Introduction
The global value of the semiconductor market is set to grow from 590 billion USD in 2021 to 1.065 trillion USD by 2030. While semiconductors are key to reducing carbon emissions through energy-efficient applications, they also produce a significant CO₂ footprint during manufacturing. However, the potential CO₂ savings in end-use applications greatly exceed the emissions produced during their production. Thus, as the demand for semiconductors grows, so does the need to make their manufacturing more sustainable.
This paper by Infineon Technologies examines energy use in semiconductor manufacturing. It focuses on the energy consumed by two exemplary products and how changes in production capacity affect this consumption.
Using discrete-event simulation, the study aims to highlight where energy savings can be achieved, helping to reduce the industry’s carbon footprint. With these observations, the industry can move towards reducing energy use while supporting technological advancements and semiconductor sustainability.
Simulation model
The researchers developed a simulation model in AnyLogic software to analyze energy consumption in sustainable semiconductor manufacturing. The model follows a discrete-event simulation approach to represent the production process realistically while keeping it simple and easy to understand. It tracks semiconductor products as they move through different stages like lithography, etching, and deposition, monitoring how much energy each process consumes.
The model also accounts for resources like cleanrooms and manufacturing equipment, measuring their energy use both when operating and when idle. It incorporates real and synthetic data to study how production levels affect energy consumption and allows researchers to test different scenarios through altering factory capacity.
The goal of the simulation was to identify which processes use the most energy and explore ways to optimize energy efficiency. By analyzing the impact of production capacity on power consumption, the model can help to find strategies for reducing energy waste and improving sustainability in semiconductor manufacturing.
Read also: Explore additional resources on simulation in the semiconductor industry.
Results
The results from the simulation model showed that cleanrooms and certain manufacturing equipment use the most energy, especially when they're not active. When the factory worked at higher capacities, it used energy more efficiently because there was less downtime. However, if the factory was too busy, delays would increase, using up more energy.
The model pointed out that processes like deposition and high-resolution lithography were using up a lot of energy. By improving these areas, the factory could save a significant amount of energy. Overall, the simulation created in AnyLogic provided clear insights on how to reduce energy consumption and make semiconductor manufacturing more sustainable.