Why Ultra-Clean Air Is Essential in Modern Electronics Manufacturing
Release time:
2025-07-22
Introduction: Compressed Air as a Critical Process Gas
In today’s electronics factories, compressed air is no longer just a source of energy—it is a direct-contact process gas. From silicon wafer slicing to chip bonding, PCB printing to optical coating, the purity of compressed air determines product quality and production success.
Stringent Environmental Requirements in Semiconductor Manufacturing
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Wafer fabrication requires ISO Class 1 standards
(Particle size ≤ 0.1μm) -
Pressure dew point must be below -70°C
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Oil content must be under 0.001 mg/m³
These demanding standards are built upon hard-learned lessons. One chip manufacturer experienced equipment failure due to compressed air contamination. Microscopic imaging showed liquid pollutants around chip edges.
Upon testing:
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Oil content reached 0.113 mg/m³ (10 times over the limit)
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Dew point was only -1°C, far short of the required -40°C
The result: high scrap rates and downtime losses in the hundreds of thousands of RMB per incident.
Fact: Around 80% of pneumatic system failures are directly caused by poor air quality. In precision electronics manufacturing, air purification is no longer a cost center—it’s a lifeline for yield assurance.
Core Technology: Breaking the Limits of Conventional Purification
The Limits of “Oil-Free” Compressors
Even so-called oil-free compressors cannot avoid environmental oil vapor intake. In industrial zones, ambient oil content often exceeds 0.4 mg/m³, far beyond the 0.01 mg/m³ ISO Class 1 threshold.
Catalytic Oxidation: A Revolutionary Breakthrough
To solve this, catalytic oxidation technology offers a transformative four-step purification method:
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Deep Oil Removal
Oil-laden compressed air enters a catalytic reactor, where hydrocarbons (C6) undergo oxidation at 300–400°C, converting entirely into CO₂ and H₂O. -
Thermal Energy Recovery
A high-efficiency heat exchanger recycles thermal energy between the incoming oily cold air and the purified hot air, achieving 90%+ heat recovery. -
Precise Temperature Control
With 99% efficient heating elements and advanced smart controls, temperature stability is maintained within ±5°C, ensuring optimal reaction conditions. -
Final Filtration & Drying
After catalytic conversion, the air passes through 0.01μm precision filters and membrane dryers, reaching ≤0.003 mg/m³ oil content and a dew point of -40°C.
This method overcomes environmental dependency—a major weakness in traditional filtration systems—offering 3x greater stability, regardless of ambient air quality, temperature, or humidity.
Real-World Application & Results
Upgrade Plan: Triple-Stage Protection
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Install CAC catalytic purifier
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Add precision dust filters
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Use membrane drying tubes at point-of-use
Achieved Outcomes
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Oil content reduced from 0.113 mg/m³ → 0.003 mg/m³
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Dew point stabilized below -40°C
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Surface contamination eliminated
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Machine downtime reduced by 70%
Advanced Practices in Display Panel Manufacturing
A more advanced system combining:
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Refrigerated dryers
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Adsorption dryers
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Ultra-fine filtration
Plus, tools like:
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Heat-regenerated dryers
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Nanometer-grade filters
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Laser particle counters for real-time monitoring
Together, these create a robust, multi-layer defense system. The oil content remains stable at 0.001 mg/m³, offering a zero-contamination environment crucial for optical coating processes.
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