Team TPR Group Work

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CASE ANALYSIS: Clean Energy is a Dirty Business 

1. Introduction. Identify the key problems and issues in the case study.  Formulate and include a
thesis statement, summarizing the outcome of your analysis in 1–2 sentences.

In the case study presented entitled “Clean Energy is a Dirty Business”, what is
generally shown is how the Bituin Marikit Corporation tries to solve the pressing problem on how
to qualify the use of recovered polyethylene glycol (PEG) and silicon carbide (SiC) used in ingot
slicing. They have already been trying for many weeks to come up with a solution for this
predicament. 

The company basically produces solar wafers through the use of silicon ingot slicing
machines. However, the silicon ingot wafering operation was indeed a very challenging process.
Because of the large amount of abrasive slurry material per month produced from making the
solar wafers, the company had to develop a strategy to dispose or make use of this byproduct.
One of its strategies was to reuse the SiC/PEG abrasive slurry a number of times to reduce the
wafering cost. In the long run, the thick slurry issue became a problem that resulted in an overall
yield of 90% well below the target of 95% . Furthermore, pressures from the Chinese
competitors indicated the need to act upon this challenge to find a solution promptly in order to
reduce cost of operation to a profitable level in the next six months or the company board would
have to shut them down. Time was basically running out for the company and its employees.

Problems identified based on the BMC marketing and finance reports include the
eroding of customers' confidence because of not meeting the companies’ yield commitment for
a period of time, resulting in the need to lower the selling price per wafer. This also affected the
net income where it did not meet breakeven much less meet the companies’ ROI commitment.
It was reported by the engineering department that 2% of the cuts were “infected” by the thick
slurry issue that resulted in an overall yield of 90% well below the companies’ target of 95%.
Red proposed to have a pilot scale line that will simulate the entire process to investigate all the
technical issues before trying it out at the production level but it would be costly. They have also
investigations and projects that they are currently pursuing such as thick slurry investigation
which discusses the use of adding sodium acetate to the slurry to prevent thick slurry formation,
successfully developing an in-house process to recover the waste PEG and SiC instead of
relying to third party which would cost them less and turning the sludge to concrete hollow
blocks and polyurethane-sludge composite material.

This case study analysis agrees to the notion of pilot testing. It also supports the
presented possible solutions for the thick slurry investigations. The analysis would agree that it
would be beneficial to continue to prove the use of adding sodium acetate to the slurry to
prevent thick slurry formation, to successfully develop an in-house process to recover the waste
PEG and SiC and to turn the sludge to concrete hollow blocks. These are all possible means of
cost reduction and would allow the company to meet the targeted yield and profits. The idea is
to make use of only “virgin” materials and “virgin” + recycled materials to yield the needed
volumes. If the addition of sodium acetate proves to be a success, then the problem with thick
slurry would be eliminated. But still, it needs to be further researched within the time frame that
was given.
 This case study analysis finds that the solution for the problem must be geared towards
lessening expenses for waste disposal of the slurry materials to lessen expenses for the buying
of raw materials for production. Making use of effective means of reusing the slurry materials
will result in the absence of the cosmetic defects, equating to better yields. Finding a viable
application of the spent material on another company or industry is also of particular solution.
This will not only help in the reduction of expenses in the recycling and disposal but can also
generate additional income to the company.  Advertisements and promotions should be utilized
to make their products known to the customers. Efforts should be made to bring back customer
confidence in the company. 

2. Background. Set the scene: background information, relevant facts, and the most important
issues.  Demonstrate that you have researched the problems in this case study. 

SOLAR ENERGY

Solar energy is radiant light and heat from the Sun that is harnessed using a range of
ever-evolving technologies such as solar heating, photovoltaics, solar thermal energy, solar
architecture, molten salt power plants and artificial photosynthesis

It is an essential source of renewable energy, and its technologies are broadly

characterized as either passive solar or active solar depending on how they capture and
distribute solar energy or convert it into solar power. Active solar techniques include the use of
photovoltaic systems, concentrated solar power, and solar water heating to harness the energy.
Passive solar techniques include orienting a building to the Sun, selecting materials with
favorable thermal mass or light dispersing properties, and designing spaces that naturally
circulate air.

In a review conducted by Kannan and Vakeesan, (2016) entitled Solar energy for future
world: - A review states that the solar industry is developing steadily all over the world because
of the high demand for energy while major energy source, fossil fuel, is limited and other
sources are expensive. It has become a tool to develop the economic status of developing
countries and to sustain the lives of many underprivileged people as it is now cost effective after
a long aggressive research done to expedite its development. The solar industry would
definitely be a best option for future energy demand since it is superior in terms of availability,
cost effectiveness, accessibility, capacity and efficiency compared to other renewable energy
sources.

SOLAR WAFERING

A solar wafer is a thin slice of a crystalline silicon (semiconductor), which works as a

substrate for microeconomic devices for fabricating integrated circuits in photovoltaics (PVs) to
manufacture solar cells. This is also called as Silicon wafer. This wafer is very vital to
photovoltaic production as well as to the power generation system of PV to convert sunlight
energy directly into electrical energy.
The formation of wafers happens with highly pure (99.9999999% purity), almost defect-
free single crystalline material. The solar market predominantly has polysilicon and silicon
wafers. However, other types of wafers such as Monocrystalline and Multicrystalline are also
used to fulfill the specific demand of customers.
According to Richter, Benick, Feldmann, Fell, Hermle and Glunz, (2017) in their study
about n-Type Si solar cells with passivating electron contact, identifying the sources for
efficiency limitations by wafer thickness and resistivity variation and knowing the result of this
work which demonstrates not only the potential of the cell structure, but also the variation of the
wafer thickness and resistivity at device level, can provide deep insights into the cell
performance.

However, Joshi, K., Ananya, Bhandarkar, and Joshi, S., (2017) in their paper about ultra
thin silicon wafer slicing using wire-EDM for solar cell application showed a typical wafer and
associated kerf profiles having a wider thickness at the entry and exit than the middle of the
wafer creating an increase in open voltage and a decrease in servo voltage increase the slicing
rate in frontal direction and cause a decrease in slicing rate in the lateral direction, consequently
decreasing the kerf-loss.

SILICON WAFER

Silicon is gray, brittle, tetravalent, chemical element. It makes up 27.8% of the earth’s
crust and next to oxygen, it is the most abundant element in nature. Some of the most common
materials that contain silicon are quartz, agate, flint, and common beach sand, among others. It
is the main component in building materials like cement, brick and glass. Silicon is also the most
common material to build semiconductors and microchips with. Ironically, silicon by itself does
not conduct electricity very well; however, it can take on dopants precisely in order to control
resistivity to an exact specification.

Before a semiconductor can be built, silicon must turn into a wafer. This begins with the
growth of a silicon ingot. A single silicon crystal consists of atoms arranged in a three-
dimensional periodic pattern that extends throughout the material. A polysilicon crystal is formed
by many small single crystals with different orientations, which alone, cannot be used for
semiconductor devices.

 SILICON WAFER MANUFACTURING PROCESS

INGOT GROWTH

  Growing a silicon ingot can range in time from one week to one month depending
on factors such as size, quality, and specification. More than 75% of silicon wafers grow
via the Czochralski (CZ) method, in which chunks of virgin polycrystalline silicon are
placed in a quartz crucible along with small quantities of the element dopants. The
adding of dopants gives the electrical properties needed to grow ingot.

SLICING

Once the ingot has gone through its full growing process, it is ground to a size
that is slightly larger than the target size of the final silicon wafer in diameter. After
passing a number of inspections, the ingot is sliced by using a diamond edge saw. The
diamond edge saw is used not only to slice the wafers so they are slightly thicker than
the target size but also to help minimize damage to the silicon wafer.

LAPPING

After the wafer has been sliced, it gets lapped. The lapping process removes saw
marks and surface defects from the wafer. It also thins the wafer out, relieving the stress
accumulated in the slicing process.
 CLEANING

After lapping, the silicon wafers go through the process of being cleaned and
etched. Sodium hydroxide or acetic and nitric acids alleviate any microscopic cracks
and/or surface damage that may have come about during lapping.

POLISHING

The final, and arguably most crucial step is the polishing of the silicon wafer. The
polishing process takes place in a clean room where the workers wear cleanroom suits
that cover their entire bodies. A fan is also blowing that blows away any small particles
that might have accumulated before entering the clean room.

SLURRY

A slurry is a mixture of solids denser than water suspended in liquid, usually water. The
most common use of slurry is as a means of transporting solids, the liquid being a carrier that is
pumped on a device such as a centrifugal pump. The size of solid particles may vary from 1
micron up to hundreds of millimeters. The particles may settle below a certain transport velocity.
Depending on the mixture the slurry may be abrasive and/or corrosive.

AVOIDING TROUBLE WITH SLURRIES

Handling slurries (a mix of solids and liquids), should be based on experience and
experiments, not theory. Much of the knowledge obtained from pneumatic conveyors and
fluidization systems can be used in understanding slurries.

  In almost all solids processing operations, there comes a time when the engineer must
deal with a slurry (a mixture of solids and liquids). This can be in a reactor, crystallizer,
centrifuge feed tank, or a pipeline. Often, slurries can be treated as just another dense liquid,
especially when residence time is not a concern or horsepower issues have been addressed.
What sets a slurry apart from normal liquids is a longer list of physical attributes, including:
particle, size, distribution, and particle shapes, with the resulting shear, settling, and drag of the
particles. Most of the major problems encountered with slurries are due to a poor understanding
of these factors or from poorly obtained slurry experimental data. However, much of the
knowledge obtained from pneumatic conveyors and fluidization systems can be used in
understanding slurries.

 MATERIAL RECYCLING

In the study of Huang, Shin, Wang, Sun and Tao (2017) entitled strategy and technology
to recycle wafer-silicon solar modules, what is shown is a three-step process to break down Si
modules and recover various materials leaving behind almost nothing for landfill. The result
shows that the recycling process for wafer-Si modules is technically, environmentally and
financially sustainable.

Additionally, Shin, Park, J. and Park, N., (2017) in their research about  methods to
recycle silicon wafers from end-of-life photovoltaic modules and solar panels by using recycled
silicon wafers showed details of an innovative recycling process to recover silicon (Si) wafer
from solar panels and by using these recycled wafers. They fabricated Pb-free solar panels
which showed properties with the thickness of over 180 µm, resistivity of 0.5–4 Ω cm, that are
almost identical to those of commercial virgin wafers and presented an efficiency equivalent to
that of the virgin cells which is also environmental friendly because it can minimize water
consumption during the cleaning process and can eliminate the use of harmful surfactants.

3. Alternatives. Outline possible alternatives (not necessarily all of them)  Explain why
alternatives were rejected Constraints/reasons Why are alternatives not possible at this time? 

1. Landfilling

This alternative seems to be the obvious and viable solution for the time being
since landfills have a big advantage when it comes to the economy and sending trash to
the dump is almost always cheaper than incinerating it or by using conversion
technologies.  However, this will not be sustainable in the long run due to the huge
quantity that has to be disposed, around 10, 000 tons of abrasive slurry material per
month, but also because throwing away these byproducts would only cost the
corporation more than give them profit. The company would have to purchase additional
land and spend even more for excavating. It will be eventually hard to find new sites for
landfill. One must assess transport costs to get the waste to the landfill site, flooding risk
from nearby rivers and water sources, impact on the surrounding area and many other
factors. More manpower is needed to dispose the byproduct. It will only lay more waste
for the corporation. Another problem with dumping in landfills is that one is not
necessarily re-using resources, assuming that the waste just sits there. Virgin materials
have to be used to make new products, which means more mining or more
manufacturing and depletion of resources. Buying raw materials for production would
cost them more.

2. Current Recycling Process

To mitigate the eventuality of having the landfilling unsustainable in the long run,
a recycling process had to be implemented. That is, to reuse the material for several
more cycles before sending it to the landfill. However, this results to the production of
thick slurry materials, the kinds which the engineers reported of having quality issues
with roughness values above specifications and of surface stains that were eventually
traced to the quality of the abrasive slurry. Thickening of the slurry during the cutting
process results in defects such as surface stains called cosmetic defects that lower the
productivity yield of the manufacturing operation, thus affecting the profits of the
company. 

4. Proposed Solution.  Provide one specific and realistic solution. Explain why this solution was
chosen. Support this solution with solid evidence: concepts from class (text readings,
discussions, lectures) , outside research and/or personal experience (anecdotes). 

A proven study of utilizing superconducting magnetic separation in recycling abrasives

from wasted slurry can be a viable solution for application. Abrasives have been recovered from
the slurry wasted in the factory where the silicon wafers for solar batteries are processed. The
slurry consists of oil and abrasives and is used in the wire saw. The viscosity of the slurry is
carefully controlled to maintain a high cutting performance though it tends to be high as the
silicon powder is accumulated in the slurry. The cutting performance of the slurry decreases as
the amount of the silicon powder increases. The abrasives, however, still have enough
performance to cut the silicon wafers. Iron segments of the wire saw were found to attach to the
SiC abrasives. The iron segments magnetize the abrasives in the mechanochemical process
and thus reduce the cutting performance of the abrasives. Due to the iron segments’ presence,
the abrasives with poor cutting performance could be separated from the slurry by means of
superconducting magnetic separator. After the magnetic separation, a centrifugal separator was
used to separate the silicon powder (Nishijima et.al, 2016). Though centrifugal separation is
able to recycle the abrasives, the abrasives separated by this method do not show high cutting
performances. Cosmetic defects brought about by this pose a problem for the company,
eventually resulting in lesser yields. However, through the use of the superconducting magnetic
separation method, the problem with thick slurry abrasives causing defects will be eradicated,
leading to better yields as a result. Recycling and reuse of the slurry material through this new
technology would be made more profitable for the company given that it will not result in any
cosmetic defects on one of the company’s end products. Superconducting magnetic separation
technology is able to recover the SiC abrasives and oil from the wasted slurry successfully, and
thus establishing a viable recycling system of the wasted slurry from the semiconductor factory.

5. Recommendations. Determine and discuss specific strategies for accomplishing the

proposed solution.  If applicable, recommend further action to resolve some of the issues What
should be done and who should do it? 

The proposed solution in our written analysis of the case, superconducting magnetic
separation, is something which depicts the world’s technological advancements. In a big and
known company like the Bituin Marikit Corp., it is a great challenge to try and invest into
something new for the company’s betterment. Thus, executing a pilot scale line that will mimic
the entire process is a great strategy. This will ensure that all technical disputes can be
scrutinized before testing it out at the production level.

Using technology to improve operational processes is a staple in any business or

company nowadays and efficiency is the holy grail that every business wants to chase. It is in
technology that both challenge and opportunity lie. It constantly throws up new and innovative
ways of altering the way people work, providing the company and every one in it the chance to
steal a march on their rivals.   

Different strategies that can be utilized in accomplishing a business’ proposed solution

or vision can include ways to generate new business opportunities and schemes to successfully
implement new technology.

Entrepreneurs often live with hope that if they build it, customers will come. But in
today’s economy, it takes a lot more than hope to get people to purchase your products or
services. New business-building practices are a must if you want to expand.

The TPR group has researched on and identified approaches when dealing with new
business opportunities just like the one that the Bituin Marikit Corp. has been given. Focusing
on the company’s core product is significant. Prospects buy when they trust that your value is
applicable to them and believe that the company is stable. It is important that one should
differentiate themselves by focusing on the unique capabilities and core products they bring to
prospects. Another step is mapping the company’s capabilities with the target clients’ needs. It
is an excellent way to determine the service strategy that the company should offer. Utilization
of marketing tools that work best for the company and the customers is also a great manner in
dealing with new business opportunities. Implement something that fits the company and the
customers one serves. Implementing the plan of action must not be neglected too. An action
 plan will give the map that the company can use to measure its progress. Aside from planning
long-term goals, it is essential to set short-term ones and even daily goals for the company.
What comes next is the actualization of the action plan. This step is somewhat straightforward.
It is important to complete daily actions and then do something extra to accelerate the success
plan.

Aside from the above mentioned strategies, the group was also able to research on
different steps to successfully implement new technology. No matter what size, companies are
constantly looking to increase productivity, efficiency, and performance. Naturally, the
implementation of new technology can accomplish that. However, while introducing new
technologies is essential in running a successful company, how the company or business
chooses to introduce these technologies can make or break their success.

To do this, it is essential to note the importance of working from the ground up. When
evaluating new technology, start from the most basic level, what's not working, what can be
expected to change with newly implemented technology, and how its success will be measured.
Ranking priorities, such as functionality and cost are important. But don't undervalue user
compatibility. Opt for systems that are accessible and intuitive to use. To offer productive
support is also a must. Once you've chosen what technology you're going to integrate, make
sure to have a complete support system for mitigating any difficulties in the transition. It is
essential to put in my mind that to make these new technologies work, no one in the company
must be uninvolved. To utilize all kinds of manpower is one great approach.  Consider a more
modern approach to training. Move away from thick paper user manuals and opt for programs
that have easily accessible digital help centers. Have everyone properly trained and comfortable
with newly introduced technology before your launch date. If the intended audience feels
intimidated when your launch comes around, or cannot access proper support when they need
it, your entire implementation could fall apart. Also, avoid the impulse to rush. It's important not
to let the pressure and need to boost productivity allow the company and the people in it to
handle implementation poorly. It may be tempting to introduce pilot programs as a means of
cycling through technologies to find the right one, but taking commitment away from new
technology integration can cause your entire process to fail. If one doesn't have a full program in
place, it will be difficult for employees to commit as well. Observing transparency is to be kept in
mind as well. It can reduce friction that may potentially arise with the introduction of new
technology. To build value within the company, open communication with employees is needed.
Address what could be at stake if the implementation fails, giving ownership to everyone
collectively. Trusting employees to become invested in the company’s success will boost their
morale and make them inclined to positivity. And lastly, maintain momentum. Put an individual
or team in charge of the technology’s success. Task them with not only overseeing the process
from start to finish, but also monitoring ongoing usage after the implementation phase is over.

References

Huang, W.-H., Shin, W. J., Wang, L., Sun, W.-C., & Tao, M. (2017). Strategy and technology to recycle
wafer-silicon solar modules. Solar Energy, 144, 22–31. doi:10.1016/j.solener.2017.01.001

Joshi, K., Ananya, A., Bhandarkar, U., & Joshi, S. S. (2017). Ultra thin silicon wafer slicing using wire-
EDM for solar cell application. Materials & Design, 124, 158–170.
doi:10.1016/j.matdes.2017.03.059 

Kannan, N., & Vakeesan, D. (2016). Solar energy for future world: - A review. Renewable and
Sustainable Energy Reviews, 62, 1092–1105. doi:10.1016/j.rser.2016.05.022 
Nishijima, S., Takeda, S., Izumi, Y., Suemoto, H. (2003). Recycling of abrasives from wasted slurry by
superconducting magnetic separation. Retrieved from:
https://www.researchgate.net/publication/3312188_Recycling_of_abrasives_from_wasted_slurr
y_by_superconducting_magnetic_separation

Richter, A., Benick, J., Feldmann, F., Fell, A., Hermle, M., & Glunz, S. W. (2017). n-Type Si solar cells
with passivating electron contact: Identifying sources for efficiency limitations by wafer thickness
and resistivity variation. Solar Energy Materials and Solar Cells, 173, 96–105.
doi:10.1016/j.solmat.2017.05.042

Shin, J., Park, J., & Park, N. (2017). A method to recycle silicon wafer from end-of-life photovoltaic
module and solar panels by using recycled silicon wafers. Solar Energy Materials and Solar
Cells, 162, 1–6. doi:10.1016/j.solmat.2016.12.038