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One of the most exciting waste minimization techniques currently being tested is the elimination of the need for rinsing from both photoresist developing and stripping operations This new process may eliminate spent developer wastes and will eliminate the spent resist stripper bath dump The photoresist, being demonstrated at Circuit Center (Dayton, Ohio) and at E G & G Mound, is applied in a production process as a thin film from a liquid solution onto a circuit board and air dried When exposed to a high-intensity ultraviolet light source, these photoresists will decompose and vaporize as inert gas There appears to be no rinsing required for these operations In fact, these operations, as we currently know them, will be eliminated, thus reducing the cost of waste treatment The existing 30-month demonstration project is a cooperative effort between the University of Dayton Research Institute, the Air Force, the US.

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Environmental Protection Agency, and the Edison Materials Technology Center (EMTEC) Depending on the actual chemistry used, the use of this new process may reduce the hazardous air emissions from these processes commonly produced with conventional semiaqueous and aqueous chemistries containing butyl cellosolve or butyl carbitol..

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60.5.4.6 Use of Nonproprietary Chemistry to Avoid Chelating Agents. Chelating agents are molecules that form a charged complex with a metal ion such as copper. They are used to enhance solubility and keep the metal ions in solution. Typical chelating agents used in printed circuit board fabrication include ferrocyanide, ethylenediaminetetraacetic acid (EDTA), phosphates, and ammonia. Chelated baths are intended to enhance etching, cleaning, and electroless plating but make waste treatment much more difficult because the metals are tightly bound in the complex, which inhibits precipitation. Often ferrous sulfate must be added to wastewaters to break the chelators prior to precipitation of metal hydroxides. The iron is precipitated as well as other metals, thus increasing the amount of sludge produced. Use of nonchelated chemistry where possible will eliminate this problem. If some chelating chemistry is required in the process, proper waste segregation should be implemented to minimize the volume of any chelated waste streams.

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Copper Sulfate Crystallization 60.6.1.1 Theory of Operation. The sulfuric acid/hydrogen peroxide etching reaction is: Cu + H2O2 + H2SO4 CuSO4 + 2H2O >> Systems employing crystallizers are designed to 1. Lower the solution temperature to lower the solubility of copper. 2. Then remove copper in the form of copper sulfate pentahydrate crystals (CuSO4 5H2O). 3. Then reheat the bath (to prevent copper from clogging the return pipe line if the bath temperature is lowered further) before transferring the bath back to its working tank. An advantage, from a waste treatment point of view, is that the bath is recycled and not routinely dumped. Other microetchants must be dumped when the copper concentration increases. The most significant advantage, from a process point of view, is that a low copper concentration can be maintained and the printed circuit board factory will minimize its purchase of microetchant chemicals. A disadvantage to this process is that, at the time of this writing, there are no outlets available to receive and recycle the crystals, so the only alternative for manufacturers using crystallizers is to dissolve the copper sulfate crystals in spent dilute (10 percent) sulfuric acid. After the copper has dissolved, this material can be pumped to another holding tank for recirculation through an electroplating cell for reclaim of the copper. (60.1)

Rinse Water Recycling Rinse waters can be treated and reused in the process. This can be accomplished in two ways. Rinse water recycling can be accomplished with a point-of-source system. In this system, the flow from selected rinses is recirculated through cation and anion exchange columns and then returned to the point of origin. It may be necessary to add a carbon filtration step for rinses containing organics. The second method would involve a central system. Selected rinses could be run through an ion exchange system for copper removal. Following this step, these rinses would pass through a general resin for cation removal, a general resin for anion removal, systems for organic removal such as activated carbon, ozonation or UV peroxide, and final filtration. In some cases, reverse osmosis could be substituted for the general ion exchange steps. Given the complexity of this treatment process, it would be cost-effective only for large printed circuit board facilities with high water use rates.

Copper Recovery via Electrowinning 60.6.3.1 Theory of Operation. Electrowinning is the reduction of copper ions to solid metallic copper at a cathode. The following are the chemical reactions governing copper recovery in an acidic solution. The reduction reactions that occur at the cathode are: Cu+2 + 2e Cu (metal) >> >> 2H + 2e H2 (gas)

(60.2) (60.3)

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