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Industrial Pretreatment Technology 2006 Pacific Northwest Pretreatment Conference – Sept. 28, 2006 By Stephen G. Edward, PE For Printed Circuit Board Manufacturing.

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Presentation on theme: "Industrial Pretreatment Technology 2006 Pacific Northwest Pretreatment Conference – Sept. 28, 2006 By Stephen G. Edward, PE For Printed Circuit Board Manufacturing."— Presentation transcript:

1 Industrial Pretreatment Technology 2006 Pacific Northwest Pretreatment Conference – Sept. 28, 2006 By Stephen G. Edward, PE For Printed Circuit Board Manufacturing at Merix Corporation in Forest Grove, Oregon

2 2 Merix Corporation - Industrial Pretreatment Technology AGENDA 1.Merix Corporation 2.Circuit Board Manufacturing 3.Industrial Wastewater Pretreatment 4.Lessons Learned and Keys to a Successful Compliance Program

3 3 History Merix Forest Grove facility built in 1982 as the Circuit Board Division of Tektronix. Market changed from captive to merchant providing small to medium volumes of high quality / high tech boards in test, internet server, and communications equipment. Spun off into separate entity as Merix Corporation in Started up a new mass lam facility in Wood Village in In 2004, added an ultra-short lead time facility in California. In 2005, added five commodity facilities in Asia. Merix Corporation - Industrial Pretreatment Technology

4 4 Merix Corporation Today Merix Corporation - Industrial Pretreatment Technology

5 5 Merix Corporation Today Merix is a leading manufacturer of technologically advanced, multilayer, rigid printed circuit boards for use in sophisticated electronic equipment. Merix provides quick-turn prototype, pre-production and volume board production to its customers. Principal markets served by Merix include data communications and wireless telecommunications, automotive, high-end computing, and test and measurement end markets in the electronics industry. Merix Corporation - Industrial Pretreatment Technology

6 6 Printed Circuit Board Manufacturing Each design custom – Design Review Laminate / Prepreg Imaging Processes Mechanical Processes Plating Processes Finishing Processes Typical Bare Printed Circuit Board Assay Merix Corporation - Industrial Pretreatment Technology

7 7 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

8 8 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

9 9 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

10 10 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

11 11 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

12 12 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

13 13 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

14 14 Printed Circuit Board Manufacturing Merix Corporation - Industrial Pretreatment Technology

15 15 Printed Circuit Board Business Challenges Global Competition Rapid Evolution of products and processes. Typical Oregon Products – –Order Size: 1-20 Panels – –Copper Layers: < 40 – –Mixed Dielectrics – –Blind and Buried Vias – –Embedded passives – –Heat Sinks Merix Corporation - Industrial Pretreatment Technology

16 16 Wastewater Characteristics Heavy Metals (Copper, Nickel, Tin, Lead, Silver, Gold, Manganese) Chelators and Complexers Acids Bases Cyanide Soluble Photoresist Polymers COD / BOD Merix Corporation - Industrial Pretreatment Technology

17 17 Industrial Pretreatment Effective Technologies – –Neutralization (pH) – –Chemical Precipitation (Metals & Photoresist) – –Clarification (Separation of Metals & Photoresist) – –Ion Exchange (Metals, including gold cyanide complex) – –Reverse Osmosis (Small dissolved solids) – –Ultrafiltration (Polymers) For efficiency, Use Appropriate Wastewater Segregation Merix Corporation - Industrial Pretreatment Technology

18 18 Merix – FG Permit Requirements Daily Flow Proportional Sampling and Analysis for: – –Metals: Ag, Cd, Cr, Cu, Mn, Pb, Ni, Zn. – –Chemical Oxygen Demand. Continuous analysis of pH. Weekly analysis for CN. Semi-annual analysis for Sulfate. Periodic analysis for TTO. Merix Corporation - Industrial Pretreatment Technology

19 19 Merix – FG Wastewater Pretreatment Facility Merix Corporation - Industrial Pretreatment Technology

20 20 Merix – FG Wastewater Pretreatment Facility Merix Corporation - Industrial Pretreatment Technology

21 21 Merix – FG Wastewater Pretreatment Facility Merix Corporation - Industrial Pretreatment Technology

22 22 Industrial Pretreatment Example 1 for Copper Wastewater Description: – –[Cu] = 50 mg/L – –Not chelated or complexed Treatment Technology: – –Adjust pH to 8.9 – –Add polymer and/or flocculant – –Clarify Results: – –[Cu] < 0.5 mg/L Complies with Permit Limits Merix Corporation - Industrial Pretreatment Technology

23 23 Industrial Pretreatment Example 2 for Copper Wastewater Description: – –[Cu] = 50 mg/L – –Chelated or complexed Treatment Technology: – –Adjust pH to 8.9 – –Add polymer and/or flocculant – –Clarify Results: – –[Cu] > 5 mg/L Exceeds Permit Limits Merix Corporation - Industrial Pretreatment Technology

24 24 Industrial Pretreatment Example 3 for Copper Wastewater Description: – –[Cu] = 50 mg/L – –Chelated or complexed Treatment Technology: – –Add Ferrous Sulfate or Sulfide Chemistry – –Adjust pH to 8.9 – –Add polymer and/or flocculant – –Clarify Results: – –[Cu] < 2 mg/L Complies with Permit Limits Merix Corporation - Industrial Pretreatment Technology

25 25 Industrial Pretreatment Example 4 for Copper Wastewater Description: – –[Cu] = 50 mg/L – –Chelated or complexed Treatment Technology: – –Pass through Ion Exchange Resin Results: – –[Cu] < 0.2 mg/L Complies with Permit Limits Merix Corporation - Industrial Pretreatment Technology

26 26 Industrial Pretreatment Example 5 for Copper Wastewater Description: – –[Cu] = 50 mg/L – –Chelated or complexed – –Contains Dissolved Photoresist Polymer Treatment Technology: – –Pass through Ion Exchange Resin Results: – –Initial: [Cu] < 0.2 mg/L Complies with Permit Limits – –Later: [Cu] = 50 mg/L Exceeds Permit Limits Merix Corporation - Industrial Pretreatment Technology

27 27 Industrial Pretreatment Example 6 for Copper Wastewater Description: – –[Cu] = 50 mg/L, Chelated or complexed – –Contains Dissolved Photoresist Polymer Treatment Technology: – –Lower pH < 5.5 – –Add Ferrous Sulfate or Sulfide Chemistry – –Raise pH to 8.9 – –Add polymer and/or flocculant and Clarify Results: – –[Cu] < 2 mg/L Complies with Permit Limits Merix Corporation - Industrial Pretreatment Technology

28 28 Industrial Pretreatment Keys Segregation Strategies Unplanned chelation or complexing. Unanticipated Photoresist impacts – –Clogging of pumps and filters. – –Coating of probes and other critical control devices. – –Coating of resin. Human Beings – –Flexible, but, subject to Errors. Merix Corporation - Industrial Pretreatment Technology

29 29 How Are We Doing? 2002: Zero Violations. 2003: Zero Violations. 2004: Three minor Permit Limit exceedances. 2005: Zero Violations to date: One paperwork Violation. Merix Corporation - Industrial Pretreatment Technology

30 30 Plan for Success Unless there is no chance for an upset, applied IP Technology should be flexible. Think stable and forgiving! Use effective administrative programs: Chemical pre- screening. Recruit and Retain quality personnel. Continuously improve education of personnel. Recognize and reward superior performance. Wastewater segregation strategy should anticipate potential upsets and errors. Merix Corporation - Industrial Pretreatment Technology

31 31 Ease of Control & Monitoring Merix Corporation - Industrial Pretreatment Technology

32 32 Ease of Control & Monitoring Merix Corporation - Industrial Pretreatment Technology

33 33 Storage for Segregation & Equalization Merix Corporation - Industrial Pretreatment Technology

34 34 Plan for Success (cont.) Benchmark to identify unknown options. – –Share environmental successes with competitors and learn from them. – –Enhanced industry performance helps minimize negative public perceptions. Institutionalize successful methods. – –Properly implemented, an EMS will enhance compliance systems. – –Merix uses the ISO International Standard as model for site Environmental Management Systems. Merix Corporation - Industrial Pretreatment Technology

35 35 Summary Must understand the manufacturing operations and its requirements. Need to understand the limitations of the specific IP Technology in the context of its application. Implement Systems that minimize surprises and the opportunity for errors. Select and retain the right quality of employees. Institutionalize continuous improvement. Merix Corporation - Industrial Pretreatment Technology

36 36 Questions? Merix Corporation - Industrial Pretreatment Technology


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