Could This Simple Innovation Solve the Semiconductor Water-Energy Dilemma?

Semiconductor manufacturers face a persistent challenge: improving water and energy efficiency in facility operations. Gains in one area often come at the expense of the other, making it difficult to achieve sustainability goals. For instance, Micron targets a 75% water conservation rate and a 42% reduction in direct greenhouse gas emissions by 2030.

A recent pilot at Micron’s Boise, Idaho facility offers a promising solution. Aqua Membranes’ 3D Printed Spacer Technology® was tested in a reverse osmosis (RO) system running alongside conventional membranes, processing reject water from an ultrapure water treatment system.

UltraFacility caught up with Aqua Membranes’ Applications Engineering Manager, Mike Schmidt, to learn more about their technology, the pilot, and what these results could mean for semiconductor facilities.

37% energy savings through efficiency gains

The pilot’s first phase, running at 100% uptime from April 2023 to January 2024, demonstrated an energy reduction of 22% over the course of the year. After improving pattern and element design, phase 2 of the pilot showed energy savings increase to 29% at startup, reaching 37% within two months.

The key innovation is the 3D printed membrane spacers deposited directly on the polyamide membrane which eliminates the bulky cross strands of traditional mesh spacers. Schmidt explained: “The standard size of a membrane’s “active area” is 400 square feet – by eliminating the cross strand of a mesh spacer, we can push that limit to 505 square feet, which is what we did in the Micron facility.” A larger active area of membrane allows the element to run at a lower overall flux, which means the system doesn’t work as hard to produce the same output.

Increased water recovery

While improved energy efficiency is a major advantage, the technology also enhances water recovery, a critical priority for semiconductor fabs aiming to boost overall water efficiency.

Instead of reducing flux, the RO skid could take advantage of the increased active area and safely recover more water over the same amount of time. “Swapping our element in and making more water out of that same skid is ideal for system operators because they don’t have to think about the capital costs of adding more pumps and membrane housings,” explained Schmidt. For facilities where footprint is at a premium, switching to 3D printed spacers could increase recovery without requiring additional space.

Reducing maintenance, extending lifetime

The pilot also recorded a fourfold decrease in differential pressure for the system, indicating less fouling and ultimately reducing maintenance requirements for the RO system.

With fewer places for foulants to catch, the need for frequent cleanings is reduced. While systems using mesh spacers typically require regular cleanings, “Since the beginning of phase 2, we have yet to see the need for a standard cleaning” Schmidt shared. Long term reduction in the use of cleaning chemicals can extend the lifetime of a polyamide membrane, as these generally degrade the performance of the flat sheet over time.

Next steps and broader impact

Since Aqua Membranes’ spacers can be printed directly onto any third-party membrane, the technology holds strong potential across a range of RO applications. For instance, integrating printed spacers into high-recovery RO systems could help offset the higher energy demands typically associated with those designs. Performance of the printed spacers can be enhanced by adjusting the pattern of spacers on the active area of the membrane, as illustrated by the further reduction in energy use from the first phase to the second phase of the pilot.

Sustainability and industry collaboration

Schmidt gave his perspective on the future of sustainability for semiconductor facilities, emphasizing the need for technologies that are both cost effective and sustainable to encourage uptake from manufacturers. “That’s where Aqua Membranes comes in. We’re not reinventing the wheel – we are upgrading a legacy system that has seen limited innovation to date. Adopting Printed Spacer Technology® delivers measurable benefits for end-users – lowering costs while reinforcing their commitment to responsible water stewardship.”

The success of this pilot installation at Micron’s Boise facility indicates that by making small, cost-effective changes without large capital costs and footprint expansions, the semiconductor industry could reap the benefits and make strides towards balancing the water-energy nexus.

Since this pilot, Aqua Membranes has expanded its partnership with Micron and has started working with other large global microelectronics customers to support sustainability goals across the industry.

To learn more about this pilot, see the results on Aqua Membranes’ profile on the UltraFacility Ecosystem.