Operations and Maintenance of Acid Waste Management at a Southwest Microelectronics Manufacturer
| Challenge: | A manufacturer of electronics test and measurement equipment needed support for managing semiconductor acid waste at its AWN facility. |
| Solution: | Aquatech addressed this challenge by deploying experienced O&M staff, developing SOPs, providing technical process optimization, conducting regular water chemistry analyses, coordinating lab tests, and implementing continuous improvement initiatives. |
| Result: | Over the past two years, Aquatech enabled the facility to achieve high uptime, regulatory compliance, and operational excellence, allowing the manufacturer to focus on its core business of electronic test equipment and software. |
This case study details how Aquatech effectively supported a leading semiconductor manufacturer in managing its AWN system, ensuring high system uptime and compliance with environmental regulations. Through skilled personnel, SOP development, and process optimization, Aquatech enabled safe wastewater discharge and reliable operations, allowing the manufacturer to concentrate on its core business of electronic test equipment and software development.
The Acid Waste Neutralization (AWN) system is a critical component in managing the waste generated from semiconductor manufacturing processes. Semiconductor manufacturing involves the use of various acids and chemicals, which, if not properly treated, can pose significant environmental and safety risks. The AWN system neutralizes these acids, making wastewater safe for discharge or further treatment.
Challenge
A manufacturer specializing in electronics test and measurement equipment and software sought support to manage acid waste generated from semiconductor operations. Its AWN facility needed to operate without unplanned outages while adhering to stringent environmental discharge limits. Specific challenges included maintaining high system uptime, precisely controlling wastewater chemistry, and ensuring compliance with environmental and safety regulations. Additionally, achieving cost-effective operations and employing skilled personnel were critical to ensuring uninterrupted and efficient operations.
Solution
To help overcome the facility’s challenges, Aquatech deployed experienced operations and maintenance (O&M) staff to operate the AWN facility during daytime shifts, with additional support available during off-peak hours, weekends, and holidays for emergencies. Key strategies included:
- Developing and implementing standard operating procedures (SOPs) for process and safety.
- Utilizing home office technical support to provide engineering and process optimization recommendations.
- Conducting regular sample analyses and maintaining detailed records of water chemistry.
- Coordinating with laboratories for comprehensive water analysis.
- Implementing continuous improvement initiatives, including proposing and evaluating improvement projects and participating in design reviews.
Result
Over the past two years, the site has achieved high plant uptime, compliance with environmental regulations, and overall operational excellence. Specific outcomes include:
- Maintaining a safe and clean work environment.
- Achieving targeted discharge limits for treated wastewater.
- Providing regular operational reports and logs.
- Executing improvement projects to enhance plant performance and reliability.
- Managing plant operations, including chemical injection rate adjustments and routine maintenance activities.
By effectively managing the AWN system, Aquatech has enabled a leading manufacturer to focus on its core business of designing, manufacturing, and optimizing electronic test equipment and software that support semiconductor technologies. This partnership contributes to the overall efficiency and sustainability of their operations and demonstrates the value of trusting outsourced water management expertise.