Project overview: Aqua Membranes saves 29% energy and Lasts 4X longer than Industry Standard

Location: Micron Boise

Application type: UPW Wastewater RO

Semiconductors, also known as “microchips,” are used in virtually every sector of electronic devices and may act as both insulators and conductors to either impede or allow the flow of electrical charge. The global semiconductor market is projected to be worth close to $1 trillion by 2033, up from $530 billion in 2023.

The semiconductor industry produces over a trillion memory chips annually and can require as much as 2,200 gallons per chip of ultra-pure water (UPW) in the manufacturing process. Ultra-pure water eliminates the chance for contaminants to contact the chip’s surface, preserving the quality of the finished product. The production of UPW can consume massive electricity, so by increasing the efficiency of reverse osmosis membranes used in UPW production, companies can reduce their energy use and cost.

Micron Technology targets energy use reduction to reach decarbonization goals

Micron Technology, a leader in memory chip manufacturing, uses reverse osmosis (RO) to achieve the level of water purity demanded by the company’s high-quality standards. Reverse osmosis is a water separation and decontamination method that uses pressure to push water through a semi-permeable membrane. In a typical RO element, sheets of membrane are spiraled around a center tube separated by a feed channel mesh, creating ample surface area for clean water to be made. With Aqua Membranes, printed features keep the sheets apart and allow feed water to flow freely across the membrane.

Micron’s 2030 sustainability goals include a 42% reduction in direct greenhouse gas emissions, a 75% water conservation rate and a 95% reuse, recycling and recovery rate for waste, with an aspiration to achieve zero hazardous waste to landfill. The company faced a significant challenge in its UPW/wastewater treatment systems that can use millions of gallons of water daily, high energy demand and limited membrane life for RO systems. To help the company meet its greenhouse gas emission reduction, water conservation, waste
reduction and energy efficiency goals, Micron needed a better solution for its water treatment processes.

The Solution: Printed Spacer Technology® from Aqua Membranes

Micron decided to test innovative Printed Spacer Technology® from Aqua Membranes to reduce the energy demands of their UPW/wastewater treatment reverse osmosis systems. This revolutionary technology promised to reduce energy consumption and decrease membrane fouling, offering a more efficient and cost- effective solution.

Unlike typical mesh feed channels, Aqua Membrane spacers are 3D printed directly on the membrane, taking up far less space and eliminating the need for the spacers to be connected to one another. Because these spacers are optimally spaced and occupy significantly less volume in the feed channel, fouling and scaling from spacer to spacer are minimized, slowing the rate of bulk fouling and reducing pressure drop.

A slower rate of fouling allows for longer intervals between cleaning, which results in lower maintenance costs and longer membrane life. A reduction in pressure drop results in greater energy savings and reduced emissions. Customers using reverse osmosis with Aqua Membranes technology waste less membrane supply, labor, energy and water, all of which improve profitability and sustainability.

Results: Two Stages of Testing

Over two years, Aqua Membranes conducted extensive testing at Micron’s Boise, Idaho, fabrication plant. The pilot included a head-to-head comparison between Aqua Membranes’ Printed Spacer Technology® and standard reverse osmosis with traditional mesh element architecture, with the base reverse osmosis membrane type being the same for both cases. The testing was divided into two stages.

In Stage 1, baseline establishment testing revealed dramatic reductions in both the fouling of the membrane and the use of energy. This system ran continuously 24 hours per day from April 2023 through January 2024.

Fouling Reduction: The printed spacers reduced the rate of differential pressure (DP) increase by 4x
compared to mesh spacers, indicating significantly less fouling.
Energy Savings: Initial tests showed a 19% energy reduction, increasing to 22% over a year.

In Stage 2, an improved pattern and element design were tested and Aqua Membranes elements showed 29% energy savings at startup, which increased to 37% over two months. The rate of DP increase showed a 4x improvement, similar to Stage 1. This system continues to operate 24 hours per day as part of the product water system at Micron’s Boise plant and the savings continue to increase.

Printed Spacer Technology® from Aqua Membranes has proven to be a game-changer for the semiconductor manufacturing industry. With unmatched substantial energy savings and improved membrane longevity, this technology supports environmental goals and offers a cost-effective solution for large-scale operations, demonstrating its scalability and practicality.

“Data doesn’t lie, and data like this shows the massive benefit of printed spacers,” said Andrew Byrnes, from the Micron Ventures team.

With Aqua Membranes, Micron was able to dramatically improve performance and reduce energy and maintenance costs. Based on the success of the Boise pilot, Micron is exploring expanding its usage of Aqua Membranes’ Printed Spacer Technology® throughout its manufacturing network.

Printed Spacer Technology® from Aqua Membranes Helps Micron Reduce Emissions and Extend Life of Reverse Osmosis System