The Role of a Bulk Specialty Gas System in Refineries and Semiconductor Manufacturing

The increase in human consumption has led to growing demands in the manufacturing sectors. Energy and innovation have been at the center of this increasing demand. The semiconductor industry is projected to hit the trillion dollar mark in 2030, all thanks to its increasing use in almost everything electrical—from cars to computers to vacuums. Refineries are experiencing this demand as U.S. oil refinery capacity hit 17.9 million barrels per day in 2021. This is due in part to the many ways that refineries use gas that aren't apparent to most, such as pump seal support for the many pumps that exist in a single refinery. This data indicates the need for refineries and semiconductor fabs to gear up and develop a more robust facility that can handle the increasing demand. 

For increasing production volume, refineries and semiconductor manufacturers should invest in gas delivery systems and cylinder systems that can support the supply conditions of bulk specialty gas, i.e., increased volume and flow rates. Let's take a look at what these bulk specialty gas systems are and how their role is crucial for improving industrial productivity and efficiency.

The Role of a Bulk Specialty Gas System

The purity requirement in semiconductor fabrication and refineries demands specialty gas for clean and precision manufacturing. The gases such as nitrogen, argon, and hydrogen are transported via storage cylinders to the site where it is connected to the gas distribution system at the source inlet. But this is not a practical solution when the demand is immense.

For high-capacity fabs and refineries, a dedicated bulk specialty gas system is required to ensure the supply of specialty gas is multiple times the volume possible with the cylinder. There are many advantages to having a bulk specialty gas system, including:

1. They keep the manufacturing environment and operators safe as they do not require constant switchovers and backup cylinders. This supports downtime reduction and minimizes the risk of exposure to toxic gases.  
2. The bulk system facilitates the reduction of cylinder handling, delivery and distribution logistics, and labor costs. In the case of bulk gas being delivered through a multi-cylinder system, the auto changeover manifolds can easily switch between the bottles without incurring any downtime. 
3. The consistent supply of gas means there is less chance of human errors and reduced opportunities for contamination. This is especially crucial for the thin wafer fabrication process.

Many refineries use outside gas vendors while others have their dedicated specialty gas plant on-site, receiving the bulk supply of gas through the pipelines. While often convenient, challenges may arise.

• Developing a robust bulk specialty gas system isn’t a small undertaking, many resources must be allocated to ensure the system is operating safely and at peak efficiency.
• The failure or mishandling of the bulk specialty gas system means a larger production process will be affected.  

Making Manufacturing Safe with Bulk Specialty Gas System

A good system design is important to overcome the challenges that a bulk specialty gas system may present. The slightest fluctuation in the process condition can lead to manufacturing errors. Thus, it is crucial that the bulk specialty gas system include components such as process sensors, monitoring systems, and controllers. These components keep the process conditions such as temperature, pressure, and flow rate in check—from the bulk gas source to the distribution point—and regulate them to meet process standards.

Swagelok’s range of high-quality components and fluid management systems ensure the efficient operation of the bulk specialty gas system.

• The fittings are robust and leak-proof which is beneficial to handle the high pressure coming from the bulk gas source. This is also important to maintain the purity of the specialty gas. 
• The pressure regulators and control manifolds regulate the pressure before it is safely fed to the semiconductor processing unit. 
• The gas panel ensures the correct rate of flow into the distribution system by minimizing build-up. 
• Custom gas distribution systems can operate as per your process requirements (pressure and temperature specification) to ensure operational safety and efficiency. 

Work With Your Local Advisor for Gas System Setup

Whether you are looking for the right component or seeking expert assistance in designing the bulk specialty gas system to handle the process conditions at your Northern California facility, Swagelok is here to help. Apart from providing a wide range of high-quality components, our advisors will offer you design assistance so you can understand the impact of the bulk system on your existing gas distribution system. With our thermal management applications, we will ensure your fluid temperature requirement remains intact—whether it is cryogenic or high-temperature. 

At Swagelok, our team of experts will work diligently to ensure the integration of your bulk specialty gas system is safe, reliable, and cost-effective. 

To find out more about how Swagelok Northern California can help you integrate bulk specialty gas systems safely at your refinery or semiconductor manufacturing facility, contact our team today by calling 510-933-6200.

About Morgan Zealear | Product Engineer, Assembly Services

Morgan holds a Bachelor of Science in Mechanical Engineering from University of California at Santa Barbara. He is certified in Section IX, Grab Sample Panel Configuration and Mechanical Efficiency Program Specification (API 682), and he is well versed in B31.3 Process Piping Code. Before joining Swagelok Northern, he was a manufacturing engineer at Sierra Instruments, primarily focused on capillary thermal meters for the semiconductor industry (ASML).