1. Field of the Invention
The present invention relates to a combustion-type exhaust gas treatment apparatus for treating a harmful and combustible exhaust gas, which contains, for example, silane gas (SiH4) or halogen gas (NF3, ClF3, SF6, CHF3, C2F6, CF4, or the like), by combustion so as to render the exhaust gas harmless.
2. Description of the Related Art
A semiconductor fabrication apparatus discharges a gas including a harmful and combustible exhaust gas, e.g., silane gas (SiH4) or halogen gas (NF3, ClF3, SF6, CHF3, C2F6, CF4). Such an exhaust gas cannot be released as it is into the atmosphere. Thus, the exhaust gas is generally introduced to a treatment apparatus, where the exhaust gas is oxidized by combustion so as to be rendered harmless. A widely-used treatment process of this type is such that a combustion-supporting gas is used to form flames in a furnace in which the exhaust gas is combusted by the flames, as seen in Japanese laid-open patent publication No. 11-218317.
A combustion-type exhaust gas treatment apparatus for use in a semiconductor industry and a liquid crystal industry potentially discharges a large amount of dust (mainly SiO2) and a large amount of an acid gas as by-products of combustion treatment of the exhaust gas. Consequently, a regular maintenance operation is required so as to remove the dust from a treatment section, or an additional mechanism, such as a scraper, is required so as to regularly scrape away the dust attached to and deposited on an inner surface of a cylindrical body of a combustion treatment chamber.
The dust attached and deposited is composed mainly of SiO2 (i.e., silicon dioxide). Other than SiO2, however, the dust may probably have toxic dust mixed therewith. The dust has various diameters ranging from 0.1 micrometers to several tens of micrometers. Moreover, the dust may exist as large blocks. Consequently, it is necessary to ensure operational safety of the dust-removal maintenance so as not to cause health damage from suction of the dust.
In the case of providing the scraping mechanism, the number of components is increased. As a result, a manufacturing cost of products would be increased, and replacement of the scraping mechanism would be regularly required, thus increasing a running cost.
Because a temperature of a combustion gas in the combustion treatment chamber is as high as about 1700° C., a heat-resisting material, such as alumina-base glass ceramic, is used for the cylindrical body that surrounds the combustion treatment chamber. However, the temperature of the combustion treatment chamber is high, and if a fluorine or chlorine gas exists, the inner surface of the cylindrical body would be corroded and wasted. Therefore, it is necessary to regularly replace the cylindrical body. Such replacement of the high-priced cylindrical body incurs a cost and requires time-consuming maintenance.
The present invention has been made in view of the above drawbacks. It is therefore an object of the present invention to provide a combustion-type exhaust gas treatment apparatus which can use a low-priced material for a body that surrounds a combustion treatment chamber, can prevent the attachment of dust to an inner surface of the combustion treatment chamber, can prevent damage from a corrosive gas to the inner surface of the combustion treatment chamber, and can reduce time-consuming maintenance and maintenance costs.
A combustion-type exhaust gas treatment apparatus according to the present invention includes a combustion treatment section for performing combustion treatment on an exhaust gas, a cooling section for cooling the exhaust gas which has been treated in the combustion treatment section, and a washing section for washing the exhaust gas with water so as to remove by-products produced by the combustion treatment. The combustion treatment section includes an exhaust-gas treatment combustor, a body made from metal and having a roughened inner surface, and a water-film formation mechanism adapted to form a water film on the inner surface of the body. The combustion treatment of the exhaust gas is performed in the body.
As described above, the present invention provides the combustion-type exhaust gas treatment apparatus including the metal body with the roughened inner surface, so that the exhaust gas is treated by combustion in the body. The water film, which is formed on the inner surface of the body, provides a water-resisting structure. Therefore, a low-priced material, such as stainless steel, can be used to form the body. Moreover, the water film, which is formed on the inner surface of the body, can wash away the dust to thereby prevent the dust from adhering to the inner surface of the body. Furthermore, the water film can wash away the corrosive gas, and therefore the inner surface of the body is not damaged. As a result, a low-priced material, such as stainless steel, can be used to form the body, thus lowering the manufacturing cost of the body itself. In addition, time-consuming maintenance and maintenance costs can be reduced.
Embodiments of the present invention will be described below with reference to the drawings. In the drawings, components or elements having the same function or structure are denoted by the same reference numerals.
In this embodiment, stainless steel is used to form the cylindrical body 18. The inner surface of this cylindrical body 18 comprises a roughened surface. Since the inner surface of the cylindrical body 18 is roughened, a wettability of the inner surface is improved, and thus a uniform water film can be formed on the inner surface in its entirety. If a stainless steel, which is a hydrophobic material, has a mirror-finished inner surface, water droplets are likely to be formed thereon. Accordingly, it is difficult to form a uniform water film on the inner surface in its entirety. Because the inner surface of the cylindrical body 18 is roughened in its entirety, the stable water film can be formed on the inner surface in its entirety of the cylindrical body 18 with no water break.
The roughened surface can be formed by blasting, which is a method of forming a rough surface with a desired roughness by ejecting abrasives (e.g., sands or glass beads) at high speed to a surface using a compressed air or centrifugal force. The roughened surface may be formed by machining, such as cutting (broaching) which uses multiple blades or a spline method which scrapes a workpiece by a combination of a vertically-linear motion of a tool and a feed motion of the workpiece. Alternatively, the roughened surface may be formed by surface treatment, such as pickling or hydrophilic coating. Pickling is conducted by immersing a workpiece in a chemical liquid (e.g., nitric acid, hydrofluoric acid, hydrochloric acid, sulfuric acid), removing the workpiece from the chemical liquid, washing the workpiece with water, and drying the workpiece. Hydrophilic coating is conducted by coating an inner surface with a hydrophilic film, such as glass fiber, silicon polymer, or Teflon (registered trademark).
A preferable temperature for decomposition of the exhaust gas is at least 1700° C. Therefore, a temperature in the combustion treatment chamber 19 is kept at around 1700° C. An amount of water supplied from the water-flow flange 20 is adjusted such that the water film A has a thickness of at least 2 mm. The water film A with a thickness of at least 2 mm can provide a heat-resisting structure, whereby the temperature of the cylindrical body 18 is kept at substantially an ordinary temperature (not more than 50° C.). Therefore, a low-priced material, such as stainless steel, can be used for the cylindrical body 18, instead of the high-priced alumina-base glass ceramic. When the temperature of the water in the water-flow flange 20 is 30° C., the temperature of the water at an outlet of the cylindrical body 18 can be at several tens of degrees or less.
When dust, which has been produced in the combustion treatment chamber 19, approaches the inner surface of the cylindrical body 18, the water film A washes away the dust, thereby preventing the dust from adhering to the inner surface of the cylindrical body 18. Similarly, when molecules of a corrosive gas approach the inner surface of the cylindrical body 18, the water film A washes away the molecules of the corrosive gas. For example, when a fluorine by-product is produced in the combustion treatment, such a fluorine by-product becomes a thin hydrofluoric acid, which does not cause damage to the inner surface of the cylindrical body 18. Therefore, even if a low-priced material, such as stainless steel, is used for the cylindrical body 18, the dust does not adhere to the inner surface, and the inner surface is not corroded by the oxidizing gas. As a result, time-consuming maintenance and maintenance costs can be greatly reduced.
In
The combustion-type exhaust gas treatment apparatus 10 comprises a cooling section 21 for cooling the exhaust gas that has been subjected to the combustion treatment, and a circulation tank 25 for storing and circulating the water which was used to form the water film A on the inner surface of the cylindrical body 18. The cooling section 21 is located downstream of the cylindrical body 18. The cooling section 21 comprises a pipe 22 which couples a lower end portion of the cylindrical body 18 and the circulation tank 25 to each other, and a pipe 27 which branches off the pipe 22 to a washing section 31. The pipe 27, which branches off the pipe 22, is inclined upwardly and is coupled to a lower end portion of the washing section (washing chamber) 31 via a vertical pipe. A water-spraying mechanism 28 for forming a water film on an inner surface of the pipe 27 is provided near a connection portion between the pipe 27 and the vertical pipe.
An inner surface of the pipe 22 is covered in its entirety with the water film which has flowed down from the cylindrical body 18, and the inner surface of the pipe 27 is covered in its entirety with the water film formed by the water-spraying mechanism 28. Because these water films serve as a heat-resisting material, temperatures of the pipes 22 and 27 can be kept at substantially ordinary temperature (not more than 50° C.), regardless of a high temperature of the exhaust gas which has been subjected to the combustion treatment. Moreover, the water films can prevent damages from the corrosive gas to the pipes. Therefore, a low-priced stainless steel can be used for the pipes 22 and 27. It has been a conventional measure to cover a surface of a gas-contact portion of a pipe made from metal, such as stainless steel, with a corrosion-resisting material (e.g., Teflon (registered trademark), or PVC) by chemical deposition, physical coating, painting or attachment. The structure according to the above-described embodiment of the present invention can eliminate the need to provide such a measure.
It is preferable to provide a cooling-acceleration mechanism, such as fin or baffle plate, on the inner surface of the pipe 22 or the pipe 27.
The washing section 31 of the combustion-type exhaust gas treatment apparatus 10 comprises filters 31a and water-spraying mechanisms 31b. After the combustion treatment, the exhaust gas is cooled by the cooling section 21, and then introduced into the washing section 31. This washing section 31 washes the exhaust gas with water so as to capture and remove by-products including the dust and the oxidizing gas produced by the combustion treatment of the exhaust gas. The dust is removed by the filters 31a, and goes down with water sprayed from the water-spraying mechanisms 31b. The dust with the water flows through the pipes 27 and 22 into the circulation tank 25, and is stored in the tank 25. In this manner, the exhaust gas is rendered harmless by the combustion treatment, cooled in the cooling section 21, and washed with water in the washing section 31. The treated exhaust gas flows through a pipe 32 and is then released into the atmosphere or other space.
The circulation tank 25 has a weir 26 therein. After flowing down through the pipe 22, the water enters a chamber at a left side of the weir 26 as in the drawing. The water in the left chamber overflows the weir 26 into a chamber at a right side of the weir 26 as in the drawing. The water in the right chamber is sucked by a pump 30 and delivered to a heat exchanger 40 via a supply pipe 34. The heat exchanger 40 performs heat exchange between the water and cooling water so that the water has a suitable temperature. Thereafter, this water is reused as circulation water. The water, containing a large amount of dust, flows into the left chamber of the circulation tank 25. The dust is formed by particles, some of which have large diameters. Since the large particles are heavy, they sink to a bottom of the chamber. On the other hand, particles with very small diameters are lightweight, and thus overflow the weir 26 into the right chamber. The particles that were moved to the right chamber are mixed into the water that is to be used as the circulation water. The particles, mixed into the circulation water, may not have an adverse effect in use of the circulation water, so long as the particles have a diameter of about 50 μm. Accordingly, it is preferable that the weir 26 have a height such that particles with a diameter of more than 50 μm cannot overflow the weir 26.
After the temperature is adjusted in the heat exchanger 40, the water is supplied as water W1 to the water-flow flange 20. The water W1 is used to form the water film A on the inner surface of the cylindrical body 18, and to form the water film on the inner circumferential surface of the pipe 22. Then, the water is returned to the circulation tank 25. Part of the water, whose temperature has been adjusted in the heat exchanger 40, is supplied to the water-spraying mechanisms 31b of the washing sections 31, and is returned to the circulation tank 25. In addition, part of the water, whose temperature has been adjusted in the heat exchanger 40, is supplied to the water-spraying mechanism 28, which forms the water film on the inner circumferential surface of the pipe 22. Then, the water is returned to the circulation tank 25. In this manner, the water circulates. Therefore, the combustion-type exhaust gas treatment apparatus 10 has an advantage of requiring a very small amount of city water or industrial water for replenishment because most of the water used in operations of the apparatus 10 is the circulation water. Furthermore, because the water is reused as the circulation water, even if the water becomes a thin hydrofluoric acid after washing the exhaust gas, this acid is not expelled to the exterior of the apparatus 10.
Part of the cooling water to be supplied to the heat exchanger 40 is supplied as cooling water W2 to a non-illustrated cooling-water passage provided in the combustion treatment section 11. This water W2 serves to cool the exhaust-gas treatment combustor 12. Part of the water delivered by the pump 30 is supplied as water W3 to the circulation tank 25 so that the water W3 flows into the circulation tank 25 from a side portion of the circulation tank 25. The water, which has flowed into the circulation tank 25, sweeps away the by-products deposited on the bottom of the circulation tank 25 toward the weir 26, thereby preventing clogging of a lower end opening of the pipe 22 with the by-products.
The combustion-type exhaust gas treatment apparatus 10 comprises a temperature sensor 41 on the cylindrical body 18, and monitors an increase in temperature of the cylindrical body 18 with the temperature sensor 41. If the water break occurs on the inner surface of the cylindrical body 18, the heat resisting effect disappears at that portion. In such a case, the cylindrical body 18 is in direct contact with the high-temperature exhaust gas, which potentially causes damage to the inner surface of the cylindrical body 18. In order to detect such situations, the temperature sensor 41 is provided on the cylindrical body 18 so as to secure the safety.
A leak sensor 42 is provided on a portion that serves as a saucer of the cylindrical body 18. If the cylindrical body 18 is damaged and a through-hole is formed, the leak sensor 42 can detect the presence of such a through-hole. In this manner, providing the leak sensor 42 can improve the safety.
Although certain preferred embodiments of the present invention have been described, it should be understood that the present invention is not limited to the embodiments described above, and various changes and modifications may be made without departing from the scope of the present invention.
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