The Role of Nitrogen Gas in Semiconductor Manufacturing

The Role of Nitrogen Gas in Semiconductor Manufacturing

Semiconductor manufacturing relies heavily on high-purity gases like nitrogen gas to create controlled environments. Maintaining the proper oxygen levels is critical in preserving production quality, as any oxygen contamination can result in defects and failures. PureAire’s Oxygen Monitors measure and help regulate oxygen levels in semiconductor manufacturing operations for safety and efficiency throughout production.

Nitrogen is a high-purity gas used throughout semiconductor manufacturing processes. Its inert nature prevents undesired chemical reactions during critical manufacturing stages, ensuring that the integrated circuits and silicon wafers remain intact.

Key roles of nitrogen gas include:

1. Purging and Blanketing: Maintains an oxygen-free environment to prevent oxidation.
2. Cooling: Efficiently cools down semiconductor equipment and materials.
3. As a Carrier Gas: Transports chemical vapors in deposition processes for uniform thin film layers up to 50,000 cubic meters of nitrogen per hour.

Oxygen Contamination in Semiconductor Manufacturing

Semiconductor manufacturers must monitor oxygen levels, as even a trace amount of oxygen can ruin the integrity of the manufactured components. Oxygen contamination can lead to increased device failure rates due to oxidation issues, affecting the reliability and longevity of semiconductor equipment.

Impact on Film Deposition Quality

In processes such as film deposition and spin coating techniques, oxygen can severely impact the quality due to:

• Oxidation: Oxygen reacts with various materials, forming undesirable oxides that compromise the structural integrity of thin films.
• Uniformity: Maintaining uniform thin film layers becomes challenging when oxygen contaminants are present, leading to defects and inconsistencies in semiconductor products.

The Importance of Monitoring Oxygen Levels: PureAire’s 10+ Year Oxygen Sensors

Measuring oxygen levels is crucial in semiconductor fabs to protect product integrity and prioritize personnel safety. Semiconductor manufacturing processes are highly susceptible to oxygen contamination, making accurate and dependable monitoring systems essential. PureAire Oxygen Monitors continuously measure oxygen levels to protect employee safety and ensure product integrity.

Key Features of PureAire’s 10+ Year O2 Sensors:

1. Longevity: Unlike other oxygen sensors, which need frequent replacements, PureAire’s sensors can last over 10 years. PureAire’s long-life oxygen sensors significantly reduce maintenance expenses and production downtime.
2. Accuracy: PureAire sensors accurately measure oxygen levels, ensuring that semiconductor environments stay within the ideal range. If oxygen levels change, the monitor’s built-in visual and audible alarms will be triggered, alerting personnel to evacuate and take corrective action. Accuracy is crucial in measuring oxygen levels to help preserve the integrity of manufacturing processes.
3. Durability: PureAire’s O2 sensors are built for harsh industrial conditions, making them ideal for use in challenging environments. The sensors perform accurately in the demanding settings found in semiconductor fabs.
4. Easy Integration: PureAire O2 sensors integrate seamlessly into existing systems, enhancing operational efficiency without requiring extensive modifications.

Why Choose PureAire O2 Sensors to Monitor Oxygen in Semiconductor Manufacturing?

1. Safety: O2 sensors detect oxygen-deficient environments by continuously measuring oxygen levels and alerting personnel before jeopardizing employee health.
2. Product Integrity: PureAire’s O2 sensors help prevent oxidation and device failures by monitoring oxygen levels and alerting personnel to take corrective action.
3. Efficiency: Long-lasting sensors mean fewer interruptions in production, leading to higher throughput and better product quality control.
4. Cost-effectiveness: Reduced need for sensor replacements translates to significant cost savings over time.

Incorporating PureAire’s 10+ year O2 Sensors into semiconductor manufacturing processes provides long-lasting, accurate oxygen monitoring, safeguarding the product’s quality and ensuring a safe working environment.

Nitrogen is an essential gas used to displace oxygen and prevent oxidation during semiconductor manufacturing, protecting the quality and reliability of the final product.

Semiconductor industry professionals who must constantly monitor oxygen levels will appreciate all the key features of PureAire’s Oxygen Monitors, which will help them achieve long-term safety and efficiency in their facilities. By utilizing PureAire’s Oxygen Monitors, semiconductor manufacturers can mitigate these risks.

FAQs (Frequently Asked Questions)

Is nitrogen used in semiconductors?

Nitrogen gas displaces oxygen from a working environment and prevents oxidation during the semiconductor manufacturing processes, ensuring the quality and reliability of the final product. Displacing or removing oxygen from certain semiconductor processes is necessary to remove contamination from the end products. Even trace amounts of oxygen can lead to production failures.

Is nitrogen used in electronics?

Nitrogen is an inert, oxygen-depleting gas utilized during electronics production. Maintaining proper oxygen levels is essential for ensuring high-quality semiconductor production, as oxygen contamination can lead to increased device failure rates and impact film deposition quality.

What are the various roles of nitrogen gas at different stages of the semiconductor manufacturing process?

Nitrogen gas displaces oxygen, prevents oxidation, and ensures the purity of gases at different stages of semiconductor processes. For example, it purges residual oxygen from channels and pipes, machines, and tools, protecting the production of integrated circuits and silicon wafers. During the deposition stage, nitrogen is used to create thin, contaminant-free film layers. Nitrogen gas ensures that the deposition occurs in a clean, controlled environment, free from impurities that could compromise the quality and performance of the final semiconductor product.

Why is effective oxygen monitoring crucial in semiconductor fabs?

Effective oxygen monitoring is crucial in semiconductor fabs that use nitrogen or other oxygen-depleting gases to remove oxygen from production processes, such as the deposition of uniform film layers. Oxygen displacement, while necessary for semiconductor production, is a safety hazard if gas leaks occur in areas where employees are present.

Why is nitrogen gas used for purging?

Purging with nitrogen removes moisture, chemical contaminants, and any remaining oxygen from piping and tubing, resulting in defect-free, high-quality products.

Can nitrogen be used as a carrier gas?

Nitrogen is a carrier gas that transports chemical vapors in deposition processes for uniform thin film layers up to 50,000 cubic meters of nitrogen per hour. Oxygen contamination poses risks such as increased device failure rates due to oxidation issues and impacts on film deposition quality.

Gas Monitor for Wastewater Facilities and Anaerobic Digesters

 

Anaerobic Digestion Process

Oxygen monitoring is an essential safety and process control measure in facilities that utilize anaerobic digesters. Although the digestion process occurs in an oxygen-free environment, it is important to monitor the surrounding areas to ensure oxygen levels are appropriate for both safety and operational efficiency. The anaerobic digestion process is a multi-stage process which includes:

• Hydrolysis: During hydrolysis, enzymes break down complex organic molecules such as carbohydrates, fats, and proteins into simpler molecules such as sugars, fatty acids, and amino acids.
• Acidogenesis: Acidogenic bacteria further break down the simple molecules produced in hydrolysis into volatile fatty acids, alcohols, hydrogen, and carbon dioxide.
• Acetogenesis: During this stage, products arising from fermentation, namely volatile fatty acids and alcohols, convert into hydrogen, carbon dioxide, and acetic acid.
• Methanogenesis: Methanogenic archaea convert acetic acid, hydrogen, and carbon dioxide into methane and water. This stage is crucial for biomethane production.

Surrounding Areas for Safety

Oxygen monitoring safeguards workers and maintains system safety in areas where gas displacement or oxygen contamination may occur.

• Confined Spaces:
  Best practices include monitoring O2 levels with oxygen detectors, such as PureAire O2 Deficiency Monitors, to ensure safe working conditions, entry points, maintenance areas, and surrounding chambers. Oxygen-deficient environments, caused by displacement from methane or carbon dioxide, pose a risk of asphyxiation.
• Headspace Monitoring:
  Fixed oxygen monitors continuously measure oxygen levels in digesters’ headspaces to confirm they are minimal. This reduces the risk of explosive conditions when methane is present.
• Gas Storage and Handling:
  Oxygen analyzers, like PureAire Oxygen Monitors, detect the presence of oxygen, which may cause contamination in biogas storage tanks and pipelines. This contamination compromises gas purity and increases the risk of fire or explosion.

Maintenance and Purge Systems

• During Maintenance:
  Digesters produce a variety of harmful gases including but not limited to methane, carbon dioxide, and hydrogen sulfide.  Personnel need to be vigilant when digesters are emptied or cleaned; using oxygen monitors ensures the internal atmosphere is free from dangerous gases and safe for entry.
• Ventilation Checks:
  Oxygen levels are monitored during the purging process to confirm adequate ventilation.

Biogas Systems

• Purity Control:
  Oxygen analyzers verify that oxygen levels remain within safe and operational limits in biogas pipelines and upgrading systems. This ensures compliance with safety standards and maximizes energy production efficiency.

Emergency Preparedness

Oxygen monitoring systems, such as PureAire O2 Deficiency Monitors, can detect accidental oxygen ingress into the anaerobic digestion system, alerting operators to potential risks to process stability or safety.

PureAire Oxygen Monitors

PureAire O2 Deficiency Monitors continuously monitor critical areas around anaerobic digesters, ensuring safety and compliance in even the most demanding environments and, in the event of a gas leak and a drop in oxygen to an OSHA action level, will set off an alarm, complete with horns and flashing lights, alerting employees to evacuate the affected area.

Our Monitors offer thorough air monitoring, with no time-consuming maintenance or calibration required. An easy-to-read screen displays current oxygen levels for at-a-glance reading by employees.

PureAire’s durable, non-depleting, long-life zirconium oxide sensor will last for more than 10 years in a normal environment without needing to be replaced.

While oxygen monitoring is not required inside the core anaerobic digesters, it is vital in ensuring safety and operational integrity in surrounding areas and systems. Oxygen monitors help protect workers, maintain biogas quality, and mitigate risks, making them an essential component of anaerobic digestion facilities.

#AnaerobicDigestion #OxygenMonitoring #BiogasSafety #IndustrialSafety #WorkplaceSafety #PureAireMonitoring #GasDetection #MethaneProduction #EnvironmentalSafety #ProcessControl

Brewers Safely Capture and Reuse Carbon Dioxide

 

Brewing beer produces carbon dioxide (CO₂), especially during fermentation (the process by which yeast converts sugars into alcohol). Estimates are that fermentation yields three times as much carbon dioxide as is actually needed to produce (including brewing, canning, and bottling) each batch of beer, with up to 15 grams of CO₂ generated per pint of beer brewed. According to the British Beer & Pub Association, over 8 billion pints of beer were consumed in the United Kingdom alone in 2019, contributing to the production of a whole lot of carbon dioxide.

While large, global breweries, with their vast financial resources, have been recapturing and reusing carbon dioxide for a number of years, most craft brewers have considered carbon recapture technology to be prohibitively expensive. They have treated excess CO₂ as waste, and vented it into the atmosphere, though that practice may make little sense, either economically or environmentally since, in order to produce subsequent batches, brewers must then turn around and purchase carbon dioxide to carbonate the beer, purge beer tanks and lines of oxygen, and to transfer the beer from tanks to bottles or cans.

And carbon dioxide purchase is a recurring line-item expense that eats into craft brewers’ profit margins.

Capturing and Reusing Carbon Dioxide

The good news is that recent technological innovations, driven in large part by companies working with NASA on space exploration and investigation, have led entrepreneurs to an awareness that CO₂ recapture may in fact now be seen as a relatively affordable, and certainly environmentally friendly, option for craft breweries. The technology involves capturing the CO₂ that has accumulated during fermentation and purifying the gas to make it suitable for reuse and/or sale.

The Washington Post has reported that Texas-based Earthly Labs has created a product called “CiCi” (for “carbon capture”), a refrigerator-sized unit that enables brewers to trap and reuse accumulated carbon dioxide. Captured CO₂ is piped from the fermentation tanks to a “dryer” to separate water from CO₂gas. The gas is next purified and chilled to a liquid for ease of storage and subsequent use.

Brewers can reuse their stored carbon dioxide to carbonate new batches of beer, as well as in the canning and bottling processes for the new beer. Craft Brewing Business, a trade website dedicated to the business of commercial craft brewing, reports that breweries can reduce monthly carbon dioxide expenses by 50 percent or more, and CO₂ emissions by up to 50%, via carbon capture technology.

Breweries that capture more CO₂ than they can use, may elect to sell the surplus to other breweries, bars, restaurants, and any other businesses that also use carbon dioxide. For instance, the State of Colorado, Earthly Labs, the Denver Beer Co., and The Clinic announced in early 2020 a pilot program in which Denver Beer Co. would sell its surplus CO₂ to The Clinic, a medical and recreational cannabis dispensary, which would then pump the carbon dioxide inside its grow rooms to stimulate and enrich plant growth.

Oxygen Monitors Can Mitigate Unseen Dangers of Carbon Dioxide

Brewers and others working around carbon dioxide need to be aware of the potential risks associated with CO₂. Carbon dioxide is an odorless and colorless oxygen-depleting gas. Since it deprives the air of oxygen, CO₂ use presents a potential health hazard for brewery personnel.

According to the Occupational Safety and Health Administration (OSHA), an environment in which oxygen levels fall below 19.5 percent is considered an oxygen-deficient atmosphere and should be treated as immediately dangerous to health or life. When there is not enough oxygen in the air, persons working in the affected area may become disoriented, lose consciousness, or even suffocate due to the lack of sufficient oxygen. Because CO₂ is devoid of odor and color, individuals working around it might well, in the absence of appropriate monitoring equipment, be unaware that a risk situation has developed.

As such, The National Fire Protection Association recommends that gas monitoring equipment be placed in storage areas or any place where carbon dioxide is used or stored.

PureAire Dual O₂/CO₂ Monitors

\

PureAire Monitoring Systems’ Dual Oxygen/Carbon Dioxide Monitor offers thorough air monitoring, with no time-consuming maintenance or calibration required. A screen displays current oxygen and carbon dioxide levels for at-a-glance reading by brewery employees, who derive peace of mind from the Monitor’s presence and reliable performance.

In the event of a carbon dioxide leak, and a decrease in oxygen to an unsafe level, PureAire’s Monitor will set off an alarm, complete with horns and flashing lights, alerting brewery personnel to evacuate the area.

PureAire’s Dual Oxygen/Carbon Dioxide Monitor is well-suited for facilities where carbon dioxide is used, such as breweries, bars, and restaurants. Our Dual O₂/CO₂ monitor includes both a non-depleting, zirconium oxide sensor cell, to monitor oxygen levels, and a non-dispersive infrared (NDIR) sensor cell, to monitor carbon dioxide levels. PureAire’s O₂/CO₂ monitors can last, trouble-free, for over 10 years under normal operating conditions.

Saving money, reducing greenhouse gas emissions, and ensuring employee safety...that is certainly something to which we can all raise a glass.

From Farm to Market: Fruit Ripening

Fruit has a brief window where it is perfectly ripe. If farmers waited until every piece of fruit was ripe before harvesting, farming would be more labor-intensive as farmers rushed to pick ripe fruits. Prices might crash due to a short-term glut of fruit on the market. To ensure a steady supply and demand, keep prices competitive, and reduce food waste, farmers use artificial ripening procedures. One method for ripening fruit after harvest involves ripening chambers. Ripening chambers using ethylene, a natural plant hormone, enable the fruit to be harvested, stored, and transported to where it will be marketed and consumed. While ethylene ripening chambers are beneficial, they are not without risks.

How Ethylene Ripening Chambers Work

While there are other ways to artificially ripen fruit in ripening chambers, ethylene has become a favorite, since it occurs naturally in fruit.
Ethylene is a natural hormone found in plants. Fruits begin to ripen when exposed to ethylene, whether the exposure occurs naturally or artificially. In ethylene ripening chambers, unripe fruits are laid out, and the chamber is sealed.Ethylene gas is then piped into the sealed chamber. As the fruit is exposed to ethylene, the fruit
“respires”,which involves intake of oxygen andemission of carbon dioxide. For the ripened fruit to have the right color and flavor, the ripening should occur in a controlled atmosphere in which the temperature, humidity, ethylene, oxygen, and CO2 concentrationaremaintained at optimum levels.
However, there is a risk of combustion from the ethylene gas, as well as decreased levels of oxygen and increased levels of carbon dioxide inside the chamber.

How Oxygen/Carbon Dioxide and LEL Combustible Monitors Protect Employees

Low oxygen levels cause respiratory distress. If oxygen levels drop below the safe threshold for breathing, which could happen in the event of an ethylene gas leak, employees could suffocate. Suffocation is also a danger when there is too much carbon dioxide in the air. Ethylene gas used in ripening chambers would be hazardous if an employee were to enter the chamber before determining that oxygen and carbon dioxide were at safe levels.

A dual oxygen/carbon dioxide (O2/CO2) monitor detects the levels of oxygen and carbon dioxide within the chamber and sounds an alarm should the oxygen level falls to an OSHA action levelor if the carbon dioxide rises to an unsafe level.  By checking the monitor’s display, an employee will know when it is safe to enter the chamber.

PureAire Monitoring Systems has developed its dual O2/CO2 monitor with zirconium oxide and non-dispersive infrared sensor (“NDIR”) cells. The cells are unaffected by changing barometric pressure, storms, temperatures, and humidity, ensuring reliable performance.  Once installed, the dual O2/CO2 monitor needs no maintenance or calibration.

Ethylene is a highly flammable and combustible gas. If the gas lines used to pipe ethylene into the ripening chambers were to develop a leak, the chamber could fill with ethylene and reach combustible levels. A combustible gas monitor, which takes continuous readings of combustible gases, would warn employees of an ethylene leak within the chamber.

PureAire Monitoring System's Air Check LEL combustible gas monitor continuously monitors for failed sensor cell and communication line breaks. The Air Check LEL gas monitor is housed in an explosion-proof enclosure. If a leak or system error should occur, an alarm will immediately alert employees.

To learn about PureAire Monitoring Systems’ dual O2/CO2 monitors or the Air Check LEL Combustible monitor, please visit www.pureairemonitoring.com.

Why Gas Distributors Play a Crucial Role in Most Everyday Businesses?

Inert gases power a wide range of industries, including pharmaceutical, automotive, manufacturing, and semiconductor. While argon, helium, nitrogen, and cryogenic gases have benefits and uses, there are also risks with other gases such as halogens, refrigerants, combustibles, or etching gases. Gas detectors can monitor storage areas and facilities where these gases are used to guard against gas leaks onsite. Learn why it's critical to use one of these monitors in combustible gases distribution facilities.

The Role of Gas Distributors

Unless companies are manufacturing their own gases onsite through, for instance, a nitrogen generator, they rely on prompt delivery of gases they need for operation.

Gas distributors store a range of inert gases for use by manufacturers. Industry regulations mandate that gas distributors follow certain guidelines for the storage and disposal of these substances to reduce the risk of fires, explosion, gas leaks, and other incidents.

When everything is working correctly, gas flows as its needed from the supply tank to, for instance, storage dewars which are then readied for delivery. If a supply line develops a leak or a storage tank is not properly sealed, gas will leak into the air.

Many of these gases have no smell, color, or odor. This means that even if a facility is following all regulations regarding gas storage, there is no way that an employee could detect a gas leak in the moment when something goes wrong.

If storage dewars are compromised, gas will leak in the storage truck and at the delivery site, spreading the risk to third parties.

When one of these toxic gases leaks into the air, the consequences are dangerous. Hydrofluoric acid, a highly corrosive substance, is harmful to the health when it's inhaled or in direct contact with skin. Ammonia, which is commonly used as a refrigerant and in paper making, irritates the skin, lungs, and eyes.

Some gases are flammable when in contact with oxygen, which elevates the risk of fire. Others, like nitrogen, deplete oxygen from the environment. When oxygen drops below a critical threshold, workers can experience respiratory distress, cognitive distress, and ultimately death via asphyxiation.

To provide fast notification and decrease the risk of health hazards, it is recommended to install a universal gas detector wherever toxic gases are used or stored. To further guard against leaks, gas distributors can invest in durable equipment and train staff on proper handling of substances and appropriate emergency responses.

How a Universal Gas Monitor Can Protect Your Staff

A universal gas monitor can detect levels of gases even when the eye and nose cannot.

OSHA, the Occupational Safety & Health Administration, oversees worker safety in all environments, including gas distribution plants. OSHA requirements to prevent workers from being harmed at work include the use of a gas monitor where dangerous substances are used. By installing a universal gas detector, you can bring your gas distribution plant in line with mandatory requirements to keep workers safe on the job.

Not all gas monitors are created equal. It's important to choose a gas monitor that is flexible, especially if you work with a range of substances, and reliable for continuous operation. Gas monitors that do not take accurate readings place worker health at risk, because they may fail to spot a low-level leak.

PureAire's universal gas monitor detects a wide range of gases, including:

·        Ammonia

·        Chlorine

·        Fluorine

·        Hydrogen chloride

·        Hydrogen fluoride

·        Nitrogen dioxide

·        Phosphine

·        and more

PureAire's universal gas monitor is designed to function optimally once set up with no routine maintenance. The renewable sensor lasts for 3 to 8 years on average. Unlike other monitors, PureAire's sensor is rechargeable onsite, to save your gas storage facility time and money. While employees can check interface readouts for peace of mind, the gas detector works 24/7 out of the box. If the unit experiences a problem, error readouts are related to the control room.

Since the monitor has a built-in LCD display, employees can check substance levels at a glance. Dual level alarm relay contacts allow gas distributors to choose the appropriate level for their purposes. Alarms provide employees with sufficient notification to close valves, exit the area, and reduce the risk of fire.

PureAire is an industry leader with more than 15 years of experience developing oxygen monitors and universal gas detectors. Our products provide reliable reports to increase safety and peace of mind. Learn more about our universal gas monitor and view full product specifications online.

 https://www.pureairemonitoring.com/universal-gas-detector/

https://www.pureairemonitoring.com/paint-booths-or-areas-using-combustible-gases/

https://www.chemicalsafetyfacts.org/ammonia/