fluidized deposition reactor for silicon production
DESCRIPTION
Presented at SolarCon China 2012CPTIC SymposiumseriesTRANSCRIPT
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Fluidized Deposition Reactor for Silicon Production
Paul Ege1, Alireza Abbasi1, Jin-Seok Seo2, Jun-Suk Lee2, Jung-Hyun Lee2 1- Reactech Process Development Inc, Canada 2- KCC Corporation, Republic of Korea
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Overview
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• Siemens Rod Deposition • High Energy / High Quality • SiHCl3(g) +H2 = HCl(g) + Si(s) • SiH4 = Si(g)+Si(s)+ H2
• Metallurgical Routes • Low Energy / Low Quality
• Fluid Bed deposition • Low Energy / Medium-High Quality • SiH4 = Si(g)+Si(s)+ H2 • SiHCl3(g) +H2 = HCl(g) + Si(s) • 4 SiHCl3= 2 H2+ 3 SiCl4+ Si(s)
• Silane Freespace • Low Energy / Medium quality
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Background Polysilicon Processes
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Background Fluidization Fundamentals
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Background Fluidized bed design elements
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Polysilicon Fluidized Bed Process Evaluation
ª Continuous granular production => Reduce operation cost
ª Excellent contact high surface volume => compact process
ª Low DP for high throughput => high capacity
ª Excellent heat transfer => low energy consumption
ª Near isothermal conditions and large
thermal reservoir
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- Complex flow patterns - Gas mix in emulsion - Gas bypass in bubbles
- Attrition and Erosion - Quality reduction - Dust generation - Pipe/Internal deterioration
- Entrainment - Powder inherent, less with TCS - Dust from abrasion/attrition
- Fouling - Wall - Nozzles/distributor
- Complex reaction kinetics - TCS, equilibrium limited - Silane, competing reactions
Advantages Challenges
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Ø JPL work in 1980ʼ’s many references Ø Furusawa Hom/Het kinetics (1988) Ø Lai & Dudukovics (MEMC) 1986
• Describes a multi step mechanism
Ø Caussat et. Al. study on FBR (1995-98) • Bubbling reactor model and exp data
Ø Mlezcko et. Al. Solarworld (2004) Ø Pina et.al REC process (2006)
• PF/CSTR approach
Ø Ydstie-Balaji independent(2009)
Ø Parker Barracuda (2010)
Polysilicon Fluidized Bed Literature
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Polysilicon Fluidized Bed Prior art (old patents)
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Polysilicon Fluidized Bed Protected designs (current patents)
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MEMC – SiH4 FBR • Two stage process; high production with dust, low
production to adsorb dust and anneal • Seed, quench, el.mag. heat, coating and valves • Recent – multiple beds for growth, and special distributor • Appears to be traditional bubbling fluid bed behavior • Dimensions and capacities not revealed
REC – SiH4 FBR • Submerged Spouted bed one or more spouts • Nozzle design with secondary orifice, internal grinding,
annular withdrawal, halogen injection, tapered bed • Recent radiant heated bed with internal liner and cooling
below injector
Others in development • Wacker, KRICT, AEP, SILIKEN – TCS based • Samsung-MEMC, KCC – Silane based • Independent developers
Polysilicon Fluidized Bed Commercial Processes
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Polysilicon Fluidized Bed Commercial design solutions
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① Review stage ü Review literature/patents for IP/Cost/Risk feasibility analysis
② Lab/Bench Scale (inches diameter) ü Establish reaction kinetics and flow for basic reactor models ü Validate process conditions and scale up strategy for pilot/commercial
③ Pilot/Demo Scale (feet diameter) ü Validate commercial challenges in long term continuous operation ü Verify scale up predictions and design for commercial ü Well instrumented small commercial unit with many interruptions ü Risk in scale best taken here!
④ Commercial Scale (meters diameter) ü Target uninterrupted production with minimum disturbance ü Start-up and stabilize, then optimize Yield/Capacity/Quality/Economics
FBR development Scope Scale and Objective of stages
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FBR development Multi Stage Effort
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FBR development Multi Level Modeling
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Reactech Process Development
FBR development CFD and CPFD for flow and scale up analysis
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FBR development Reactor Model for design/analysis/control
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Characteristics
OBJECTIVE Experimental methods to verify a wide range of parameters that are important
in reactor model development and for design purposes
Particle– External • Fluidization/Entrainment/Reactivity • Porosity/Density, Size/Shape, Umf, DPf, Ut Gas • Fluidization/Entrainment • Density, Viscosity Fluid bed • Void, Solid Mixing, Gas dispersion, Mass and
Heat transfer Entrainment • TDH, Freeboard flow/void, Cyclone feed/
efficiency, Dipleg operation
Pressure and Temperature • Global / Time average => Mb, Hb, Void fraction • Fluctuations => frequency, regime, forces • Correlations => size, velocity • Delta T=> Solids mixing Intrusive probes • Capacitance/Fiberoptic/DP • Local bubble and void properties Non Intrusive probes • x-ray, γ-ray, capacitance • High speed samples => local bubble properties • Multiple samples => Tomography Tracer studies • Gas dispersion • Solids mixing (solid tracer, heat pulse)
FBR development Experimental
Methods
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Ø Polysilicon FBR is promising technology for low cost high quality production
Ø Prior art allows development of Polysilicon FBR. Challenge will be to avoid design details already patented
Ø Significant development challenges require serious long-term effort from lab through pilot to commercial scale.
Ø REC successfully commercialized new technology
Ø Several new projects at different development stages
Ø KCC progressing well with solid foundation from Bench scale efforts fast approaching demonstration scale pilot production
Conclusions
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