INSPIRE - Integrated Sustainable Production through Innovative Resource Efficiency

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An uncomfortable truth is that electronics is globally one of the most polluting industries. Semiconductors ("chip manufacturing") is overtaking automakers with the world's largest chip producer TSMC (Taiwan Semiconductor Manufacturing Corporation) now producing more CO2 than GM (General Motors), and Intel rapidly approaching this crossover threshold.Manufacturing contributes far more to CO2 than use, for an Apple iPhone this is almost 80% of its total carbon footprint, \>50% of which is due to the integrated circuit (IC or "chip").PragmatIC is building a new high-volume manufacturing facility at an investment of \>£40Mn and scheduled to come online end of 2022\. Once complete this will be the UK's first 300mm semiconductor fab. INSPIRE presents an opportunity to develop and demonstrate new methodologies which can be a flagship project within the semiconductor industry and support a move to net zero manufacturing process both within the UK and internationally. PragmatIC aims to scale manufacturing globally through local installation and operation of manufacturing-lines sited next to demand. Many of these approaches can be transferred into the mainstream semiconductor and electronics manufacturing sectors.INSPIRE (Integrated Sustainable Production through Innovative Resource Efficiency) focuses on decarbonisation, improved resource efficiency and improved productivity (all intrinsically linked). Distributed sensors (both existing and additional) across PragmatIC's manufacturing system generate data which will be used as follows:\* "Smart" influent water control including rainwater capture and storage linked to weather forecast\* Optimising influent water quality to meet "good enough" quality through tuneable water treatment\* Effluent recovery through onsite treatment and return\* Replacement of organic solvents with aqueous/gaseous alternatives to reduce VOC content\* Optimisation of high-quality nitrogen quality and usage requirements\* Development of machine-learning approaches to manufacturing optimisationThe INSPIRE project fits with themes of smart connected factories, connected and versatile supply chains and adaptable, flexible manufacturing operations and skills.The project aims to reduce carbon emissions of PragmatIC's production process by over 6,000,000 kg CO2 per year, through reductions in offsite transportation in waste, minimisation of tap-water and, where possible, elimination of VOCs from waste-streams.Partners: PragmatIC (Lead), DevTank, Hydrocell & Suez Water Technologies and Solutions.