At KOSA Filtration, we've been engineering high-purity fluid-handling systems for nearly two decades. Over the years, I've seen the semiconductor and electronics industries push the boundaries of ultra-high-purity (UPW) requirements. Our heat exchangers are designed to meet these stringent demands, ensuring that particle and ionic contamination are kept to an absolute minimum.
Materials and Construction
All of our shell-and-tube and plate heat exchangers are constructed from 316L stainless steel, meeting the ASME BPE 2019 and 3-A Sanitary Standard 2022 requirements. This material choice is crucial for maintaining UPW cleanliness, as it minimizes particle shedding and corrosion. We use electro-polished surfaces with a Ra < 0.5 µm finish to further reduce surface roughness and potential contamination points. The welds are fully penetrating and polished to match the surrounding surface finish, ensuring there are no crevices or dead legs where contaminants can hide.
Design Considerations for UPW Systems
Designing for UPW systems means paying meticulous attention to detail. Here are some key aspects we focus on:
- Sub-micron filtration: Our systems are designed to accommodate 0.2 µm absolute-rated filtration, ensuring that even the smallest particles are removed.
- Minimal extractables: We use materials and construction techniques that meet the <1 ppb extractables requirement, crucial for maintaining UPW purity.
- Efficient fluid dynamics: Our designs promote laminar flow and minimize turbulence, reducing the risk of particle entrainment and ensuring >99.9% recovery of the UPW fluid.
We also adhere to SEMI F57 and F72 standards for particle and ionic control, respectively. This ensures that our heat exchangers can handle the demanding requirements of semiconductor and electronics manufacturing processes.
Cleaning and Maintenance
Easy cleaning and maintenance are non-negotiable for UPW systems. Our heat exchangers are designed with clean-in-place (CIP) capabilities, allowing for efficient and effective cleaning without disassembly. This reduces the risk of contamination during maintenance and ensures that the system can be quickly returned to service. All wetted parts are designed to be fully drainable, preventing the accumulation of stagnant fluid and reducing the risk of bacterial growth.
Quality Control and Traceability
We implement rigorous quality control measures at every stage of production. Each heat exchanger is subjected to thorough inspections and testing to ensure it meets our exacting standards. We maintain full traceability of all materials and components, providing our customers with the documentation they need to meet their own quality and regulatory requirements. This level of control is essential for industries where even the slightest contamination can have significant consequences.
A Real-World Example
Last year, we worked with a contract semiconductor manufacturer who was struggling with particle contamination in their UPW systems. Despite their best efforts, they couldn't achieve the sub-5-particle/mL specifications required for their latest production line. We installed our shell-and-tube heat exchangers, designed with sub-micron filtration and efficient fluid dynamics in mind. Within a month, they were meeting their specifications consistently.
Application Engineering Support
Every application is unique, and our application engineers are ready to discuss your specific requirements. Whether you're designing a new system or upgrading an existing one, we can provide the technical expertise you need to ensure UPW cleanliness. Let's talk about your application and how our heat exchangers can help you meet your purity goals.
Related product silos: LIQUID FILTRATION, DUST FILTRATION, CONTROLVALVE, HEAT EXCHANGER.