Energy-saving Solutions for Microelectronic Semiconductor/Green Factory-Guolian Green Technology(Wuxi) Joint Stock Co., Ltd.

Energy-saving Solutions for Microelectronic Semiconductor/Green Factory

Electronics industry refers to an industrial chain that involves electronic material, electronic parts and components and complete machine production. Due to the huge number of enterprises in the industry, and some highly energy-consuming processes, advanced group control and energy conserving technologies are being increasingly adopted in addition to development and research of new technologies and organization of large-scale high-efficiency production. As such, green production that aims to save energy, reduce consumption and lower emission has become an inevitable trend of development of the electronics industry.
In the production technical process and environmental control of electronic products, cooling and heating are too often needed at the same time. In addition, in some areas, certain requirements are placed on temperature, humidity, air flow rate, cleanness and pressure gradient. In order to meet those conditions, the following auxiliary systems have been designed for the production process of electronic products.

Energy consumption in the electronics industry is considerable. In the overall energy consumption, energy consumption related to environmental maintenance accounts for about half of the total energy consumption. In particular, A/C system accounts for the majority of power consumption. Its main characteristics include:

The electronic plants have a large area and large storey height. A high exhaust rate needed for emission of hazardous gas and process heat. The fresh air volume is large and fresh air cooling load is heavy. The indoor temperature in is generally low in summer. These have resulted in a heavy overall load. The A/C load index in summer is generally above 300W/m2. In extreme cases, it could reach 800W/m2.
The air handling process is complicated (thermal and humidity treatment and filtering) and there are several function sections of the air handling unit. In addition, the A/C equipment is large in size and the pipelines in the A/C unit room are complicated and difficult to arrange.
The electronic clean room has a high control level over particles and floating dust filtering.
For the A/C unit, cross contamination between the processed air and the unprocessed air should be prevented. Stringent requirements are posed on air system leakage ratio of the unit.
The ventilation rate of electronic clean room is high and the fresh air volume is high. This means the unit should have a higher strength and pressure bearing capacity.
The humidity and temperature control is strict. Intelligent automatic control devices should be provided.

Energy conserving schemes commonly used by Johnson Controls in electronics factories include:

Energy Management and
Sub-metering Platform
Free Cooling System
High-energy-efficiency Chiller Plant
Automatic Online Cleaning System of Condenser
Chiller Plant Group Control
AHU Intelligent Control
Steam Condensation Water Recovery
Boiler Flue Gas Heat Recovery
High-efficiency Magnetic Suspension Variable-frequency Unit
Air Compressor Heat Recovery
Dry-expansion Constant Temperature Humidity Unit, Transition Season

Pre-transformation System Chart

Take an electronics factory as an example. The water chilling unit before transformation is used as the cooling source. The municipal steam is used as the heating source. The heating and cooling system diagrams are shown below:

Post-transformation System Chart

York high-efficiency heat pump unit is used in the transformation scheme. One end supplies chilling water and the other end supplies hot water, so as to realize combined heating and cooling. This way, maximum overall energy efficiency of the system is achieved. Its schematic diagram is as follows:

Combined Cooling and Heating

The chilled water system of an ordinary electronics factory has different characteristics depending on the specific requirements for process and comfortableness. Guolian Green Technology advocates separation of the two systems to achieve respective optimized operation. This could significantly reduce energy consumption of the user and increase the economic benefit noticeably. Furthermore, full-year heating and cooling are needed for most of the electronics factories. This means the heat pump unit of combined cooling and heating of Guolian Green Technology has a broad application perspective.

Fan Filter Units

Centralized Fresh Air Handling + FFU Purifying A/C System

Generally speaking, the return air cooling with large circulation capacity is undertaken by the modular small fan filter unit FFU (Fan Filiter Unit) of heat exchanger coil with fewer inner tube rows, lower head-on wind speed and high water temperature (12-17C). As the first company to develop FFU, the FFU products provided by Envirco brand of Air Distribution Technologies are widely used in electronic factories. At the same time, it can provide infinite speed regulation of FFU, Console group control, PC centralized control and so on.

Energy Audit

Through energy audit, energy consumption monitoring, energy data statistics and analysis, Guolian Green Technology allows management of electronics factories to control the energy cost proportion and energy consumption development trend in a more accurate way. In addition, the energy conservation and consumption reduction tasks of enterprises are assigned to each production department and workshop. This way, the responsibilities are clearly divided, and sound and stable development of the enterprise is guaranteed.