IPA Purification via Ion Exchange and Membrane Dehydration
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Solution Overview
Problem
Conventional methods for purifying isopropyl alcohol (IPA) in semiconductor manufacturing face challenges such as high energy consumption, large-scale equipment requirements, and inefficiencies in removing water and ionic impurities, leading to increased costs and environmental loads.
Innovation Solution
A method and apparatus combining first ion exchange treatment, membrane dehydration, distillation, and second ion exchange treatment to remove impurities like water, ionic impurities, metals, and fine particles from IPA, utilizing ion exchange resins and membranes to achieve high-purity IPA recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a distillation method is used to purify alcohol to predetermined purity, then the purity of alcohol is improved, but large-scale distillation equipment is required and enormous energy is consumed
Solution Approach 1:
The purification process is divided into multiple sequential steps: first ion exchange treatment, membrane dehydration, distillation, and second ion exchange treatment. Each step removes specific types of impurities, allowing the use of smaller, more efficient equipment for each function rather than one large distillation system, thereby reducing overall energy consumption while achieving high purity
Solution Approach 2:
Ion exchange resins and membranes are introduced as intermediary substances to remove impurities before distillation. These intermediaries selectively capture water and ionic impurities, reducing the burden on the distillation step and lowering the energy required for purification
2Manufacturing precision
If a distillation method is used to purify alcohol to predetermined purity, then the purity of alcohol is improved, but large-scale equipment is required and equipment cost increases
Solution Approach 1:
The single large distillation equipment is segmented into multiple smaller units performing different functions: ion exchange columns, membrane dehydration units, and smaller distillation equipment. This segmentation reduces equipment scale and complexity while maintaining purification effectiveness
Solution Approach 2:
Mechanical distillation is partially replaced with chemical and physical separation methods (ion exchange and membrane dehydration). These alternative mechanisms remove impurities without requiring large-scale thermal processing equipment, reducing both equipment size and complexity
3Manufacturing precision
If conventional purification methods are used, then alcohol purity is improved, but ionic impurities and water removal efficiency is insufficient
Solution Approach 1:
Ion exchange resins serve as intermediary substances that selectively bind and remove ionic impurities from the alcohol solution. The membranes act as intermediaries to separate water molecules based on size and polarity. These intermediaries provide reliable and efficient removal of specific impurity types that conventional methods cannot effectively address
Solution Approach 2:
Membranes with specific pore structures are used to physically separate water and impurities from alcohol molecules. The porous structure allows selective passage of molecules based on size and properties, ensuring efficient and reliable removal of water and ionic impurities while maintaining high alcohol purity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces energy consumption and equipment costs while achieving high-purity IPA, extending membrane life and ensuring efficient removal of impurities, thereby reducing the environmental impact and manufacturing costs.
Implementation Method 1
a step of performing dehydration treatment using a dehydration membrane on the liquid treated in the first ion exchange step
Implementation Method 2
separation in a case where the fluid in contact with the membrane is in a gas phase is particularly referred to as the vapor permeation method
Implementation Method 3
a first ion exchange step of performing ion exchange treatment on an alcohol-containing liquid
Implementation Method 4
a distillation step of performing distillation on the dehydration-treated liquid
Data Source
AI summary
A method of purifying an alcohol, such as isopropyl alcohol, includes a first ion exchange step of performing ion exchange treatment on an alcohol-containing liquid; a step of performing dehydration treatment using a dehydration membrane on the liquid treated in the first ion exchange step; a distillation step of performing distillation on the dehydration-treated liquid; and a second ion exchange step of further performing ion exchange treatment on the liquid obtained in the distillation step to obtain a purified alcohol.