Abstract
Workers in semiconductor factories have occupational health risks from exposure to chemical substances. This work analyzed hazardous chemical substances in the key process of a semiconductor factory in China, and studied cancer and non-cancer health risks and occupational health risks of workers. Research results show that more than half of the processes contain compounds such as hydrogen fluoride, chlorine, hydrogen chloride, ammonia and 2-propanol, and their concentrations vary greatly depending on the process. The occupational exposure index (Ei) of some processes is greater than 1, which means that there are adverse occupational health risks, including wet etching (WETCH), physical vapour deposition (PVD), furnace process (FUR), chemicals storehouse (CS) and diffusion (from inspection area). The pollutants with a high contribution rate to Ei vary with the process, and WETCH (operating area) has the highest contribution rate of sulphuric acid (93.33%). The Hazard Quotient (HQi) of PVD and CS is far greater than 1, indicating that there is a non-cancer risk. The lifetime cancer risk (LCRi) of wastewater treatment and CS is greater than 10−4, which indicates a risk of cancer. The General Engineer has higher health risks than the Duty Engineer due to the higher exposure frequency.
Keywords
Introduction
As a modern chemical-intensive industry, semiconductor manufacturing has become one of the industries with the most serious occupational diseases. 1 The working environment of workers involves physical hazards (noise, power frequency electric field) and chemical hazardous agents (Organic solvent, acids, alkalis, metals and their compounds, of which chemical hazards are accounted for a large proportion.2–7 These harmful chemicals can damage multiple organ systems such as the respiratory tract, cardiovascular system and nervous system, and cause cancer and skin damage.8–16 Workers working in semiconductor factories may be exposed to chemical hazards that can cause occupational diseases.
Some studies have analyzed specific pollutants in semiconductors and found that although the exposure levels of most pollutants are lower than the current exposure limit,17,18 individual pollutants (gallium, indium and arsenic) have adverse effects on the health of workers.19,20 In addition, some scholars have studied the occupational health risks of workers exposed to photolithography process,17,21,22 and the wastewater treatment.23–25 The occupational health risks faced by workers in semiconductor factories vary due to the types of pollutants and processes, and a comprehensive evaluation and analysis are required.
According to the measurement data of the working environment in the past, more than 98% of the concentration of harmful contaminants evaluated in the semiconductor factory are below the current occupational exposure limits (OELs), and the concentration of most chemical substances are below than 50% of the OELs.2,4,26 In fact, due to the wide variety of semiconductor raw materials and the complex production process, workers are exposed to a variety of pollutants. Therefore, it is impossible to confirm whether workers have adverse health effects based on specific chemical hazards lower than OELs. Some scholars have concluded that the cumulative health risk value of each process in industries such as recycling workshops and oil refineries is much greater than a single pollutant.27,28 For factories with complex processes, the cumulative health risks can provide a more comprehensive view of workers’ occupational health risks. However, there are few comprehensive assessments of occupational health risks in the semiconductor industry, mainly for protecting state-of-the-art technology, 29 resulting in the lack of sufficient hard data on the current pollutant levels in semiconductor factories. Therefore, it is urgent to conduct a comprehensive assessment of the pollutant levels of the key processes of semiconductor factories and the occupational health risks of workers.
Based on previous findings, the occupational exposure risk research of workers mostly adopts the recommended threshold limit value (TLV) by American Conference of Government Industrial Hygienists (ACGIH), 30 and there are also studies adopting the occupational health standards recommended by the other two organizations, namely, Occupational Safety and Health Administration (OSHA) 31 and National Institute for Occupational Safety and Health (NIOSH).32,33 The occupational thresholds provided by these three institutions are actually different, and there is no relevant comparison and research on how to choose amongst them for occupational health risk assessment in the semiconductor industry.
In this study, we carried out field harmful contaminants measurement in a semiconductor factory from one of the top ten factories in China, in order to understand the harmful contaminants emission data from different specific processes in the semiconductor factories and to investigate the process-specific characteristics of harmful contaminants pollution and their consequent health risks. The research covers most of the key processes of semiconductors, including operating processes and inspection processes. The operating processes include photolithography (LITHO), diffusion (DIFF), etching (ETCH) and thin film deposition (TF). There are a total of 27 kinds of pollutants, including metals and their compounds, acids, bases and volatile organic compounds (VOCs). U.S. Environmental Protection Agency (US EPA) standard methods are used to assess the potential health risks of chemical pollutants, 34 including cancer and non-cancer risks. Occupational exposure cancer risk is assessed using methods of the US Centers for Disease Control and Prevention (US CDC). The threshold limit values used in the assessment were from four institutions such as ACGIH, OSHA, NIOSH and China Occupational Exposure Limits (COEL).31–33,35 The comprehensive assessment of the carcinogenic risk caused by occupational exposure of semiconductor workers is of importance to the workers and the industry.
Materials and methods
Study design
This study selected a top 10 semiconductor factory in China with an annual output of about 400,000 chips. From 5 to 9 November 2018, hazardous pollutants were sampled at the location of the main processing equipment of the specific process, covering most of the key processes of the semiconductor factory. Figure 1 shows simplified flow charts including the specific operation processes, where samples were collected for each working zone in the chip industry. Simplified flow charts showing the specific operation processes where samples were collected for each working zone in the chip industry.
According to the type of operation, the workflow is divided into operation processes and inspection processes. The operation processes include photolithography (LITHO), diffusion (DIFF), etching (ETCH) and thin film deposition (TF). The DIFF processes include furnace process (FUR), ion implantation (IMP) and rapid thermal processing (RTP). The ETCH processes include wet etching (WETCH) and dry etching (DETCH). The TF processes include chemical mechanical polishing (CMP), physical vapour deposition (PVD) and chemical vapour deposition (CVD). There are production process inspection (PPI), waste gas/wastewater treatment (WG/WW), chemicals storehouse (CS) and power equipment area (PE) in inspection area. In order to distinguish the processes throughout this article, processes that are not marked as inspection areas belong to the operating area.
Sample collection and analysis
The species of chemical substances and their sampler, detection limits, collected air volume, measurement methods and references in this study.
Specification, applicable and scope of the devices.
A total of three occupational exposure limit concentrations were detected, including the TLV-TWA (time-weighted average) concentration representing an 8-h workday within a 40-h workweek, the TLV-STEL (short-term exposure limit) concentration for a 15-min TWA exposure that should not be exceeded at any time during a workday and the TLV-C (Ceiling) concentration that should not be exceeded during any part of the working exposure. For most substances, it is very important to apply TWA alone or together with STEL. For certain substances (such as irritating gases), only TLV-C is applicable. Therefore, sampling and analysis were carried out according to the existing TLVs of chemical hazardous agents in GBZ 2.1. 35
Environmental conditions of sampling sites.
Quality assurance and quality control
All instruments and equipment in this study had been calibrated to ensure accurate monitoring. While air samples were taken, one parallel sample was analyzed for every ten samples and each sample has a field blank. The relative deviation of the target in parallel samples should be less than or equal to 5%. The blank control sample must go through the same process (including field exposure, transportation, storage and laboratory analysis) and procedures as the sample to reduce systematic errors. All detected compounds and their method detection limits (MDLs) are listed in Table 1.
Non-cancer and cancer risks assessment using the US EPA method
Long-term exposure of workers to harmful chemical substances may cause health risks of cancer or other toxic effects (non-cancer). As workers wear work clothes and rubber gloves, the risk of skin exposure and oral intake is low, so this paper focuses on the assessment of workers' inhalation health risks. 26 The method recommended by the US EPA was used to assess non-cancer and cancer risk of chemicals via inhalation.34,54,55
Abbreviations: ATSDR (Agency for Toxic Substances and Disease Registry, Centres for Disease Control and Prevention (US CDC)); 57 IRIS (Integrated Risk Information System, US EPA); 56 HEAST (Health Effects Assessment Summary Tables, US EPA); 59 OEHHA (Office of Environmental Health Hazard Assessment); RfC (reference dose for chronic oral exposure); 58 SF: slope factor (SF of styrene obtained from United States Environmental Protection Agency’s Cumulative Exposure Project, others from IRIS).
Compounds with an LCR value greater than 1 × 10−4 are regarded as ‘identified risks’, between 1 × 10−5 and 1 × 10−4 regarded as ‘probable risks’, between 1 × 10−6 and 1 × 10−5 regarded as ‘possible risk’, less than 1 × 10−6 regarded as ‘negligible risk’. 61
The non-cancer risk indicator is expressed by hazard quotient (HQ), which can be given by equation (2). The EC can be given as equation (3).
34
The values of AT (72.4 years) were taken from China’s human exposure parameters. 62 There are two main types of workers in semiconductor factories, namely, operators and inspection workers. Operators are divided into general engineer and duty engineer. The daily exposure time (ET) of the two is 8 h (5 days a week) and 11 h (four shifts and two operations, meaning two shifts in 4 days). The inspector has a daily exposure time (ET) of 4 h (5 days a week). The exposure frequency (EF) of the general engineer from operators and the inspector are 250 days, after deducting 104 statutory holidays and 11 statutory holidays. The exposure frequency (EF) of the duty engineer is 171 days, after deducting 11 statutory holidays. The exposure duration (ED) of worker is usually calculated as 35 years.
Parameters used for the LCR and HQ estimation.
ED: the exposure duration; EF: the exposure frequency; ET: the exposure time; AT: average lifetime.
For a given toxic chemical substance in the air, when the non-carcinogenic risk HQ is greater than 1, long-term exposure could cause non-carcinogenic health hazards, and HQ < 1 means a safe level. 63
Risk assessment for occupational exposure using the ACGIH method
Average concentration of compounds detected during semiconductor manufacturing.
Subscript: TWA: time-weighted average; STEL: short-term exposure limit; C: ceiling.
Results and discussion
General emission characteristics
According to the existing threshold limits of hazardous chemical substances in the Chinese standard GBZ 2.1, 35 this study tested the hazardous chemical substances in semiconductor factories, including its corresponding TLV-TWA, TLV-C or TLV-STEL. The chemical hazardous substances and their average concentrations of the main processes are shown in Table 6. Table 6 shows the various processes of the semiconductor industry that involve the use of potentially hazardous chemicals in the working environment, such as metal and their compound, organic solvents, acids and toxic gases. Methane and n-Butyl acetate were not detected because the actual concentration was lower than the minimum detection concentration of the equipment.
The chemical substances in the air could vary due to different processes. There is more than one hazardous chemical substance in every process. Amongst them, the CS has the most types of pollutants, including fluorides, nitrogen dioxide, nitrogen monoxide and sulphuric acid. In semiconductor factories, almost half of the processes contain compounds such as fluoride, hydrogen fluoride, chlorine, nitrogen dioxide, chlorine, ammonia and 2-propanol. However, some hazardous chemical substances, including nitric oxide, boron trifluoride, sulphuric acid, ozone, phosphoric acid, hydrogen sulphide, methanol, cyclohexanone, acetic acid, n-Butyl acetate and arsine have only been detected in a few processes. For example, nitric oxide is only in the CS, methanol in the LITHO, hydrogen sulphide in the PE and arsine in the IMP and CS.
The concentrations of these compounds could vary with different processes. The ratio of compound concentration in different processes ranged from 1 to 1786. Amongst them, the average of TWA of nitrogen dioxide in FUR was 0.02 mg/m3, and the average of TWA in PE was 0.0001 mg/m3 and the ratio of the two was 200. Therefore, we should focus on the nitrogen dioxide concentration level of FUR. In addition, the ratio of STEL concentration of sulphur hexafluoride was 1786, and the ratio of STEL concentration of ammonia was 333. To sum up, the concentration levels of the same chemical substance in different processes are different and should be explained independently according to the process.
In summary, the equipment and chemical reagents used in their workplaces are different because of the difference in processes, resulting in differences in the types and concentration levels of chemical pollutants. Therefore, this may lead to differences in the occupational risks of workers exposed to different process environments, and it is not comprehensive to study the occupational health risks of workers exposed to certain pollutants or specific processes only. We should conduct differentiated analysis based on different processes and set corresponding protective measures according to the types of chemical substances.
Non-cancer and lifetime cancer risk assessment
Figure 2 shows the non-cancer health risk value (HQ) of hazardous chemical substances in different processes in a semiconductor factory. The three processes of IMP, WETCH and CVD in the operation area are not subject to inhalation cancer and non-cancer health risk assessments because workers wear self-contained respirators. Non-cancer health risk value HQ of general engineer and duty engineer exposed to different processes.
The results in Figure 2 show that the HQ value of a general engineer was generally higher than that of a duty engineer, indicating that general engineers in semiconductor factories have a higher non-cancer health risk. The reason is that a general engineer has a higher exposure frequency (EF) than a duty engineer.
Figure 2 shows that the HQ values of the general engineer and duty engineer exposed to the PVD were 22.07 and 20.76, respectively. The HQ value of the inspector in the CS was 7.74. The HQ value is far greater than the safety threshold of 1, which indicates that there is an unfavourable non-cancer health risk for workers. Therefore, workers exposed to the process of PVD and CS need to consider their occupational health risks. The HQ value of other processes is much smaller than the threshold value 1, including 11 processes such as LITHO, FUR, DETCH and CMP.
However, due to the limitations of current research, the toxicity mechanisms of some pollutants have not been grasped by relevant international organizations, resulting in their RFC values not being updated, such as nitrogen dioxide, nitric oxide, hydrogen peroxide and ozone. Therefore, the HQ calculated in this study may be lower than the actual value.
In this study, the cancer health risk value of inhalation of arsenic was calculated only for workers’ exposure in the WW and CS. This is because the parameter (SF or UR) for quantitative estimate of carcinogenic risk from inhalation exposure have not been assessed under the IRIS and other Program. The calculated LCR value ranged from 4.30 × 10−6 to 2.11 × 10−4, and the average value was 1.08 × 10−4. The average value of LCR was greater than 1 × 10−4, so the WW is considered to be an ‘identified risk’. The average value of LCR in the CS was 0.22, which is far greater than 1 × 10−4, so this process is considered a ‘determined risk’.
Occupational exposure health risk assessment
In order to obtain a more comprehensive view of the occupational health risks of semiconductor factories, the Ei value was calculated based on five thresholds, including ACGIH, NIOSH, OSHA and COEL, min (ACGIH, NIOH, OSHA and COEL). The min (ACGIH, NIOH, OSHA and COEL) means to take the minimum of the reference values of ACGIH, NIOSH, OSHA and COEL as the threshold limit.
Figure 3 shows the Ei calculated based on min (ACGIH, NIOH, OSHA and COEL). For the ETWA value of a single chemical substance in Figure 3, the sulphuric acid in the WETCH and PVD were 1 and 1, respectively, and arsenic in the CS was 5. These values all exceeded the threshold 1, which means that there is an occupational health risk. For the ESTEL value, arsenic in the CS was 25, far exceeding 1, which means a high occupational health risk. Other chemical hazardous substances were less than the threshold limit, indicating that the occupational health risks to workers are small or negligible. The occupational exposure indexes (Ei) assessment of individual and total chemical material in various processes in semiconductor factories. Ei was calculated using the occupational exposure limits (OELs) of min (ACGIH, NIOSH, OSHA and COEL).
Although the Ei value of a single chemical substance in most semiconductor factories was less than 1 (Figure 3), there was more than one pollutant for a certain process, resulting in differences in the cumulative occupational risk (Ei) of each process. The ETWA value of WETCH, PVD and CS was 1.09, 1.07 and 6.12, respectively. The ESTEL in the CS was 25.85. The EC values of FUR and DIFF in the inspection area were 1.03 and 1.11, respectively. There are occupational health risks. Therefore, there are occupational health risks in the WETCH, PVD, FUR, CS and DIFF of inspection area.
Figure 4 compares the Ei values calculated using the five TLVs including ACGIH, NIOSH, OSHA, COEL and min (ACGIH, NIOSH, OSHA and COEL). For ACGIH, the ETWA of WETCH, PVD and CS is 1.08, 1.07 and 6.09, respectively. For NIOSH, the ESTEL of the CS was 25.33. For OSHA, the ETWA of the CS was 5.57. For COEL, the ETWA of the CS and the ESTEL of the CS, were 5.58 and 2.78, respectively. The cumulative value of occupational health risk (Ei) varies amongst different institutions because of different TLVs. The cumulative occupational exposure indexes (Ei) assessment of total chemical material in various processes in semiconductor factories. Ei was calculated using the occupational exposure limits (OELs) of ACGIH, NIOSH, OSHA, COEL and min (ACGIH, NIOSH, OSHA and COEL).
In order to clarify the contribution of pollutants in each process to occupational health risks, the proportion of pollutants in each process to Ei was calculated, as shown in Figure 5. Figure 5 shows the contribution rate of pollutants for processes with occupational health risks (Ei ≥1) when using TLVs of min (ACGIH, NIOSH, OSHA and COEL) to calculate. When using TLVs-TWA, the WETCH (operation area) has the largest contribution rate of sulphuric acid (93.33%), followed by hydrogen peroxide (6.56%), ammonia (1.53%) and 2-Propanol (0.07%) contributed the least. Other process contributions rate includes PVD (sulphuric acid and hydrogen peroxide) and CS (arsenic, sulphuric acid and hydrogen peroxide). When using TLVs-STEL, in the CS, the contribution ratio of chemical substances is arsenic, sulphur dioxide in order. When TLVs-C are used for risk assessment, the contribution rate of pollutants includes FUR (hydrogen chloride, phosphine and chlorine), and the DIFF of inspection area (ozone, phosphine, arsine and chlorine). Contribution ratio of pollutants with occupational health risks in various production processes.
In summary, for different processes, the chemical substances that contribute to the occupational health risk are different.
Comparison with other research and national standards
Comparison with other researches and national standards.
There are also differences in the health risks for different types of workers. Some scholars have found that maintenance workers exposed to arsine have higher occupational health risks than operating tools. 19 In this study, there are similar conclusions. In other words, compared with the duty engineer, the general engineer in semiconductor factories have a higher non-cancer health risk.
In addition, previous studies have shown that the concentration of pollutants in semiconductor factories is mostly less than TLVs of the institutions, such as, OSHA, 31 ACGIH, 30 NIOSH 33 and COEL; 35 that is, there is no occupational health risk. However, the process in the semiconductor factory in this study has occupational health risks, such as WETCH, PVD, FUR CS and DIFF (the inspection area), no matter what, the basis is one of institution (ACGIH, NIOSH, OSHA and COEL). This is because the target of occupational health risk assessment in previous research is a single chemical substance while this research is the cumulative risk value of all chemical substances in the process. The reason is that for workers, their workplace is exposed to more than one chemical substance.
In this study, there are differences in the application of TLVs of different institutions for occupational health risk assessment. There are two main reasons for this difference. The first reason is that the TLVs set by different institutions are different. ACGIH, NIOSH and OSHA are the main occupational health standards in the United States of America, and their purposes and basis are different. TLVs established by OSHA are required to be enforced. The TLV standard formulated by ACGIH is updated fastest, but it is a TLV of academic interest. OSHA’s PEL standard is the slowest to update, resulting in the lack of corresponding threshold limits for most chemical substances, and the existing threshold limits are higher than ACGIH. The value of COLE mainly refers to ACGIH. With the deepening of the understanding of harmful factors, many limits of TLVs have been decreasing year by year. As a result, ACGIH’s TLVs values are mostly lower than those of other institutions. The second reason is the lack of TLVs for certain chemicals in these four organizations.
Therefore, for industrial occupational health risk assessment, it is recommended to conduct a comprehensive assessment based on the TLVs of multiple institutions. In addition, most of the pollutant concentrations in semiconductor factories in previous studies were lower than the occupational exposure limits of institutions. However, many processes in semiconductor factories studied in this paper have occupational health risks, such as WETCH, PVD, FUR CS and DIFF (the inspection area).
Conclusion
Workers in semiconductor factories have occupational health risks from chemical exposure. This research conducted detection and analysis of chemical hazardous agents in a number of key processes in a semiconductor factory in China and studied the inhaled cancer and non-cancer health risks, and the occupational health risks of workers.
The research results show that there are many types of chemical substances in each process of a semiconductor factory, and the concentration varied greatly depending on the process, and the ratio ranged from 1 to 1786. The inhalation health risk assessment showed that the HQ value of the general engineer was higher than that of the duty engineer due to the higher exposure frequency. The HQ of physical vapour deposition and chemical substance storage areas is far greater than the safety threshold 1, indicating a non-cancer risk. The LCR of the wastewater area is greater than 10−4, and there is a health risk of cancer.
93% of the compounds are less than the occupational exposure limit, except for the sulphuric acid (in the WETCH and PVD) and arsenic (in the CS). Furthermore, the cumulative occupational exposure limit Ei of some processes is greater than 1, which means that there may be unfavourable occupational health risks, for example, the WETCH, PVD, FUR, CS and DIFF (the inspection area).
To sum up, the contribution of pollutants to occupational health risks in each process is different, and the research on each kind of pollutants in semiconductor factories should be analyzed in combination with their processes. In addition, the occupational health risks of workers exposed to semiconductor factories cannot be ignored, especially the generation of new pollutants in semiconductor factories due to technology update. Due to the different occupational exposure limit standards of the indicators of various institutions, there are differences in the occupational health risk assessment of workers, which should be comprehensively assessed. ACGIH can be referenced first due to its fast update.
Footnotes
Authors’ contributions
All authors contributed equally in the preparation of this manuscript.
Declaration of conflicting interests
The author(s) declared no potential conflicts of interest with respect to the research, authorship, and/or publication of this article.
Funding
The author(s) disclosed receipt of the following financial support for the research, authorship, and/or publication of this article: This work was supported by the National Key Research and Development Program of China (Grant No. 2018YFC0705300).
