Four solid steps to decarbonise semiconductor manufacturing

Semiconductor production is an invisible yet essential force behind the sustainability transition. These microchips are found in innovations such as solar panels, wind turbines, electric vehicles, and smart grids. This allows us to use energy more efficiently and achieve a more sustainable future.

However, the production of these chips is far from sustainable. Due to the growing global demand for advanced electronics solutions, the need for semiconductors is increasing significantly. Miniaturisation – more functionality and more powerful microchips – is a key driver of progress in the electronics industry. The result: production requires increasingly more complex processes, leading to a significant increase in energy and water consumption and the emission of chemicals such as greenhouse gases.

A Worrying Prediction

Recent research shows that if the growth of the semiconductor industry continues, CO2 emissions will increase by around 8% annually – a worrying prediction. The need for sustainability in the semiconductor industry becomes even clearer when we compare the impact with other sectors: while total global emissions are around 50 billion tonnes, the ICT industry is responsible for 1.2 billion tonnes, and semiconductor manufacturing for around 175 million tonnes.

Here’s where we Chart the Challenges

Besides decarbonisation, the semiconductor industry has other major sustainability challenges:

• Planetary boundaries: planetary boundaries, set by the Stockholm Resilience Centre show how much pressure the earth can withstand before irreparable damage occurs. The semiconductor industry must stay within these boundaries to avoid ecological tipping points that could lead to serious environmental damage, such as loss of biodiversity.
• Recovery of Natural Resources: Key raw materials such as lithium, cobalt and neodymium are essential for the technologies of the future, but their availability is limited. Efficient and sustainable methods are needed for the extraction and use of these materials, as well as effective recycling methods to reduce our dependence. Consider the recovery of noble gases such as helium and neon, chemicals and rare and expensive metals.
• Use of hazardous substances: The presence of hazardous substances such as PFAS (poly- and perfluoroalkyl substances) and SVHCs in semiconductor manufacturing processes is a major concern. This is because these chemicals have harmful effects, both on human health and the environment. Regulations on the use of these substances are getting stricter, and may even lead to mandatory phase-outs.
• Water: The production of semiconductors requires large amounts of ultrapure water, placing a heavy burden on available resources. A single semiconductor factory can consume tens of millions of litres of water per day, equivalent to the water consumption of a small city. Companies in the semiconductor industry therefore strive to optimise their water consumption and invest in technologies that enable reuse.

Four concrete measures: roadmap to a sustainable future

To make semiconductor production more sustainable, Deerns, together with its clients, develops roadmaps using four concrete measures:

1 – Establishing Ambitions

This involves translating sustainability ambitions into concrete goals for the production facility. Many companies have set their ambitions based on the UN’s Sustainable Development Goals (SDGs). For example, a concrete target could be to reuse at least 60% of water in the production process by 2027, thereby significantly reducing water consumption. The following three SDGS are especially urgent for the electronics industry:

• Countering climate change: Reducing CO2 emissions and other greenhouse gases; using energy resources more efficiently
• Clean water and sanitation: Water reuse; water efficiency
• Protected ecosystems, forests and biodiversity: Reducing harmful emissions; using resources responsibly

2 – The 30-year Outlook

When futureproofing a factory, it is important to look beyond short-term needs and rather adopt a 30-year outlook. What’s up next when considering technological developments, raw material requirements, new regulations and societal trends?

3 – Identify the Main ‘Culprits’

Deerns identifies the main ‘culprits’ within the production processes and supply chain. This helps to identify where the greatest potential for improvement lies, as well as the risk and feasibility of the proposed measures.

4 – Creating a Clear Overview

Complete the picture with detailed reports, scenario analyses, interim milestones and associated investments. With this information, implementation can begin in a focused and efficient way.

Deerns not only helps semiconductor manufacturers draw up these roadmaps but also guides their implementation. With our expertise in the semiconductor industry and in-depth knowledge of sustainability, we can provide valuable advice at process level. We also assess whether the measures to be taken are economically feasible and feasible in an environment where production must continue 24 hours a day, 365 days a year. This is how we support companies in electronics and chip production to overcome the tough challenge of meeting global demand while securing a greener future.