench stations and wet process equipment that provides highly reliable results for precision processes. They also provide world-class service, and customer support. Call 866-803-1533 or email [email protected] for a free quote or consultation to discuss your requirements.

How Technology Manufacturers Use Chemical Delivery Systems

How-Chemical-Delivery-Systems-are-Used-by-Technology-Manufacturers

Technology manufacturing requires the safe handling of chemicals as well as their delivery in accurate amounts. Corrosive chemicals are used for etching, cleaning and plating materials such as silicon chips, metal parts, solar system components and printed circuit boards. The chemicals have to be stored securely, delivered to the process in precise amounts, and neutralized before disposal. Automated chemical delivery systems reduce waste and operator error while allowing the supply of defined amounts of each chemical with a high degree of precision.

Technology manufacturers use these systems to supply chemicals to wet processing equipment. Acids are used to etch away layers of material on wafers of silicon, printed circuit boards or other substrates. Sections of the layers to be etched are covered in protective material and are not removed by the etching. In this way microscopic structures and conducting paths can be created. The requirements for chemical delivery systems depend on the application of the wet processing equipment and on the chemicals to be used.

The key to supplying effective chemical delivery systems is a flexible approach combined with the ability to develop systems customized to meet the needs of the manufacturer. Companies that manufacture silicon wafers have different requirements from those that manufacture micro-electro-mechanical systems, hard disk drives or solar cells. The cleaning and etching processes of different technology manufacturers use various chemicals and widely varying amounts and process control strategies. Their chemical delivery systems must be resistant to corrosion, be safe to operate, allow the storage of large amounts of chemicals and include flexible software to control distribution. An equipment supplier has to have a good understanding of the processes involved so that they can standardize the parts of the system that can remain the same while developing custom solutions to match the needs of each technology manufacturer.

Modutek specializes in designing and manufacturing systems that provide outstanding performance and reliability with the ability to be highly customizable. The systems incorporate user-friendly features that promote safe and cost-effective operation. In a typical custom application, water use, and the number of defective parts produced is reduced while consistency of results increases.

Modutek’s chemical delivery systems feature all Teflon fluid paths, double containment cabinet construction, leak detection and chemical level sensing. Double wall plumbing and system data logging are available. Chemical storage can be in large tote chemical containers or 55-gallon drums close to the wet process station. Manufacturers that use different chemicals can improve throughput because the Modutek’s systems are designed for quick chemical change.

The software that automates a chemical delivery system is a key factor in the system’s flexibility and Modutek can customize the software to meet the needs of the technology manufacturer. Typically a touch screen shows error messages on start-up and then displays a flow diagram showing the status of key components such as metering pumps, valves and level switches. Since these may be different for particular customized applications, the software must be easily adaptable. All the software for Modutek’s chemical delivery systems is written in house. This means that Modutek has the in house expertise and capability to make changes in the software as needed and can provide excellent technical support without having to rely on exterior sources.

The Modutek chemical delivery systems are suitable for any technology manufacturer application. They are specifically designed for easy customization and provide reliable, cost-effective operation. For additional information about Modutek’s Chemical Delivery Systems or related products call 866-803-1533 or email [email protected]

Benefits of Using Modutek Acid Neutralization Systems

Benefits of Using Modutek Acid Neutralization SystemsAcid neutralization systems adjust the pH value of a process stream in self-contained systems, either continuously or in batches. Effluent monitoring ensures that automatic discharges take place only when the pH values are within set limits. The systems are easy to install with high efficiency and low cost operation. A wide variety of available sizes allows accurate matching to the requirements of particular applications.

Normally acid neutralization systems adjust the pH of a process discharge to within adjustable limits, depending on the application. When discharged into a public sewer, neutralization within a pH range of 6 to 9 is typical. For mildly acidic or alkaline streams with high flow rates and stable characteristics, compact and low cost continuous flow neutralization can be used. When the pH levels fluctuate, inflows are irregular or when the flows are highly acid or alkaline, the use of batch systems is appropriate. These systems neutralize the particular batch and only allow a discharge when the set criteria are reached. A final monitoring chamber for sampling and for recording discharge pH gives operators full control of the effluents.

Flexible Application

Modutek’s acid neutralization systems are available in a wide variety of sizes and configurations. They are designed to suit the requirements of different production facilities and applications, including for semiconductor fabrication, in research centers and in universities. Sizes range from 5 to 500 gpm and installation can be indoor or outdoor, depending on availability of plumbing and electrical connections. The self-contained units are compact and easy to install with an on board reagent tank option. Systems up to 100 gpm are of unitized construction with steel reinforced thermo welded polypropylene while larger systems are skid-mounted.

System Features and Characteristics

Modutek designs its systems with an emphasis on safety and reliability while keeping costs low and saving space. Neutralization systems can operate in fully automatic mode for both acid and alkaline streams. Secondary containment is standard and automatic mode ensures that discharge only occurs when the stream is within permitted pH values. For normal operation, a two-stage system is usually sufficient but three-stage systems are available for especially demanding applications. The control system requires a 120 V AC supply but the mixers and pumps can operate on 120 V or 208 V AC.

The control of the process stream pH is micro-processor based while alarms are handled by a PLC with a touch screen. This combination results in high accuracy and reliability while making it easy to calibrate the sensors and adjust the set points. Neutralizing chemicals are injected into the process with two metering pumps for each stage. Larger systems add pressure control valves.

Alarms include high and low pH in the final monitoring chamber and low level in the reagent storage tanks. There is a liquid sensor in the double containment and all the alarms can be tied into relays for remote signaling at the control panel. Ethernet access for remote signaling is also available and a digital chart recorder monitors and tracks the pH of the process discharge. As a result, there is a continuous record of the pH levels and of alarm conditions during automatic operation.

Overall Benefits

Modutek’s acid neutralization systems offer operators handling chemicals a complete range of neutralization options and system sizes in convenient configurations. The low cost systems are inexpensive to install and reliably ensure that process streams stay within required pH ranges. While operation is fully automatic, comprehensive alarms and monitoring lets the operator check that the system is functioning as intended. If you need more information or would like a quote for your specific requirements contact Modutek by calling 866-803-1533 or sending an email to [email protected]

Acid Neutralization Systems from Modutek

Acid Neutralization SystemModutek Corporation designs and manufactures a complete line of self contained industrial waste acid neutralization systems that are easy to install and inexpensive to operate. Batch sequence reactor systems as well as Continuous flow neutralization systems are also available.

The task of all neutralization systems is to adjust the pH of the process stream to a defined acceptable discharge range. Normally adjusting the pH balance to a neutral range from 6 to 9 pH is what most industrial applications are held to before discharging water into the public sewer. Generally continuous flow neutralization systems are well suited for relatively high flows of mildly acidic or alkaline (e.g. 2.0 < pH < 12.0) waste water. Compared to batching systems continuous systems are smaller and less costly, however, they are also more limited. For more demanding industrial applications, such as those with fluctuating pH balance flows or those characterized by highly acidic or highly alkaline waste water, a batch system would be the better choice since it only discharges when the treated effluent meets a specific discharge criteria.

Applications where continuous flow neutralization systems are typically used include:

  • Influent chemistry is relatively constant and not characterized by large swings with incoming pH or chemistry
  • Influent flow is relatively constant and not characterized by large flow surges
  • Used as a single stage in a more complex application such as fluoride removal or heavy metal reduction
  • Effluent pH limit is not highly constrained (range of < 2.0 pH units)

Continuous Flow Neutralization systems

Modutek offers compact two and three stage continuous flow neutralization systems that are completely self-contained. They provide fully automatic operation and use a compact design in either single or double containment and range in size from 5 to 500 gpm.

Acid Neutralization System Features:

  • Available in many sizes -from 5 to 500 gpm in single or double containment
  • Indoor/Outdoor Installation -for installation flexibility
  • Fully Automatic Operation- Treats both alkaline or acidic waste streams in a fully automatic operation
  • Two or Three Stage Systems
    • Two stage systems can handle normal applications
    • Three stage systems are used for the most demanding plant conditions
  • Microprocessor Based pH Control
    • High accuracy, ease of calibration and reliability
    • Strip chart recorder for continuous monitor and record
  • Unitized Construction
    • 5 to 100 gpm systems use unitized construction with steel reinforced thermo welded polypropylene
    • Larger sizes designed with skid mounted process tanks in fiberglass, polyethylene, or lined steel
  • System Alarms- PLC w/Touch screen
    • High and low pH in final chamber
    • Low level reagent storage tanks
    • Liquid sensor in double containment
    • Remote Ethernet Access
  • Light Tower
  • Reagent chemicals injected with two metering pumps per stage
  • Large flow systems utilize pressurized control valves and larger pumps

Electrical Requirements

  • Control system – 115 volts. Mixers and pumps can be 115, 230, or 460 volts.

Batch Sequence Reactor Systems

Modutek’s Batch Sequence Reactor Systems provide effective treatment of wastewater that contains common heavy metals such as Copper, Nickel, Lead and Zinc as well as metal anions, Fluorides, and chelated or complex metals.

Modutek’s Batch Sequence Reactor system can effectively remove and can effectively address the following:

  • Common Heavy Metals Removed by Precipitation and Flocculation-Copper, Nickel, Lead, Zinc.
  • Metal Anions Chemically Reduced – Chromium, Arsenic.
  • Fluorides Removed by Calcium or Magnesium
  • Trace Metals Removed by Ion Exchange Resins or Flocculation

Modutek’s Batch Sequence Reactor System provides high reliability and programmed automation and includes the following features:

  • Programmed chlorination and pH adjustment to eliminate bacteria.
  • Programmed Reaction Sequences – Multiple reagents may be fed, including a polymer flocculent to aid growth of precipitate particles.
  • Built-in Holding Tank – Wastewater is stored in holding tank and is automatically processed when sufficient volume is collected.
  • Double Containment – The entire system is double contained in a triple-welded polypro outer shell with leak detection.
  • Alarms will sound to alert for high/low pH, low reagent levels, high tank levels, and leakage in double containment space. Final Monitor and Alarms –Specific ion measurements are available.

For more details on system specifications refer to the acid neutralization systems site page. If you need more information about selecting the right neutralization system for your application or want a quote, call us at 866-803-1533.

Acid Neutralization Systems Provided by Modutek

Acid Neutralization Systems Provided by ModutekAn Acid Neutralization System is vitally important for any company that uses chemicals in their manufacturing process. Chemicals need to be neutralized before they can be discharged. Normally, the requirement in most industries is that chemical waste be discharged with pH range of between 5 to 9 pH. The benefits of Modutek’s Acid Neutralization Systems are discussed below.

Modutek has been designing and manufacturing Acid Neutralization Systems since in the 1990s. Each system is self-contained, is inexpensive to operate, and can be installed easily at your company. Because these Acid Neutralization Systems are designed in-house, they can be modified to fit in the space you have available. Along with the physical dimensions of the Acid Neutralization System, the throughput capacity can also be tailored for your specific production needs.

Industries that generally use Acid Neutralization Systems include Photovoltaic Solar Cell Manufacturers, Pharmaceutical or Biotechnology, Semiconductors, Aerospace, Laboratories, Chemical Processing/Manufacturing, Metal Plating/Finishing, and Medical Devices. No matter what industry your company is in, if you need an Acid Neutralization System, the systems manufactured by Modutek Corporation have many benefits:

  • All Acid Neutralization Systems manufactured by Modutek Corporation are completely self-contained
  • The compact systems are available in two-stage or three-stage systems
  • They are available in many sizes ranging from 5 to 500 gpm
  • They can be installed indoors or outdoors for added flexibility
  • They feature fully automatic operation that treats both acidic or alkaline waste streams
  • Automatic discharge occurs only within desired limits
  • The final monitor chamber is set up for ease of sampling and recording all pH before discharge occurs
  • Stripchart recorders offer continuous monitoring and recording of the pH discharge
  • The system includes an alarm system for high and low pH in the final chamber as well as a PLC with Touch Screen

The Acid Neutralization Systems from Modutek provide the following options:

  • Integrated Lift Stations
  • BMS Systems
  • Surge Pumps
  • Paperless Chart Recorders
  • Data Logging
  • Remote Alarm Panels
  • Process Equipment Integration

The Acid Neutralization Systems from Modutek can easily be incorporated with the other equipment used in your manufacturing process. We offer various sizes which can be customized to meet your requirements. If you would like to learn more about Acid Neutralization Systems produced by Modutek Corporation, call 866-803-1533 or email [email protected].