EP3649078A1 - Procédé de production de silicium polycristallin - Google Patents

Procédé de production de silicium polycristallin

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Publication number
EP3649078A1
EP3649078A1 EP16823183.5A EP16823183A EP3649078A1 EP 3649078 A1 EP3649078 A1 EP 3649078A1 EP 16823183 A EP16823183 A EP 16823183A EP 3649078 A1 EP3649078 A1 EP 3649078A1
Authority
EP
European Patent Office
Prior art keywords
gas
fluidized bed
ppmv
hydrogen
polycrystalline silicon
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP16823183.5A
Other languages
German (de)
English (en)
Inventor
Harald Hertlein
Dirk Weckesser
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Wacker Chemie AG
Original Assignee
Wacker Chemie AG
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Filing date
Publication date
Application filed by Wacker Chemie AG filed Critical Wacker Chemie AG
Publication of EP3649078A1 publication Critical patent/EP3649078A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/02—Silicon
    • C01B33/021—Preparation
    • C01B33/027—Preparation by decomposition or reduction of gaseous or vaporised silicon compounds other than silica or silica-containing material
    • C01B33/03—Preparation by decomposition or reduction of gaseous or vaporised silicon compounds other than silica or silica-containing material by decomposition of silicon halides or halosilanes or reduction thereof with hydrogen as the only reducing agent
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/02—Silicon

Definitions

  • the invention relates to polycrystalline silicon granules and to a process for the production thereof in a fluidized bed reactor.
  • Granules of polycrystalline silicon are an alternative to polysilicon, which is produced by the Siemens process. While the polysilicon in the Siemens process is obtained as a cylindrical silicon rod, which usually requires time-consuming and costly crushed before its further processing to so-called Chippoly and optionally purified, has polysilicon granular bulk properties and can directly as a raw material, for example, for single crystal production for
  • Polysilicon granules are usually produced in a fluidized bed reactor. This is done by fluidization of silicon particles by means of a gas flow in a fluidized bed, which is heated by a heater to high temperatures. The addition of a silicon-containing reaction gas causes a pyrolysis reaction on the hot surface of the silicon particles. Here, elemental silicon is deposited on the silicon particles and the individual particles grow continuously in diameter.
  • the process can be operated continuously by the regular withdrawal of silicon particles and the addition of smaller silicon particles as seeds (also referred to as "seed".)
  • the silicon-containing reaction gas can be silicon halogen compounds (eg chlorosilanes or bromosilanes), monosilane (SiH 4 ), or Mixtures of these gases with hydrogen can be used, Such deposition methods and corresponding devices for this purpose are known, for example, from US 2008/0299291 AI.
  • exhaust gas which consists of unreacted reaction gas and gas shaped by-products, in particular halosilanes, composed.
  • the treatment of this exhaust gas in particular the recovery of unused hydrogen, increased attention for cost reasons.
  • the treatment of the resulting in the silicon deposition exhaust gas is basically known, for example from EP 2 551 239 AI. Corresponding cycles can also be found in Figures 7 and 8 at page 58 in O'Mara, B. Herring, L. Hunt: Handbook of Semiconductor Silicon Technology; ISBN 0-8155-1237-6.
  • the exhaust gas is fed to a multiple condensation device, wherein the condensate via a
  • Distillation column is separated into low-boiling and high-boiling fractions.
  • the low-boiling components are returned to the separation.
  • the high-boiling components usually contain a large portion of silicon tetrachloride (STC), which can be converted in a conversion device (converter) to trichlorosilane (TCS).
  • STC silicon tetrachloride
  • TCS trichlorosilane
  • the remaining after the condensation gaseous portions of the exhaust gas are fed to an adsorption.
  • the hydrogen is separated from the other components of the gas stream and recycled as recycle gas to the deposition process.
  • fresh gas (externally generated or provided), for example produced by means of a steam reformer, can also be added to the recycle gas.
  • constituents of the reaction gas may be added.
  • Polysilicon serves as a starting material for the production of monocrystalline silicon by means of crucible pulling (Czochralski
  • Polysilicon is also required for the production of monocrystalline or multicrystalline silicon by means of drawing or casting, which is used to manufacture solar cells.
  • a significant problem in the production of single-crystal silicon are dislocation defects (one-dimensional, i.e., line-shaped perturbations) and stacking faults (two-dimensional, i.e., areal perturbations) in the crystal structure of the obtained silicon crystals. Both phenomena reduce the yield, since basically only silicon crystals are suitable for use in the photovoltaic and electronics industry, which do not exceed a certain number of crystal defects.
  • the number of stacking faults in silicon wafers should be less than 300 per square centimeter.
  • Nitrogen concentrations in the reaction gas was deposited, no increased inert incorporation of nitrogen can be detected.
  • the deposition temperature is usually not increased above a critical value of about 1080 ° C. Common are temperatures below 1000 ° C. For reasons of economy, however, it would be desirable to increase the deposition temperature, since this would be accompanied by a higher reaction rate and consequently an increased reactor output.
  • the object underlying the present invention was to provide a polysilicon granule which causes no or only a small number of dislocation and stacking defects in the secondary product in its further processing.
  • the polysilicon granules should also be produced by a particularly economical method.
  • Silicon granules having the features of claim 12.
  • Continuous (cycle) processes for the treatment of exhaust gases or the recovery of hydrogen in the production of polysilicon and the corresponding cycle gas systems are known in principle.
  • Si 3 N 4 crystallites in the interior and on the surface of the polysilicon granules do not melt due to their high melting point in subsequent processes such as drawing or casting processes and thus cause the dislocation and stacking faults in the secondary product.
  • the underlying mechanism has not yet been finally clarified.
  • the nitrogen content in the recycle gas is less than 500 ppmv (parts per million by volume), preferably less than 100 ppmv, more preferably less than 10 ppmv, especially less than
  • the lower nitrogen content in the recycle gas makes it possible with particular advantage, the fluidized bed reactor with higher deposition temperatures, in particular above 1100 ° C, to operate as is customary in known from the prior art reactors.
  • the increased deposition temperature leads to an increased reaction rate and thus to an increase in reactor output.
  • the cost-effectiveness of the process is thus improved without the product quality being impaired.
  • the deposition of the elemental silicon at a deposition temperature between 1000 and 1300 ° C / preferably between 1080 and 1250 ° C, more preferably between 1100 and 1200 ° C.
  • the nitrogen content of the cycle gas is preferably determined by means of a measuring device.
  • the measuring device is a gas chromatograph.
  • a sample can be taken from the reaction space and / or the cycle gas system and the
  • the measuring device can also be provided directly at the site of the sampling.
  • the sample is preferably taken at a point of the cycle gas system, at which the exhaust gas from the reactor
  • Possibilities are conceivable. By such a combination can be determined whether an unwanted nitrogen entry occurs more in the reaction space of the reactor or during the continuous process of the exhaust gas treatment. Alternatively or additionally, it may be provided to take one or more samples at different points of the cycle gas system, for example in front of or behind (upstream or downstream) of an adsorption device.
  • external hydrogen is meant in particular hydrogen, which is supplied from an external source becomes.
  • the external source may be, for example, a reservoir or a steam reforming device. It is preferably high-purity hydrogen, in particular hydrogen of quality 3.0 or higher, for example 5.0.
  • the circulating gas system is preferably completely decoupled from the reaction space of the reactor in the time until it falls below the limit value.
  • the cycle gas system is purged with external hydrogen until the nitrogen limit value is reached. If the circuit gas system is not assigned a measuring device, the purging duration can also be for a certain period of time, for example a
  • the temperature of the fluidized bed and / or a reactor wall is increased until the nitrogen limit value has fallen below again.
  • the limit value in the exhaust gas of the fluidized bed reactor is measured.
  • the temperature of the fluidized bed and / or the reactor wall can be increased by reducing the amount of reaction gas introduced into the reactor.
  • the reaction gas is usually colder than the fluidized bed temperature when entering the reactor. This means that the reaction gas has a certain cooling effect. A reduction of the amount of reaction gas can therefore lead to a reduction of this cooling effect.
  • the fluidized bed temperature increases.
  • a temperature increase can be achieved by lowering the fluidized bed (lowering the vortex Layer height) can be realized within the reactor.
  • the reaction space can basically be heated via the reactor wall.
  • the fluidized bed within the reaction space is usually colder than the reactor wall and can thus cool it.
  • Up to 90%, preferably up to 40%, particularly preferably up to 10%, of external hydrogen can be added to the cycle gas.
  • the halosilane component of the reaction gas is a chlorosilane, in particular trichlorosilane (TCS).
  • the specific mass flow of halosilane is preferably in a range between 1600 and 12,000 kg / h 2 .
  • the reaction gas is preferably blown into the fluidized bed via one or more nozzles, in particular arranged at the bottom of the reactor.
  • the fluidizing gas which is responsible for the fluidization of the silicon particles in the fluidized bed is preferably hydrogen. It is also conceivable to use an inert gas other than nitrogen, such as helium or argon or an Inertga hydrogen mixture.
  • a pressure build-up with hydrogen followed by a pressure reduction takes place before starting the process - before the reactor is started - within the reactor.
  • this pressure build-up and pressure reduction takes place several times in succession, in particular three times in succession.
  • the cycle gas system may be comprised of this pressure build-up and pressure reduction. Preferably, however, it is provided that the cycle gas system is decoupled from the reaction space before the pressure build-up and pressure reduction and optionally a separate one
  • Rinsing program in particular with hydrogen, passes through.
  • the pressure build-up preferably takes place with a hydrogen volume flow (standard cubic meter [m 3 ] per hour [h]) per
  • Reactor volume (V R [m 3 ]) between 10 and 7000 m 3 / hV R , preferably between 300 and 1500 m 3 / hV R , more preferably between 500 and 1000 m 3 / hV R , in particular from about 520 m 3 / hV R.
  • V R [m 3 ] Reactor volume between 10 and 7000 m 3 / hV R , preferably between 300 and 1500 m 3 / hV R , more preferably between 500 and 1000 m 3 / hV R , in particular from about 520 m 3 / hV R.
  • Another aspect of the invention relates to polycrystalline silicon granules having a nitrogen content of less than 2 ppba. It particularly preferably has a nitrogen content of less than 1 ppba, in particular less than 0.5 ppba.
  • Preferred measurement methods for determining the nitrogen content are SIMS (Secondary Ion Mass Spectrometry), FTIR (Fourier Transform Infrared Spectroscopy) and / or analysis by means of an oxygen / nitrogen / hydrogen analyzer (e.g., ONH836 series from LECO).
  • no Si 3 N 4 could be detected by means of scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX).
  • SEM scanning electron microscopy
  • EDX energy-dispersive X-ray spectroscopy
  • Silicon granules in particular taking into account the detection limits of the abovementioned measuring methods, free of Si 3 N 4 .
  • the polycrystalline silicon of the present invention is considered to be free of Si 3 N 4 when no Si 3 N was detected in 200 SIMS analyzes.
  • the surface of the polycrystalline silicon granules preferably has a surface roughness of 20000 Ra 400 nm, preferably 10000> Ra ⁇ 700 nm.
  • the determination of the upper ⁇ surface roughness can be effected by means of optical profilometry.
  • the chlorine content of the polycrystalline silicon granules measured with the aid of a neutron activation analysis or X-ray fluorescence analysis is preferably between 0.01 and 30 ppma, more preferably between 0.1 and 20 ppma, in particular between 0.2 and 10 ppma.
  • Another aspect of the invention relates to the use of the polycrystalline silicon granules for the production of monocrystalline or multicrystalline silicon.
  • the monocrystalline silicon preferably has a number of stacking faults of less than 300, preferably less than 200, more preferably less than 100, in particular less than 10 per square centimeter.
  • the monocrystalline silicon preferably has a number of dislocation errors of less than 3, preferably less than 1, more preferably less than 0.3, in particular less than 0.1, per meter rod length.
  • the polysilicon granules according to the invention are preferably used for the production of single crystals by the Czochralski or Floatzone process.
  • Single-crystal silicon produced from polycrystalline silicon according to the invention by means of crucible pulling (Czochralski (CZ) method) preferably has an offset-free length of the single crystals of greater than 70%, preferably greater than 83%, particularly preferably greater than 87%, in particular greater than 90%.
  • polysilicon granules according to the invention for the production of multicrystalline silicon by means of block casting or continuous casting, multicrystalline block solidification in a Bridgman furnace (Bridgman-Stockbarger method), vertical gradient freeze (VGF) process, ribbon growth process Edge-defined film-fed growth (EFB) process and Direct Wafer TM process (1366technologies).
  • Bridgman furnace Bodgman-Stockbarger method
  • VVF vertical gradient freeze
  • EFB Edge-defined film-fed growth
  • Direct Wafer TM process 1366technologies
  • Multicrystalline silicon produced from the polycrystalline silicon according to the invention has an increased
  • Nitrogen in the silicon Si 3 N deposits are formed. These occur in the form of crystalline, needle-shaped and fibrous crystals. They can occur singly or in the form of clusters, often in conjunction with
  • Silicon carbide deposits are formed, for example, on crucible walls during the
  • Si 3 N 4 is not electrically conductive, but 4 crystallites show up along Si 3 N in multicrystalline
  • Fig. 1 shows the diagram of a plant for carrying out the method according to the invention.
  • the plant 20 according to FIG. 1 comprises three fluidized bed reactors 1, wherein the fluidized bed 2 is indicated in each case by dashed fields.
  • Each fluidized bed reactor 1 has at its reactor head 4 via an exhaust pipe 3, is discharged with the exhaust gas from the fluidized bed reactor 1.
  • a fluidizing gas in the present example, hydrogen
  • the hydrogen is external hydrogen withdrawn from a reservoir 15 and having a purity of 5.0.
  • reaction gases 1, in the present example TCS and hydrogen are fed to the reactors 1 via a gas line 17.
  • the reaction gases are each taken from a feed line 16 and can in principle be supplied to the reactor 1 together or separately from one another.
  • the exhaust gas discharged from the fluidized bed reactors 1 via the exhaust gas lines 3 is fed to a heat exchanger 11.
  • the heat exchanger 11 which usually comprises a plurality of condensation stages, separation into high-boiling constituents (for example hydrogen and impurities such as
  • Phosphines methane, nitrogen and arsenic compounds
  • low boiling components e.g., halosilanes
  • the still contaminated hydrogen in an adsorber 9, which has the task to remove the impurities such as phosphorus compounds (for example, phosphines), methane, hydrogen chloride and / or arsenic compounds.
  • the recovered hydrogen then passes through the gas lines 13 as recycle gas back into the reactors 1.
  • the cycle gas external hydrogen can be supplied from the reservoir 15.
  • heat exchanger 11, compressor 10, adsorber 9 and gas lines 13 is a circular gas system, in particular for the recovery of hydrogen.
  • the system 20 comprises a device 7 for silane / halosilane treatment.
  • This device 7 the low-boiling components of the exhaust gas are supplied.
  • the device 7 has the task of separating the recovered from the exhaust gas by means of condensation stages silane / halosilane mixtures.
  • the silane / halosilane mixture leaving the device 7 via a line 8 can either be returned as gas and / or liquid to the reactors 1 or used for other processes.
  • the gas chromatograph 12 serves to determine the nitrogen content at various points of the cycle gas system.
  • polysilicon granules were prepared by the process according to the invention with a nitrogen content in the recycle gas of less than 1000 ppmv (Examples 1, 4-6, 8, 10, 11).
  • polysilicon granules were further prepared in a reactor of identical construction, wherein the nitrogen content in the recycle gas was at or above 1000 ppmv (Examples 2, 3, 7, 9).
  • the deposition temperature was below the critical for the formation of Si 3 N temperature (T k ) of 1080 ° C. In the case of Examples 3 to 6, 8, 10 and 11, the deposition temperature was above T k (column 2, Table 1).
  • the nitrogen content in the recycle gas (column 3, table 1) was determined in each case with a gas chromatograph (GC) (process GC: Siemens Maxum edition II, separation column: RTX-1 fused-silica capillary, Fa. Restek, column length: 60 m) , The sample was taken via a sampling line at the exhaust pipe at the reactor head.
  • GC gas chromatograph
  • the content of silicon nitride (Si 3 N 4 ) in the polysilicon granules was determined by means of a scanning electron microscope (SEM) with EDX analysis unit. For this purpose, in each case several samples of the silicon granules obtained were analyzed at 200 sites and the maximum values were determined (column 4, Table 1).
  • An Si 3 N 4 content of 0% means that all 200 measurements were below the detection limit of 1 ppba.
  • a content of 1% means that 2 out of 200 measurements were above this detection limit.
  • offset-free rod length column 7, Table 1
  • the determination of the offset was observed optically when pulled to single crystal by a change in the pull edge.
  • the offset-free rod length (Ziehausbeute) is the percentage of the total rod length, which is free from dislocation errors. When measuring the entire rod length, the initial and final cone created during the drawing process are ignored. Relevant is therefore only the cylindrical rod length.
  • the number of stacking faults (Column 5, Table 1) in the obtained single crystals was determined by counting under the light microscope (Test Method ASTM F416). For the stacking error counts, test disks of the silicon rods were oxidized. Subsequently, the oxide layer was etched off and the defects were visualized with a structure etching. The counting of the defects was carried out under a light microscope with the aid of an image recognition software.
  • Examples 3,4, 8 and 10 show how the proportion of nitrogen in the recycle gas affects the Si 3 N 4 content in the polysilicon granules.
  • the granules from the above examples were all prepared at a 'deposition temperature of 1 ° C above T k, ie at 1081 ° C.
  • a nitrogen content of 1000 ppmv leads to a Si 3 N 4 content of 1.5%.
  • this Si 3 N 4 -containing granules for the production of silicon single crystals only 66% of the total rod length are offset-free.
  • Example 10 Reducing the nitrogen content in the recycle gas by more than half to 450 ppmv as in Example 10 lowers the Si 3 N 4 content of the granules to 0.5% and leads to single-crystalline silicon as a secondary product with 82% offset-free length.
  • the granules of Example 8 which was prepared at a nitrogen content of only 94 ppmv, no Si 3 N 4 was detectable. It was possible to obtain monocrystalline silicon with 90% offset-free rod length.
  • the deposition rate increases exponentially by three times and thus significantly increases the economic ⁇ friendliness of the process.
  • the granules of Examples 5, 6 and 11 were prepared at a deposition temperature well above T k .
  • the granules from Example 5 (T k + 23 ° C) was at a nitrogen content of only 0.4 ppmv produced. Si 3 N 4 was undetectable. In the secondary product, an offset-free length of 89% could be achieved.
  • the granules from example 6 were produced at a deposition temperature of 1202 ° C. and a nitrogen content of 550 ppmv. This nitrogen content in combination with the high deposition temperature resulted in a Si 3 N 4 -Ghalt of 2%. Accordingly, only a non-offset length of 55% could be obtained in the secondary product.
  • the granules according to Example 11 were also prepared at 1202 ° C. However, the nitrogen content in the recycle gas was only 0.4 ppmv. As in Example 5, Si 3 N 4 could no longer be detected. The offset-free length of the secondary product was 89%.

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Silicon Compounds (AREA)

Abstract

L'invention concerne un procédé de production de granulés de silicium polycristallin dans un réacteur à lit fluidisé. Ce procédé comprend une fluidisation de particules de germes de silicium au moyen d'un gaz de fluidisation dans un lit fluidisé qui est chauffé au moyen d'un dispositif de chauffage, du silicium élémentaire étant déposé par pyrolyse sur les particules de germes de silicium par addition d'un gaz de réaction contenant de l'hydrogène et du silane et/ou de l'halosilane, de manière à former les granulés de silicium polycristallin. Dans un processus continu, les gaz brûlés sont évacués du réacteur et l'hydrogène récupéré à partir de ces gaz brûlés est recyclé en tant que gaz de recyclage dans le réacteur à lit fluidisé. Le gaz de recyclage présente une teneur en azote inférieure à 1000 ppmv. En outre, l'invention concerne des granulés de silicium polycristallin présentant une teneur en azote inférieure à 2 ppba.
EP16823183.5A 2016-12-14 2016-12-14 Procédé de production de silicium polycristallin Withdrawn EP3649078A1 (fr)

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US (1) US11440803B2 (fr)
EP (1) EP3649078A1 (fr)
JP (1) JP6977041B2 (fr)
KR (1) KR102220841B1 (fr)
CN (1) CN110049948B (fr)
CA (1) CA3045350A1 (fr)
MY (1) MY194441A (fr)
WO (1) WO2018108258A1 (fr)

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WO2018108258A8 (fr) 2019-05-16
CN110049948B (zh) 2022-10-11
JP6977041B2 (ja) 2021-12-08
WO2018108258A1 (fr) 2018-06-21
CN110049948A (zh) 2019-07-23
KR102220841B1 (ko) 2021-02-26
CA3045350A1 (fr) 2018-06-21
MY194441A (en) 2022-11-30
JP2020502027A (ja) 2020-01-23
US11440803B2 (en) 2022-09-13
US20200131043A1 (en) 2020-04-30
KR20190074317A (ko) 2019-06-27

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