Treatment of slurry copper waste by ultrafiltration and ion exchange.

Abstract

A method for treating a waste stream from a copper CMP process containing dissolved copper and abrasive particles having a number-weighted average size of less than 0.75 μm includes introducing the waste stream into a feed tank, flowing the waste stream from the feed tank to an ultrafiltration module, filtering the waste stream through a membrane of the ultrafiltration module to form a lean filtrate, directing the lean filtrate from the ultrafiltration module to an ion exchange unit to remove dissolved copper and produce a treatment aqueous solution having a copper concentration lower than the copper concentration of the waste stream, backwashing the membrane ultrafiltration module to remove slurry solids from the membrane of the ultrafiltration module, and combining the removed slurry solids with the treatment aqueous solution to form a mixed discharge stream having a copper concentration suitable for discharge to the environment.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Serial No. 63 / 006,269, entitled "TREATMENT OF SLURRY COPPER WASTEWATER WITH ULTRAFILTRATION AND ION EXCHANGE," filed April 7, 2020, the entire contents of which are incorporated herein by reference. [Background technology]

[0002] Aspects and embodiments disclosed herein relate to systems and methods for reducing the concentration of one or more metal species from a waste stream, and in particular to systems and apparatus for removing one or more metal species from a chemical mechanical planarization waste slurry stream. Summary of the Invention

[0003] According to one embodiment, a method for treating an aqueous waste stream from a copper chemical mechanical polishing process, the method comprising: introducing the aqueous waste stream into a feed tank; flowing the aqueous waste stream from the feed tank to an ultrafiltration module; filtering the aqueous waste stream through a membrane of the ultrafiltration module to form a lean filtrate; directing the lean filtrate from the ultrafiltration module through an ion exchange unit to remove the dissolved copper and produce a treated aqueous solution having a copper concentration lower than that of the aqueous waste stream; backwashing the membrane ultrafiltration module to remove the slurry solids from the membrane of the ultrafiltration module; and combining the removed slurry solids with the treated aqueous solution to form a mixed discharge stream having a copper concentration suitable for discharge to the environment.

[0004] In some embodiments, the method further includes directing the solids-lean filtrate from the ultrafiltration module to a filtrate holding tank, and directing the solids-lean filtrate from the filtrate holding tank to an ion exchange unit.

[0005] In some embodiments, backwashing the ultrafiltration module comprises backwashing the membrane of the ultrafiltration module with low-solids filtrate from a filtrate holding tank.

[0006] In some embodiments, the method further comprises directing the solids-lean filtrate used to backwash the ultrafiltration module and the removed slurry solids to a backwash holding tank.

[0007] In some embodiments, the method further comprises settling the removed slurry solids in a backwash holding tank.

[0008] In some embodiments, the method further comprises directing the supernatant from the backwash holding tank to a feed tank.

[0009] In some embodiments, the method further comprises adjusting the pH of the aqueous waste stream in the feed tank.

[0010] In some embodiments, adjusting the pH of the aqueous waste stream in the feed tank comprises adjusting the pH of the aqueous waste stream to a pH of about 3.

[0011] In some embodiments, filtering the aqueous waste stream through the membrane of the ultrafiltration module includes filtering about 40 gallons per square foot of membrane area per day (GFD) through the membrane of the ultrafiltration module while maintaining an inlet pressure of the ultrafiltration module at less than about 1.5 pounds per square inch.

[0012] In some embodiments, backwashing of the ultrafiltration module is performed after a predetermined time of filtering the aqueous waste stream in each filtration and backwash cycle.

[0013] In some embodiments, introducing the aqueous waste stream into the supply tank comprises introducing the aqueous waste stream into the supply tank such that the concentration of abrasive particles having a size of 0.50 μm or greater is at least 10 6 / ml of aqueous waste stream.

[0014] According to another aspect, a method is provided for facilitating treatment of an aqueous waste stream from a copper chemical mechanical polishing process, the waste stream comprising concentrated dissolved copper and slurry solids comprising abrasive particles having a number-weighted average size of less than 0.75 μm. The method includes providing an ultrafiltration module, an ion exchange module, and a backwash holding tank, fluidly connecting the ultrafiltration module upstream of the ion exchange module, fluidly connecting the backwash holding tank to a backwash outlet of the ultrafiltration module, fluidly connecting a solids outlet of the backwash holding tank to an outlet of the ion exchange module, and fluidly connecting a supernatant outlet of the backwash holding tank to an inlet of the ultrafiltration module.

[0015] According to another aspect, a system for treating an aqueous waste stream from a copper chemical mechanical polishing process, the system comprising slurry solids including concentrated dissolved copper and abrasive particles having a number-weighted average size of less than 0.75 μm, includes a feed tank fluidly connectable to a source of the aqueous waste stream, an ultrafiltration unit having an inlet fluidly connectable to an outlet of the feed tank, an ion exchange unit containing a medium operable to remove copper from the stream passing through the ion exchange unit and having an inlet fluidly connectable to a filtrate outlet of the ultrafiltration unit, and a backwash holding tank having an inlet fluidly connectable to a backwash outlet of the ultrafiltration unit, a settled solids outlet fluidly connectable to a purified water outlet of the ion exchange unit, and a supernatant outlet fluidly connectable to the feed tank.

[0016] In some embodiments, the system further comprises a filtrate holding tank fluidly connectable between the filtrate outlet of the ultrafiltration unit and the inlet of the ion exchange unit.

[0017] In some embodiments, the system further comprises a backwash pump configured to direct filtrate from the filtrate holding tank, through the ultrafiltration unit, and to the backwash holding tank.

[0018] In some embodiments, the system further comprises a controller configured to cause the system to perform a method including introducing an aqueous waste stream into a feed tank, flowing the aqueous waste stream from the feed tank to an ultrafiltration unit, filtering the aqueous waste stream through a membrane of the ultrafiltration unit to form a solids-lean filtrate, directing the solids-lean filtrate from the ultrafiltration unit through an ion exchange unit to produce an aqueous treatment solution having a copper concentration that is lower than the copper concentration of the aqueous waste stream, backwashing the membrane of the ultrafiltration unit to remove slurry solids from the membrane of the ultrafiltration unit, and combining the removed retentate solids with the aqueous treatment solution to form a mixed effluent stream having a copper concentration suitable for release to the environment.

[0019] In some embodiments, the controller is further configured to cause the system to allow the removed slurry solids to settle in a backwash holding tank.

[0020] In some embodiments, the controller is further configured to cause the system to adjust the pH of the aqueous waste stream within the supply tank.

[0021] In some embodiments, the controller is further configured to cause the system to adjust the pH of the aqueous waste stream to a pH of about 3 in the feed tank.

[0022] In some embodiments, the controller is further configured to cause the system to filter about 40 gallons of aqueous waste stream per square foot of membrane area per day through the membrane of the ultrafiltration unit while maintaining an inlet pressure of the ultrafiltration unit at less than about 1.5 pounds per square inch. [Brief explanation of the drawings]

[0023] The accompanying drawings are not intended to be drawn to scale. In the drawings, each identical or nearly identical component illustrated in various figures is represented by the same numerical numeral. For clarity, not every component is labeled in every figure. In the following drawings: [Figure 1A] FIG. 1A illustrates the measured particle size of particles of abrasive material in a sample of waste slurry from a copper (Cu) chemical mechanical polishing (CMP) process; [Figure 1B] FIG. 1B illustrates the measured concentration of particles of abrasive material in a sample of waste slurry from a CuCMP process; [Figure 2] FIG. 2 is a schematic diagram of a CMP slurry waste treatment system in accordance with one or more embodiments of the present invention; [Figure 3] FIG. 3 illustrates the calculations for determining the total Cu concentration in the effluent from an example CuCMP slurry waste treatment system; [Figure 4] Figure 4 illustrates the system configuration used to evaluate various methods of operating the ultrafilter to filter different samples of CuCMP slurry. [Figure 5] FIG. 5 illustrates the fluid inflow and outflow directions into the ultrafilter during filtration and backwash evaluation of CuCMP slurries; [Figure 6] FIG. 6 illustrates steps in the chemically enhanced backwash of an ultrafilter used in filtration evaluation; [Figure 7A] FIG. 7A is a chart of inlet pressure versus time during operation of an ultrafilter for filtration of CuCMP slurry under a first set of conditions; [Figure 7B] FIG. 7B is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions; [Figure 7C] FIG. 7C is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions; [Figure 7D] FIG. 7D is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions; [Figure 7E] FIG. 7E is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions; [Figure 7F] FIG. 7F is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions; [Figure 7G] FIG. 7G is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions; [Figure 7H] FIG. 7H is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions; and [Figure 7I] FIG. 7I is a chart of inlet pressure versus time during operation of the ultrafilter for filtration of CuCMP slurry under another set of conditions. DETAILED DESCRIPTION OF THE INVENTION

[0024] (Detailed explanation) Semiconductor microelectronic chip (microchip) manufacturers have developed advanced manufacturing processes to shrink the electronic circuits on microchips to smaller and smaller dimensions. Smaller circuit dimensions include smaller individual minimum feature sizes or line widths on a single microchip. Reducing the minimum feature sizes or line widths allows more computer logic to be packed onto a microchip.

[0025] Many modern semiconductor manufacturing processes use copper (Cu) instead of older aluminum-based processes to form Cu microchip circuits on silicon wafers. Copper has lower electrical resistance than aluminum, which allows microchips to operate at much faster speeds with less heat generation than microchips that utilize aluminum as an electrical conductor within the microchip. Cu has been introduced into ultra-large-scale integrated (ULSI) and complementary metal-oxide-semiconductor (CMOS) silicon structures and is utilized as the interconnect material, vias, and trenches on these silicon structures. Cu is now the preferred interconnect material for fully integrated multilevel integrated circuit microchips.

[0026] ULSI silicon structures are integrated circuits containing over one million transistors, while CMOS silicon structures are integrated circuits containing n-type metal oxide semiconductor (N-MOS) and p-type metal oxide semiconductor (P-MOS) transistors on the same substrate.

[0027] Chemical-mechanical polishing (CMP) planarization of copper metal layers is used as part of many modern semiconductor manufacturing processes. CMP planarization provides a flat substrate working surface for microchips. Because current technology cannot effectively etch copper, semiconductor manufacturing equipment tools employ polishing steps to prepare the surface of silicon wafers.

[0028] Chemical-mechanical polishing of integrated circuits involves the planarization of semiconductor microelectronic wafers. Local planarization of microchips operates chemically and mechanically to smooth the surface at a fine level, down to about 10 μm. Global planarization of microchips extends to heights of about 10 μm or greater. CMP planarization equipment is used to remove material before subsequent precision integrated circuit manufacturing steps.

[0029] The CMP planarization process involves a polishing slurry consisting of an oxidizer, abrasive, complexing agent, and other additives. The polishing slurry is used in conjunction with a polishing pad to remove excess copper from the wafer. Polishing the wafer with the chemical / mechanical slurry removes silicon, copper, and various trace metals from the silicon structure. The chemical / mechanical slurry is introduced to the silicon wafer on the planarization table in combination with the polishing pad. Oxidizers and etchants are introduced to control the removal of material. A deionized water rinse is often used to remove debris from the wafer. Ultrapure water (UPW) and deionized water from reverse osmosis (RO) membranes can also be used in semiconductor manufacturing equipment tools to rinse silicon wafers.

[0030] The CMP planarization process introduces Cu into the process water, and government regulatory agencies have written stringent regulations for wastewater from the CMP planarization process, similar to those for wastewater from electroplating processes, even though CMP planarization is not an electroplating process.

[0031] It is desirable that the Cu ions in solution in the wastewater be removed from the by-product polishing slurry for acceptable wastewater treatment.

[0032] Microchip CMP planarization produces by-product "grinding" (polishing) slurry wastewater containing Cu ions at levels of approximately 1 to 100 mg / L. The by-product polishing slurry wastewater from microchip planarization also contains abrasive solids, such as silica, alumina, and / or one or more other metal oxides, sized at approximately 0.01 to 1.0 μm in diameter at levels of approximately 500 to 2000 mg / L (500 to 2000 ppm). Figures 1A and 1B illustrate the particle size and concentration of abrasive particles observed in waste slurry samples from a Cu CMP process. Sample 11194 was taken from a waste Cu polishing slurry stream after the pH was adjusted to 3.27 in a customer's system. Sample 38C was taken from a waste Cu polishing slurry stream collected before the customer's acidification step and acidified to pH 4 in the laboratory using sulfuric acid. Sample 38D was from a spent Cu polishing slurry stream collected prior to the customer's acidification step and was acidified in the laboratory to a pH of 3 using sulfuric acid. Sample 39A1 was a sample of the spent Cu polishing slurry stream spiked in the laboratory with virgin slurry (3.35 mL / L) to simulate high solids conditions. The pH of this sample after the addition of virgin slurry was 7.0. Sample 39A2 was a sample of the spent Cu polishing slurry stream, also spiked in the laboratory with virgin slurry (3.35 mL / L) to simulate high solids conditions. The pH of this sample was adjusted to pH 3 with sulfuric acid. As can be seen from the table in Figure 1, the number-weighted mean particle size for each sample without the virgin slurry spike was less than 0.75 μm.

[0033] An oxidizer consisting of hydrogen peroxide (H2O2) is typically used to help dissolve Cu from microchips during the CMP process. Thus, levels of hydrogen peroxide (H2O2) of about 300 ppm or more may also be present in by-product polishing slurry wastewater.

[0034] A chelating agent such as citric acid or ammonia may also be present in the by-product polishing slurry to facilitate keeping the Cu in solution.

[0035] CMP slurry wastewater, including the rinse stream, is discharged from some CMP tools at a flow rate of about 10 gpm and may contain dissolved Cu at concentrations of about 1 to 100 mg / L.

[0036] Fabrication facilities operating multiple tools will typically generate sufficient amounts of Cu to become an environmental concern when discharged into the fabrication facility's effluent. A treatment program is desirable to control the discharge of Cu present in CuCMP wastewater before it is introduced into the fabrication facility's wastewater treatment system.

[0037] Wastewater treatment systems in semiconductor manufacturing facilities often feature pH neutralization and fluoride treatment. "End-of-the-line" treatment systems typically do not include equipment for removing heavy metals such as Cu. An apparatus and method for providing point-source treatment for Cu removal would eliminate the need to install expensive end-of-the-line Cu treatment systems.

[0038] Considering the logistics of the equipment as well as the characteristics of the waste solutions, a point-source Cu processing equipment that is compact and can meet the emissions requirements of a single CuCMP tool or a cluster of CuCMP tools is desirable.

[0039] Ion exchange technology is effective in concentrating and removing low-level contaminants from large volumes of water. Ion exchange is also used effectively in wastewater treatment to remove specific contaminants. To economically remove specific contaminants from wastewater using ion exchange, selective resins, or resins with ion selectivity for the specific ions that must be removed, are often used. In the 1980s, many ion exchange resin manufacturers developed selective resins. These resins gained widespread acceptance due to their higher capacity and selectivity for specific ions than traditional cation and anion resins.

[0040] Cation-selective resins have demonstrated the ability to remove transition metals from solutions containing complexing agents such as gluconate, citrate, tartrate, and ammonia, as well as some weak chelating compounds. These selective resins are called chelating resins, and their ion-exchange sites grab and attach the transition metal. The chelating resin breaks the chemical bond between the complexing agent or weak chelating chemical.

[0041] Ion exchange resins are used to extract Cu ions from the solution.

[0042] Wastewater containing copper slurries can be treated with ion exchange to remove dissolved Cu. Typically, the slurries pass through the ion exchange column without clogging. However, recently, new CuCMP slurries have been utilized that have smaller abrasive particle sizes than previously utilized CuCMP slurries. The abrasive particle size distribution and concentration in the waste stream from a CMP tool using this new slurry are shown in Figures 1A and 1B, previously discussed. Waste streams from CMP tools using examples of this new type of slurry have been observed to clog ion exchange systems as they pass through. Without being bound by theory, it is believed that lowering the pH (to 3) before passing through the ion exchange system causes the abrasive particles to adhere to each other and grow, leading to clogging. Despite the ion exchange system, the pH is typically lowered to obtain better Cu removal.

[0043] In one embodiment, a system and method for ion exchange processing of Cu-containing slurries is proposed, consisting of an ultrafilter and a thickener tank. Slurry Cu waste enters the ultrafilter system. In some embodiments, the ultrafilter system is operated in filtration mode for 32 minutes and in backwash mode for 2 minutes. During backwash mode, filtrate can be back-processed through the ultrafilter system at twice the forward flow rate. In some embodiments, the backwash itself lasts approximately 0.6 minutes. For the remaining 1.4 minutes, there is no forward or backflow through the ultrafilter system. During the backwash cycle, any solids removed by the ultrafilter system are flushed from the ultrafilter system. The backwash is directed to a thickener tank, where the solids settle. Settling of the solids can occur within a few seconds. The supernatant (overflow) of the thickener tank, which is largely solid-free, can be returned to the ultrafilter. The solids can be allowed to slowly flow into the ion exchange system effluent. Although these solids still contain some Cu (e.g., about 15 mg / L), the amount is reduced sufficiently by settling not to cause a significant increase in Cu in the combined ion exchange effluent / slurry solids discharge. Assuming 0.1 mg / L of Cu in the ion exchange effluent, the Cu level after combining the settled slurry solids with the ion exchange effluent will be 0.145 mg / L, still well below the discharge target of 0.5 mg / L used in many jurisdictions.

[0044] Referring to FIG. 2, the operation of the system is as follows.

[0045] An incoming Cu-containing CMP slurry waste stream 105 is introduced into a feed tank 110. The CMP slurry waste stream 105 may have been pretreated by pH adjustment to have a pH of about 3 before being introduced into the feed tank 110. Additionally or alternatively, the CMP slurry waste stream 105 may be pH adjusted to a desired pH, e.g., about 3, in the feed tank 110 by introducing a pH adjuster 140 from a source of pH adjuster (e.g., sodium hydroxide sulfuric acid) into the feed tank 110. During downflow operation, the Cu slurry waste flows from the feed tank 110 through a feed pump 115 into the ultrafilter module 120. The Cu slurry waste is filtered through the membrane of the ultrafilter module 120, producing a low-solids filtrate. In some embodiments, the membrane of the ultrafilter module 120 is a polyethersulfone membrane having a pore size of 0.02 μm. The filtrate from the ultrafilter 120 is directed to a filtrate holding tank 125, from which it is pumped through a Cu ion exchange system 130. The Cu ion exchange system 130 may utilize a resin such as LEWATIT® TP207 weakly acidic, macroporous ion exchange resin with chelating iminodiacetic acid groups (Sybron Chemicals Inc., a LANXESS Company, Birmingham, NJ), or other resins and / or system components such as those disclosed in U.S. Pat. No. 7,488,423, which is incorporated herein by reference, and may be operated as disclosed therein.

[0046] At set intervals (e.g., every 32 minutes), the ultrafilter is backwashed using filtrate from the filtrate holding tank 125. The backwash, which contains the slurry solids removed by the ultrafilter 120, is directed to the backwash holding tank 135, which operates much like a sludge thickener tank. As the solids are collected, they are allowed to settle. The resulting supernatant liquid is returned to the feed tank 110. Because the supernatant liquid may contain some residual solids, it is sent to the feed tank 110 rather than to the ion exchange system 130.

[0047] The solids in the backwash holding tank 135 settle. The concentrated / settled solids are then pumped at a controlled rate to the ion exchange system effluent, where they are recombined with the now Cu-free (or essentially Cu-free, e.g., having 0.1 mg / L or less of dissolved Cu) effluent from the ion exchange system 130 and discharged. While the solids still contain some leachable Cu, their amounts have been significantly reduced so that the Cu in the combined effluent is insignificant, and the combined effluent may be discharged to the environment in many jurisdictions.

[0048] The solids, still containing infiltrated Cu, are concentrated in the backwash holding tank 135. Calculations indicate that when the solids are reintroduced, the overall Cu level in the ion exchange system effluent increases only slightly. Calculations for an example system are shown in FIG. 3, which show that when fed with a waste stream containing 15 mg / L of Cu, the total concentration of Cu in the final combined effluent from the system is 0.145 mg / L, less than 1% of the initial concentration in the waste stream.

[0049] The system may include a computerized controller 145 that controls the system's different valves V, pumps, and sources of pH adjusters 140 to carry out the method embodiments disclosed herein. Connections between the controller 145 and the valves, pumps, and sources of pH adjusters are not shown for ease of illustration. [Example]

[0050] Example - Ultrafiltration Test (Sample description) Several CuCMP slurry samples were received and evaluated. The following list details the samples (volume and label): (Sample # Volume Label) 11190 2x1L D1X SCW Slurry Sample 11193 1x55gal Influent 11245 1x55gal D1X SCW influent, pH approximately 9.5 11244 1x2.5gal D1X SCW Slurry Sample (PL8109)-1A 11245 1x2.5gal D1X SCW Slurry Sample (PL8109)-1B 11246 1x2.5gal D1X SCW Slurry Sample (Cu4545)-2A 11247 1x2.5gal D1X SCW Slurry Sample (Cu4545)-2B

[0051] (Explanation of ultrafilter) The ultrafilter used to evaluate the treatment methods for the different test samples contained a single multibore polyethersulfone tube with seven 9 mm channels.

[0052] Below is a general description of the ultrafilter used in the tests: A diagram of the experimental setup is shown in Figure 4. (Ultrafilter - membrane) - Structural material: Polyethersulfone (PES) - Quantity 1 - Total surface area: 1.07 sq ft - Inflow pump type: positive displacement - Backwash pump type: positive displacement (Operation parameters) - Back Pulse Frequency (min) 30 to 120 - Back Pulse Flow Rate (GFD) 135 - Inlet Flow Rate (GFD) 35 to 40 (operating mode) Several operating conditions were considered: - Standard operation: Deadhead type operation, producing only a filtrate stream. This is a 32 minute cycle with a 36 second backwash. - Extended run: Deadhead type operation, producing only a filtrate stream. 2-hour cycle including a deionized water rinse (to ensure the solids removed in the backwash are copper-free) and a deionized water backwash. - Long-run flow-through: A side stream is recirculated from the concentrate back to the inlet at approximately 25% of the total flow rate over a 2-hour cycle. Another rinse with deionized water removes copper from the solids. The direction of fluid flow into and out of the ultrafilter during filtration and backwashing is shown in FIG.

[0053] (Chemically Enhanced Backwash) Once the inlet pressure reached approximately 12 PSI, the membrane was cleaned. The cleaning performed during the ultrafiltration test was a chemically enhanced backwash, or CEB for short. Typically, this involves taking a portion of the filtrate and adjusting it to a pH of 12 with sodium hydroxide and / or a pH of 2 with sulfuric acid. These solutions are then used as the CEB solution. There is a soaking period of 5 to 60 minutes, after which the membrane is backwashed again using regular filtrate and the operating process is resumed.

[0054] However, for this test, some modifications were made due to the presence of Cu in the filtrate, and the modified process is detailed below. - Run deionized water through the system for 10 minutes. - Backwash with sodium hydroxide solution. - Soak for 5 to 60 minutes. - Rinse with deionized water. - Backwash with sulfuric acid solution. - Soak for 5 minutes. - Rinse with deionized water. - Restart operation (if changing conditions, run the base synthetic solution for a few hours to ensure the CEB was successful). This chemically enhanced backwash step is shown in FIG.

[0055] (Operating conditions) The first few conditions tested were to determine feasibility for use in ultrafiltration.

[0056] (Condition 1) - Base solution: Sample #11225 - Spiking solution: 3.35mL / L slurry sample #11190 - pH: From original pH to pH 6.96 - Backwash frequency: 32 minutes - Flow: 43GFD - Total driving time: 4 hours

[0057] [Table 1]

[0058] (Condition 2) - Base solution: Sample #11225 - Spiking solution: 3.35mL / L slurry sample #11190 - pH: 3 (sulfuric acid is used to lower the pH) - Backwash frequency: 32 minutes - Flow: 43GFD - Total driving time: 4 hours

[0059] [Table 2]

[0060] (Condition 3) - Test objective: To determine whether UF is a viable alternative to microfiltration. - Base solution: deionized water with the addition of copper sulfate and peroxide, followed by synthetic samples. - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH: 3 (requires 14 mg / L sulfuric acid) - Backwash frequency: 32 minutes - Flow: 38GFD - Total driving time: 10 hours

[0061] [Table 3-1] [Table 3-2] [Table 3-3]

[0062] A chart of inlet pressure versus time for the ultrafilter operated under condition 3 is shown in Figure 7A. The inlet pressure increased with each subsequent filtration run, reaching a maximum of 12 psi after 8 hours / four filtration and three backwash runs.

[0063] (Condition 4) - Test objective: To extend the operating time between backwashes - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 120 minutes - Flow: 38GFD - Total driving time: 9 hours 40 minutes

[0064] [Table 4-1] [Table 4-2] [Table 4-3]

[0065] A chart of inlet pressure versus time for the ultrafilter operated under condition 4 is shown in Figure 7B. The inlet pressure increased with each subsequent filtration run, reaching a peak of over 12 psi after approximately 10 hours / 5 filtration and 4 backwash runs.

[0066] (Condition 5) - Test objective: Determine whether flow-through mode will prolong operation - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 120 minutes - Flow: 38GFD - Total driving time: 8 hours

[0067] [Table 5-1] [Table 5-2] [Table 5-3]

[0068] A chart of inlet pressure versus time for the ultrafilter operated under condition 5 is shown in Figure 7C. The inlet pressure increased with each subsequent filtration run, reaching a maximum value of nearly 12 psi after approximately 8 hours / four filtration and three backwash runs.

[0069] (Condition 6) - Test purpose: Standard operating mode - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 32 minutes - Flow: 38GFD

[0070] [Table 6-1] [Table 6-2] [Table 6-3]

[0071] A chart of inlet pressure versus time for an ultrafilter operated under condition 6 is shown in Figure 7D. The inlet pressure initially increases with each subsequent filtration run, remaining stable at about 1.2 to 1.3 psi between 4 and 16 hours of operation, and then begins to increase with subsequent runs, reaching a peak of just over 1.4 psi after about 18 hours / 34 filtration and 33 backwash runs.

[0072] (Condition 7) - Test objective: Standard operating mode with backwash supernatant decanted into the supply tank - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 32 minutes - Flow: 40GFD

[0073] [Table 7-1] [Table 7-2] [Table 7-3] [Table 7-4] [Table 7-5]

[0074] A chart of inlet pressure versus time for an ultrafilter operated under Condition 7 is shown in Figure 7E. In this chart, data from 21.91 hours to 27.31 hours is invalid due to a gauge failure. It can be seen that the maximum inlet pressure at the end of each filtration run remained fairly stable at about 1.5 psi, with many filtration runs reaching a lower maximum inlet pressure between hours 7 and 13 of operation.

[0075] (Condition 8) - Test objective: Determine if reconstitution of all backwash solids will increase inlet pressure or affect longevity of operation. Standard operating mode with backwash supernatant decanted into the feed tank. Backwash solids were collected and added to the feed. - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 32 minutes - Flow: 40GFD

[0076] [Table 8-1] [Table 8-2] [Table 8-3]

[0077] A chart of inlet pressure versus time for the ultrafilter operated under condition 8 is shown in Figure 7F. The maximum inlet pressure initially increased to about 10 psi for the subsequent filtration runs, but then decreased and remained fairly stable at about 8 psi for the subsequent filtration runs.

[0078] (Condition 9) - Test objective: Determine whether operation for 1 hour between backwashes is feasible. - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 60 minutes - Flow: 40GFD

[0079] [Table 9-1] [Table 9-2] [Table 9-3]

[0080] A chart of inlet pressure versus time for the ultrafilter operated under Condition 9 is shown in Figure 7G. The inlet pressure increased with each subsequent filtration run, reaching a peak of over 10 psi after approximately 16 hours / 16 filtration and 15 backwash runs.

[0081] (Condition 10) - Test objective: To investigate the effect of biogrowth accumulation, the backwash supernatant is decanted into the feed tank and the standard operating mode is repeated. - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 32 minutes - Flow: 40GFD

[0082] [Table 10-1] [Table 10-2] [Table 10-3] [Table 10-4] [Table 10-5]

[0083] A chart of inlet pressure versus time for the ultrafilter operated under condition 10 is shown in Figure 7H. The inlet pressure increased with each subsequent filtration run, reaching a peak of 10.75 psi after approximately 28.5 hours of operation.

[0084] (Condition 11) - Test objective: To determine if the addition of biocide will prevent biological growth and will not impair inlet pressure or operating life. - Base solution: deionized water with added copper and peroxide - Spiking solution: Slurry samples #11244 and #11245 were used at 3.35 mL / L each. - pH:6 - Backwash frequency: 32 minutes - Flow: 40GFD

[0085] [Table 11-1] [Table 11-2] [Table 11-3] [Table 11-4]

[0086] A chart of inlet pressure versus time for the ultrafilter operated under condition 11 is shown in Figure 7I. The inlet pressure increased with each subsequent filtration run, reaching a maximum value of between 6.0 and 6.5 psi after approximately 26 hours of operation.

[0087] The above examples have demonstrated the effectiveness of the disclosed ultrafilter for filtering aqueous waste streams from a copper chemical mechanical polishing process containing concentrated dissolved copper and slurry solids including abrasive particles having a number-weighted average size of less than 0.75 μm, and for restoring filter porosity and inlet pressure by backwashing or chemical cleaning. Operation under at least some conditions, e.g., Conditions 6 and 7, provided that the ultrafilter recovers with each backwash, maintaining a maximum inlet pressure during filtration of less than about 1.5 psi over an extended number of filtration and backwash cycles.

[0088] The phraseology and terminology used herein are for purposes of description and should not be considered limiting. As used herein, the term "plurality" refers to two or more items or components. The terms "comprising," "including," "carrying," "having," "containing," and "involving," regardless of written description or claims, are open-ended terms, i.e., meaning "including but not limited to." Thus, the use of such terms is intended to encompass the subsequently listed items, and equivalents thereof, as well as additional items. Only the transitional phrases "consisting of" and "consisting essentially of" are closed or semi-closed transitional phrases, respectively, with respect to the claims. The use of ordinal numbers such as "first," "second," and "third" in the claims to modify claim elements does not, per se, imply a priority, precedence, or chronological order in which the actions of a method are performed of a claim element relative to other elements, but is merely used as a label to distinguish a claim element having a certain name from other elements having the same name (but using an ordinal number).

Claims

1. 1. A method for treating an aqueous waste stream from a copper chemical mechanical polishing process comprising slurry solids comprising concentrated dissolved copper and abrasive particles having a number weighted average size of less than 0.75 μm, comprising: introducing an aqueous waste stream into a supply tank; flowing the aqueous waste stream from the supply tank to an ultrafiltration module; filtering the aqueous waste stream through a membrane of an ultrafiltration module to form a low-solids filtrate; directing the lean filtrate from the ultrafiltration module to a filtrate holding tank; directing the lean filtrate from the filtrate holding tank to an ion exchange unit to remove dissolved copper and produce a treated aqueous solution having a copper concentration that is lower than the copper concentration of the aqueous waste stream; backwashing the membrane ultrafiltration module to remove slurry solids from the membrane of the ultrafiltration module, where backwashing the ultrafiltration module includes backwashing the membrane of the ultrafiltration module with solids-lean filtrate from the filtrate holding tank; directing the lean filtrate used to backwash the ultrafiltration module and the removed slurry solids to a backwash holding tank; allowing the removed slurry solids to settle in a backwash holding tank; and combining the removed slurry solids with the treated aqueous solution to form a mixed effluent stream having a copper concentration of less than 0.5 mg / L for discharge to the environment. A method comprising:

2. 10. The method of claim 1, further comprising directing the supernatant from the backwash holding tank to a feed tank.

3. 10. The method of claim 1, further comprising adjusting the pH of the aqueous waste stream in the feed tank.

4. 4. The method of claim 3, wherein adjusting the pH of the aqueous waste stream in the feed tank comprises adjusting the pH of the aqueous waste stream to a pH of 3.

5. 10. The method of claim 1, wherein filtering the aqueous waste stream through the membrane of the ultrafiltration module comprises filtering 150 liters of the aqueous waste stream per square foot of membrane area per day through the membrane of the ultrafiltration module while maintaining an inlet pressure of the ultrafiltration module below 10.3 kPa.

6. 10. The method of claim 1, wherein backwashing of the ultrafiltration module occurs after a predetermined period of filtering the aqueous waste stream in each filtration and backwash cycle.

7. introducing the aqueous waste stream into the supply tank to a concentration of said abrasive particles having a size of 0.50 μm or greater of at least 10 ６ 10. The method of claim 1, comprising introducing an aqueous waste stream having a concentration of 0.15 to 0.5 ml / ml.

8. 1. A system for treating an aqueous waste stream from a copper chemical mechanical polishing process, comprising slurry solids including concentrated dissolved copper and abrasive particles having a number weighted average size of less than 0.75 μm, comprising: a supply tank fluidly connected to a source of the aqueous waste stream; an ultrafiltration unit having an inlet fluidly connected to the outlet of the supply tank; an ion exchange unit containing a medium operable to remove copper from a stream passing through the ion exchange unit, the ion exchange unit having an inlet fluidly connected to the filtrate outlet of the ultrafiltration unit; a filtrate holding tank fluidly connected between the filtrate outlet of the ultrafiltration unit and the inlet of the ion exchange unit; a backwash holding tank having an inlet fluidly connected to the backwash outlet of the ultrafiltration unit, a settled solids outlet fluidly connected to the purified water outlet of the ion exchange unit, and a supernatant outlet fluidly connected to the feed tank; a backwash pump configured to direct filtrate from the filtrate holding tank, through the ultrafiltration unit, and to the backwash holding tank; Including, the system.

9. 9. The system of claim 8, comprising: introducing an aqueous waste stream into a supply tank; flowing the aqueous waste stream from the supply tank to an ultrafiltration unit; filtering the aqueous waste stream through a membrane in an ultrafiltration unit to form a low-solids filtrate; directing the lean filtrate from the ultrafiltration unit through an ion exchange unit to produce a treated aqueous solution having a copper concentration that is less than the copper concentration of the aqueous waste stream; backwashing the membrane of the ultrafiltration unit to remove slurry solids from the membrane of the ultrafiltration unit; and combining the removed and retained solids with the treated aqueous solution to form a mixed effluent stream having a copper concentration of less than 0.5 mg / L for discharge to the environment. The system further includes a controller configured to cause the system to perform a method including:

10. 10. The system of claim 9, wherein the controller is further configured to cause the system to settle the removed slurry solids in a backwash holding tank.

11. The system of claim 10 , wherein the controller is further configured to cause the system to adjust the pH of the aqueous waste stream in the supply tank.

12. 12. The system of claim 11, wherein the controller is further configured to cause the system to adjust the pH of the aqueous waste stream in the supply tank to a pH of 3.

13. 13. The system of claim 12, wherein the controller is further configured to cause the system to filter 150 liters of aqueous waste stream per square foot of membrane area per day through the membrane of the ultrafiltration unit while maintaining an inlet pressure of the ultrafiltration unit below 10.3 kPa.

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