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Membrane Filtration System Intern: Diana Wu Wong, 4th year University of California, San Diego B.S Environmental Engineering

July 17th, 2015

Skyworks Solutions, Inc. Proprietary Information#Advisors/ Mentors

Facilities and Utilities Manager: Laura Garcia Facilities Manager: Luis A. Robles Water Treatment Engineer: Edgar Osvaldo Velazquez

Skyworks Solutions, Inc. Proprietary Information#22-25 seconds

Overall Skyworks Water SystemOptional: Bottom Bar for Call Out Text One Line Only

Skyworks Solutions, Inc. Proprietary Information#This is the Overall Water System of Skyworks. Everyday Skyworks provides 130 gpm of clean water for the production of chips and wafers with the processes called sawing and singulado. The water from the city is first processed through various preliminary filtrations, then goes through the process called Reverse Osmosis to filter out the majority contaminants delivering the best quality of water. This water is then used for the processes mentioned above. Then, in order to conserve water, the contaminated water first goes through the Ultra filtration system for a preliminary filtration before proceeding to the reverse osmosis system to alleviate the use of the R.O.

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Problem Statement Optional: Bottom Bar for Call Out Text One Line Only

Feed Water

ReverseOsmosis R.O Pre Filter Use Point

UF System Increase Demand of Water Increase demand of products Future expansion Increase of Cost Rapid membrane fouling

Skyworks Solutions, Inc. Proprietary Information#So in a more basic structure. The feed water goes through a series of R.O pre filter systems, then to the Reverse Osmosis. The product goes to the use point, which is used by both sawing and singulado. Part of the water will go to the drain and the rest will be recycled by the UF system and filtered back to the Reverse Osmosis.

The problem that we are looking into tackling lies on the UF system. As the demand of water increases due to increase of demands of producs and future expansion, the cost of the membranes increases and rapid membrane fouling occurs.

This leads us to the problem statement: Since the water feeding the UF system is more polluted, it causes more damage to the membranes that help filter out these contaminants. Causing frequent changing of this costly membranes. As Skyworks expands the water demand increases and therefore the lives of these membranes are shortened. The goal that was given to me was to find a solution to prolong the life of the membrane. 4

WhyEnvironmentalCheap

Skyworks Solutions, Inc. Proprietary Information#55So Why?Why do we care? Why do we even use the UF system? First it is environmental. Conservation of water and the promote sustainabiliy. Resources are replenishing. Morally right Second, its cheap. How so?

WhyEnvironmental Cheap

Water Recycled 226,054 m3/ per year

Without UF $ 542,530 USD/ pear year With UF $ -542,530 USD/ pear yearOperational fee $ 64,800 USD/ per yearMembrane fee (8) $ 217,240 USD/ per year $ -260,490 USD/ per year

Skyworks Solutions, Inc. Proprietary Information#66The current UF system recycles a total of 226,054 m3 per year. Given that we pat 36 pesos (2.4 USD) per cubic meter, without the UF we would spend a total of 542,530 USD. Now with the UF system we save these 540,000 USD, taking into account the operational fee, that is maintenance and energy fee, and the cost of the membranes, 217,240 USD for 8 membrane replacements. The total cost that we save is 260,490 USD per year. A significant economic and environmental impact to the community.

Basic Understanding UF systemsOptional: Bottom Bar for Call Out Text One Line Only

Skyworks Solutions, Inc. Proprietary Information#So now you have a very simplified solution on how the waste water system works and on what we use it. Heres a closer look on how the Uf system works. Ultrafiltration (UF) uses hollow fibers of membrane material and feed waters from inside the shell through the membrane to the outside. Suspended solids and solutes of higher molecular weight are retained, while water with low molecular weight solutes passes through the membrane. Although its pore size is approximately 0.01 micron, it cannot remove dissolved substances as efficiently as the Reverse Osmosis (0.0001 micron). Therefore ultrafiltration is often used as the pretreatment for Reverse Osmosis (R.O). These can sort out 99.999% of bacteria, viruses.7

Basic Understanding Skyworks UF systemModel: HydraCAP 60

Feed Water 6010 NTUPost Prefilter555 NTUProduct0.15 0.05 NTUExhaust 120 10 NTU

226,054 m3 water recycled / year

Turbidity [NTU]: Concentration of suspended solids

Skyworks Solutions, Inc. Proprietary Information#Skyworks uses two HydraCAP 60 UF systems that average the flow of 130 5 gpm feed water with 55 5 NTU from the exhaust water of both the Sawing and Singulado process as a pretreatment for the Reverse Osmosis. The feed water first goes through a basic pre-filter of pore size 100 microns prior to the UF system, removing approximately 4 NTU of high weight molecules. Then, it feeds into the UF system with around 50 5 NTU and comes out with 0.15 0.05 NTU of product and 120 10 NTU of exhaust. In terms of SDI, it has varied from week to week in the past week. And heres the trend between the turbidity and SDI

Show the Turbidity and SDI test excel graph to show trend. 8

Basic Understanding Skyworks UF systemMembrane Life

July 8th showed Over-Range results, a total of 31,745 m3 water recycled (51 days) before membrane replacement. Current demand needs 8 membrane replacements per year.

Skyworks Solutions, Inc. Proprietary Information#We also used current data that allows for us to have more accurate projections. So looking at this table provided by skyworks. The current membrane was installed during may 19th and by July 8th, the membranes were showing signs of failure. In this period of time of 51 days, a total 31,745 m3 of water was recycled. We take this as the life of a membrane. The current demand is 8 membrane replacements per year. Keep in mind that each membrane replacement is 16 membranes a total of 27,155 USD per replacement. As mentioned before, our goal is to reduce the number of membranes replaced per year. 9

Solutions

Skyworks Solutions, Inc. Proprietary Information#

Skyworks Solutions, Inc. Proprietary Information#Without further due, I present you the potential solutions to this problem. 10

UF PretreatmentSolutionOptional: Bottom Bar for Call Out Text One Line Only

Feed Water

ReverseOsmosis R.O Pre Filter Use Point

UF System

Skyworks Solutions, Inc. Proprietary Information#The main source of our problem is what? The polluted water source. So our solution is to make the water source less polluted to decrease the damage of the membrane. In order to do this, we add a Pretreament for the UF system.11

SolutionMethodsMechanical Filtration Metal Screen Pre-UF HydraCAP 60 exhausted membrane

Skyworks Solutions, Inc. Proprietary Information#

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Mechanical Filtration Amiad SAF 1500

10-800 microns screen size

70-800 gpm

Projected Equipment and Installation Price: $40,000 USD

Skyworks Solutions, Inc. Proprietary Information#Mechanical filtration is a process in which contaminants in a waste stream are filtered or screened out. This method is effective in preventing particles, even very tiny ones like mud and sludge, from moving downstream. Nevertheless, solids build up on the filtering media and restrict the water flow requiring some type of maintenance over short period of time. Whats cool about the this specific series produced by Amiad is that it has a self cleaning process.

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Pre-UF Exhausted HydraCAP 60

StrengthsWeaknesses

Removes particles as small as 0.01 micronReduces use of Pretreatment ChemicalsRemoval of colloidal materials

Single use Unpredictability of SaturationHigher Energy Cost and Water Consumption Projected Equipment and Installation Price: $40,000 USD

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Mech Filtration vs Pre-UFMembrane Life Projection Membrane Replacements per yearWater ConsumptionQuantity of backwash water Energy ConsumptionEnergy feeService policy feeTotal Cost

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Amiad SAF 1500 vs Pre-UFMembrane Life Projection

Skyworks Solutions, Inc. Proprietary Information#Explain the data

Theoretically speaking the Pre-UF should result the longest lifetime of the membranes because the pore sizes is 0.01 micron. But we are still unsure about the saturation rate of the membranes, so to be safe, we have a larger range of estimation. But whats wrong with this projection? Its only an estimate on what might happen. There is no concrete evidence of the direct correlation between the turbidity and the membrane life, but there are signs that if we lower it, it will lower the membrane fouling rate, we are just not sure to what extend.

If we stopped here, we could can answer the question that was given at the beginning, the if wanted to prolong the life of the membrane, the Pre-UF would be the one. 16

Amiad SAF 1500 vs Pre-UFMembrane Life Projection

Skyworks Solutions, Inc. Proprietary Information#Explain the data

Theoretically speaking the Pre-UF should result the longest lifetime of the membranes because the pore sizes is 0.01 micron. But we are still unsure about the saturation rate of the membranes, so to be safe, we have a larger range of estimation. But whats wrong with this projection? Its only an estimate on what might happen. There is no concrete evidence of the direct correlation between the turbidity and the membrane life, but there are signs that if we lower it, it will lower the membrane fouling rate, we are just not sure to what extend.

If we stopped here, we could can answer the question that was given at the beginning, the if wanted to prolong the life of the membrane, the Pre-UF would be the one. 17

Amiad SAF 1500 vs Pre-UFWater Consumption

Amiad SAFPre-UFTime for backwash15 seconds 120 secondsFlow interruptionnoyesBackwash water per cycle 7 gallons/ cycle250 gallons/ cycle Frequency When reached 7psi differenceEstimate 7 cycles per day Per hourTotal water used /day 50 gallons (0.2 m3)/ day 6000 gallons (22.71 m3)/ dayWater spent m3/ year73 m38289.15 m3 Water spent / year* USD$ 175$ 19,893

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Amiad SAF 1500 vs Pre-UFEnergy Consumption

Amiad SAFPre-UFHours of operation24 hours24 hoursEnergy Consumption $ 25.525 USD/ month$ 1250 USD/ month Service policy fee$ 0 USD$ 2125 USD /monthTotal monthly fee$ 25.525 USD$ 3375 USDEnergy and Service fee per year $ 306.3 USD$ 40,500 USD

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Amiad SAF 1500 vs Pre-UFNo Pretreatment Amiad Case 1Amiad Case 2Amiad Case 3Pre-UFAnnual Pretreatment Operation USD--------$ 306.3 $ 306.3 $ 306.3 $ 40,500 Annual UF Energy Consumption USD$ 64,800 $ 64,800$ 64,800$ 64,800$ 64,800Annual number of Membranes replaced USD82742-4Annual cost of UF membranes USD$ 217,240$ 54,310 $ 190,085$108,620 $54,310 -$ 108,620Annual amount of water recovered226,054 m3226,054 m3226,054 m3226,054 m3198,709 m3Annual amount of water recovered USD-$ 542,530-$ 542,530-$ 542,530-$ 542,530-$ 481,276Annual amount of water spent backwashing USD-----$ 175$ 175$ 175$ 19,893Annual fee -$ 260,490-$ 422,938-$ 287,164-$ 368,629-$301,773 -- -$247,463

Skyworks Solutions, Inc. Proprietary Information#We mentioned before that the 20

ConclusionPerform a Particle Size Distribution (PSD lab test) If the results show: Most particles are bigger than 10 micron (Case 1) Amiad SAF 1500 Increase in 44.8% in savings Most particles are smaller than 10 micron (Case 2) Pre-UF Increase -5.8%-22% in savings Particles are Equally Distributed (Case 3) Amiad SAF 1500Increase 41.5% in savingsRisks Amiad SAF 1500: Particles might be soft and easy to break Pre-UF: If membrane replacement >4, then reduces cost savings.

Recommended Practice

Skyworks Solutions, Inc. Proprietary Information#2121

Acknowledgement I would like to thank my mentors Luis A. Robles and Edgar Osvaldo Velazquez who have been inspirations throughout my internship period to become more knowledgeable, hard working and patient. I would also like to thank my coworkers from Facilities and Laura Garcia for being kind to me .

To my internship advisor Professor Farhat Beg for being encouraging and supportive throughout my internship.

To Citlalli, Loren and Matt for helping us manage our lives at Skyworks and in Mexicali

At last, I would like to thank Skyworks and UCSD for giving me the opportunity to explore my career options and learn all I hoped to learn.

Skyworks Solutions, Inc. Proprietary Information#222222