WO2022045239A1 - 多結晶シリコン破砕塊及びその製造方法 - Google Patents
多結晶シリコン破砕塊及びその製造方法 Download PDFInfo
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- WO2022045239A1 WO2022045239A1 PCT/JP2021/031313 JP2021031313W WO2022045239A1 WO 2022045239 A1 WO2022045239 A1 WO 2022045239A1 JP 2021031313 W JP2021031313 W JP 2021031313W WO 2022045239 A1 WO2022045239 A1 WO 2022045239A1
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- polycrystalline silicon
- cleaning
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- crushed
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- 229910021420 polycrystalline silicon Inorganic materials 0.000 title claims abstract description 176
- 238000004519 manufacturing process Methods 0.000 title claims description 21
- 229910052751 metal Inorganic materials 0.000 claims abstract description 89
- 239000002184 metal Substances 0.000 claims abstract description 88
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 56
- 229910052802 copper Inorganic materials 0.000 claims abstract description 33
- 239000010949 copper Substances 0.000 claims abstract description 33
- 229910052742 iron Inorganic materials 0.000 claims abstract description 31
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 31
- 239000011701 zinc Substances 0.000 claims abstract description 31
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims abstract description 28
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 claims abstract description 25
- 238000004140 cleaning Methods 0.000 claims description 229
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 claims description 130
- 239000007864 aqueous solution Substances 0.000 claims description 99
- 238000005406 washing Methods 0.000 claims description 84
- 238000000034 method Methods 0.000 claims description 59
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 claims description 54
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 30
- 229910052710 silicon Inorganic materials 0.000 claims description 26
- 239000010703 silicon Substances 0.000 claims description 26
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 15
- 239000002253 acid Substances 0.000 claims description 10
- 229910052759 nickel Inorganic materials 0.000 claims description 10
- 229910052721 tungsten Inorganic materials 0.000 claims description 7
- 239000011737 fluorine Substances 0.000 claims description 6
- 229910052731 fluorine Inorganic materials 0.000 claims description 6
- 229910052804 chromium Inorganic materials 0.000 claims description 5
- 229910052719 titanium Inorganic materials 0.000 claims description 5
- LVXIMLLVSSOUNN-UHFFFAOYSA-N fluorine;nitric acid Chemical compound [F].O[N+]([O-])=O LVXIMLLVSSOUNN-UHFFFAOYSA-N 0.000 claims description 4
- 229910052750 molybdenum Inorganic materials 0.000 claims description 4
- 239000011575 calcium Substances 0.000 claims description 3
- 239000011651 chromium Substances 0.000 claims description 3
- PXGOKWXKJXAPGV-UHFFFAOYSA-N Fluorine Chemical compound FF PXGOKWXKJXAPGV-UHFFFAOYSA-N 0.000 claims 1
- 239000007788 liquid Substances 0.000 description 33
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 28
- 229910001868 water Inorganic materials 0.000 description 27
- 239000012535 impurity Substances 0.000 description 25
- 238000005530 etching Methods 0.000 description 23
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 20
- 229910017604 nitric acid Inorganic materials 0.000 description 20
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 19
- 238000011109 contamination Methods 0.000 description 19
- 229920005591 polysilicon Polymers 0.000 description 11
- 239000000047 product Substances 0.000 description 10
- 239000000243 solution Substances 0.000 description 9
- 238000001035 drying Methods 0.000 description 8
- 239000001257 hydrogen Substances 0.000 description 8
- 229910052739 hydrogen Inorganic materials 0.000 description 8
- 229910021421 monocrystalline silicon Inorganic materials 0.000 description 8
- 229910021642 ultra pure water Inorganic materials 0.000 description 8
- 239000012498 ultrapure water Substances 0.000 description 8
- 230000000694 effects Effects 0.000 description 7
- 150000002739 metals Chemical class 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- 229920005989 resin Polymers 0.000 description 7
- -1 silane compound Chemical class 0.000 description 7
- 239000002994 raw material Substances 0.000 description 6
- 235000012431 wafers Nutrition 0.000 description 6
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 5
- 239000003929 acidic solution Substances 0.000 description 5
- 238000001095 inductively coupled plasma mass spectrometry Methods 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000002344 surface layer Substances 0.000 description 5
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 4
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 4
- 229910017052 cobalt Inorganic materials 0.000 description 4
- 239000010941 cobalt Substances 0.000 description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000007654 immersion Methods 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 4
- 239000004810 polytetrafluoroethylene Substances 0.000 description 4
- WGTYBPLFGIVFAS-UHFFFAOYSA-M tetramethylammonium hydroxide Chemical compound [OH-].C[N+](C)(C)C WGTYBPLFGIVFAS-UHFFFAOYSA-M 0.000 description 4
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 3
- 229910000531 Co alloy Inorganic materials 0.000 description 3
- 229910002651 NO3 Inorganic materials 0.000 description 3
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 3
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical compound [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 description 3
- 239000004809 Teflon Substances 0.000 description 3
- 229920006362 Teflon® Polymers 0.000 description 3
- 238000005229 chemical vapour deposition Methods 0.000 description 3
- 230000003749 cleanliness Effects 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
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- 238000000605 extraction Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000001556 precipitation Methods 0.000 description 3
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 3
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 2
- 230000002378 acidificating effect Effects 0.000 description 2
- 150000007513 acids Chemical class 0.000 description 2
- 238000007792 addition Methods 0.000 description 2
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
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- 239000000356 contaminant Substances 0.000 description 2
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- 230000001066 destructive effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 150000002431 hydrogen Chemical class 0.000 description 2
- 150000002500 ions Chemical class 0.000 description 2
- 150000002823 nitrates Chemical class 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000006722 reduction reaction Methods 0.000 description 2
- 239000004065 semiconductor Substances 0.000 description 2
- 229910000077 silane Inorganic materials 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- ZDHXKXAHOVTTAH-UHFFFAOYSA-N trichlorosilane Chemical compound Cl[SiH](Cl)Cl ZDHXKXAHOVTTAH-UHFFFAOYSA-N 0.000 description 2
- 239000005052 trichlorosilane Substances 0.000 description 2
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 2
- 239000010937 tungsten Substances 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- JPVYNHNXODAKFH-UHFFFAOYSA-N Cu2+ Chemical compound [Cu+2] JPVYNHNXODAKFH-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004480 active ingredient Substances 0.000 description 1
- 238000005273 aeration Methods 0.000 description 1
- 239000012670 alkaline solution Substances 0.000 description 1
- 230000002238 attenuated effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- SLLGVCUQYRMELA-UHFFFAOYSA-N chlorosilicon Chemical compound Cl[Si] SLLGVCUQYRMELA-UHFFFAOYSA-N 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 229910001431 copper ion Inorganic materials 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 239000003344 environmental pollutant Substances 0.000 description 1
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- 239000012634 fragment Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 150000007522 mineralic acids Chemical class 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 235000005985 organic acids Nutrition 0.000 description 1
- 235000006408 oxalic acid Nutrition 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 238000005554 pickling Methods 0.000 description 1
- 231100000719 pollutant Toxicity 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 239000008213 purified water Substances 0.000 description 1
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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
- C01B33/037—Purification
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/80—Compositional purity
Definitions
- the present invention relates to a polycrystalline silicon crushed lump, and more particularly to a polycrystalline silicon crushed lump having a clean surface, which is obtained by crushing a polycrystalline silicon rod.
- the present invention also relates to a method for producing a polycrystalline silicon crushed mass.
- High-density integrated electronic circuits require high-purity single crystal silicon wafers.
- a single crystal silicon wafer is obtained by cutting out from a single crystal silicon rod manufactured by the CZ method (Czochralski method).
- Polycrystalline silicon, also called polysilicon, is used as a raw material for producing this CZ method single crystal silicon rod.
- the Siemens method is known as a method for producing such polycrystalline silicon.
- the silicon core wire placed inside the Belger-type reaction vessel is heated to the precipitation temperature of silicon by energization, and gas and hydrogen of a silane compound such as trichlorosilane (SiHCl 3 ) and monosilane (SiH 4 ) are added to this. It is supplied and polycrystalline silicon is precipitated on the silicon core wire by a chemical vapor deposition method to obtain a high-purity polysilicon rod.
- a silane compound such as trichlorosilane (SiHCl 3 ) and monosilane (SiH 4 )
- the obtained polycrystalline silicon rod is crushed and sorted into a size suitable for manufacturing the equipment used in the next process or the object to be manufactured in the next process, and then transported to the next process.
- metal impurities even in small amounts, cause defective sites in single crystal silicon wafers used in high density integrated electronic circuits and the like, which ultimately degrades device performance and limits circuit density. I will let you. For this reason, it is necessary to reduce the concentration of metal impurities on the surface of polycrystalline silicon crushed lumps as much as possible, and cleaning is performed to remove metal impurities on the surface and improve the surface cleanliness. ..
- the hydrofluoric acid aqueous solution used in the second cleaning treatment also undergoes dissolution (etching) of the silicon surface by nitric acid, thus causing the metal on the surface of the polysilicon. Impurity contamination is improved to a large extent.
- Non-Patent Document 1 page 16
- copper has a high redox potential, and even if it is ionized, it comes into contact with silicon again, is reduced, and reattaches to the silicon surface. Therefore, copper is a metal having a very high heat diffusion rate in silicon, and therefore, due to the low removability, if even a small amount remains in the crushed lump of polycrystalline silicon which is a raw material, this is the final product. There was a concern that it would diffuse to the device region on the surface of the crystal substrate, resulting in deterioration of electronic circuit performance and reliability (see Non-Patent Document 2, Paragraph 3).
- Patent Document 2 A method for producing a crushed mass is proposed (Patent Document 2). That is, according to the method of Patent Document 2, the surface is contaminated with tungsten or cobalt by performing cleaning with an alkaline aqueous solution containing hydrogen peroxide as a second cleaning step following the first cleaning step with the aqueous nitric acid solution. It is possible to obtain a polycrystalline silicon crushed mass in which the amount of hydrogen peroxide is greatly reduced. According to this method, most of the surface metals other than tungsten and cobalt can be satisfactorily reduced, the total concentration thereof is 15.0 pttw, and the copper concentration is also reduced to 0.30 pttw or less in the examples. ..
- Patent Document 3 includes a first cleaning step using an acidic cleaning solution containing hydrofluoric acid, hydrochloric acid and hydrogen peroxide, and nitric acid and hydrofluoric acid as a method for cleaning the crushed polycrystalline silicon mass.
- a method comprising a second cleaning step using a cleaning solution is disclosed. Further, in the examples of Patent Document 3, the details of the cleaning process are disclosed as follows.
- the polysilicon fragments were cleaned by the following treatment: 1.
- Pre-cleaning Pickling for 20 minutes with HF / HCl / H 2 O 2 aqueous solution containing 5% by weight of HF, 8% by weight of HCl and 3% by weight of H 2 O 2 with water at 25 +/- 5 ° C.
- the stripping due to corrosion of silicon was about 0.02 ⁇ m. Wash at 2.22 ° C for 5 minutes.
- Key cleansing Corrosion at 8 ° C. for 5 minutes in HF / HNO 3 aqueous solution containing 3 % by weight HF and 365% by weight of HNO with water. The scraping due to corrosion was about 12 ⁇ m. 4. Wash at 22 ° C for 5 minutes.
- Patent Document 2 can significantly reduce the surface metal concentration in the washed polycrystalline silicon crushed mass, and in particular, the copper concentration, which is not easily removable by washing with hydrofluoric acid, is also carried out. It is an excellent method that can reduce the value to the value in the example, but on the other hand, the removability of iron and zinc is not satisfactory. That is, in the cleaning method of Patent Document 2, many surface metal concentrations can be reduced because of the large effect of cleaning with an alkaline aqueous solution containing hydrogen peroxide in the second cleaning step. This is because even a metal that is not sufficiently removed by the action of hydrofluoric acid is oxidized by contact with the hydrogen peroxide to increase its solubility in an alkaline aqueous solution (preferably pH 9 to 14).
- an alkaline aqueous solution preferably pH 9 to 14
- Non-Patent Document 1 see FIG. 2, page 16, right column, line 8 to page 17, left column, line 6,.
- the adhesiveness to the oxide film surface formed on the silicon surface largely depends on the pH change of the cleaning liquid, and the cleaning liquid in the acidic to neutral range can be kept low in surface concentration.
- the adhesion of silicon to the surface of the oxide film is greatly increased. This is because the iron and zinc easily form hydrated ions with H2O in an acidic solution, whereas they form complex ions with OH ⁇ in an alkaline solution, and the oxide film is formed. It is thought that this is because it easily adheres to the surface.
- the cleaning step of Patent Document 3 is similar to the cleaning step of the present application described later, but differs in that a cleaning aqueous solution containing hydrochloric acid is used in addition to hydrofluoric acid and hydrogen peroxide in the first cleaning step.
- Hydrofluoric acid aqueous solution is a strong acidic solution, and exhibits high removability by ionizing and dissolving many metals.
- this effect is attenuated in the presence of other acids, especially hydrochloric acid, especially Na, Mg, Al, K, Ca, Cr, Fe, Ni, Co, Cu, Zn, W, Ti adhering to polysilicon.
- Mo, especially Fe and Zn have been found to be inadequately removable by the studies of the present inventors.
- the present inventors have continued to study diligently.
- the first cleaning is performed with a cleaning aqueous solution containing hydrogen peroxide and hydrochloric acid and the content of hydrochloric acid is equal to or less than a predetermined value, and then the second cleaning is performed.
- the present invention has been completed by finding that the above-mentioned problems can be solved by washing with an aqueous solution of fluorinated nitrate.
- the present invention is a polycrystalline silicon crushed mass having a surface metal concentration of 15.0 pptw or less and a copper concentration of 0.30 pttw or less among the surface metal concentrations. Further, the present invention provides a polycrystalline silicon crushed mass characterized in that the total concentration of iron and zinc among the surface metal concentrations is 2.00 pttw or less.
- the present invention comprises the method for producing the above-mentioned polycrystalline silicon crushed mass.
- A Crushing process of polycrystalline silicon rod
- B First cleaning in which the crushed lump of the obtained polycrystalline silicon rod is brought into contact with an aqueous solution for first cleaning containing hydrogen peroxide and hydrofluoric acid and having an acid content other than hydrofluoric acid of 3% by mass or less.
- Process (C) A second cleaning step of contacting the cleaned product of the polycrystalline silicon crushed mass that has undergone the first cleaning step with a second cleaning aqueous solution composed of fluorine.
- the above-mentioned manufacturing method comprising the above-mentioned production method is also provided.
- the surface of the crushed polycrystalline silicon lump of the present invention is highly cleaned, and the metal impurity concentration is 15.0 pttw or less, particularly the copper concentration is 0.30 pttw or less, but the total concentration of iron and zinc is also 2. It is at a low level of .00 pttw or less.
- iron and zinc if remaining on the surface of silicon, cause defects and become major metals that cause deterioration of electronic circuit performance and reliability. Therefore, the polycrystalline silicon crushed mass of the present invention, in which these are reduced in a compatible manner with the above copper, is a CZ method single crystal for cutting out a single crystal silicon wafer having few defects in the semiconductor field where the circuit density is increasing. It is extremely useful as a raw material for manufacturing silicon rods.
- the polycrystalline silicon crushed mass according to the present invention is obtained by crushing and classifying a polycrystalline silicon rod.
- the above-mentioned polycrystalline silicon rod is not limited in the manufacturing method, but usually, the one manufactured by the Siemens method is targeted.
- the Simens method is a vapor phase deposition of polycrystalline silicon on the surface of a silicon core wire by contacting a silane raw material gas such as trichlorosilane or monosilane with a heated silicon core wire by a CVD (Chemical Vapor Deposition) method. It is a method of (precipitation).
- the obtained polycrystalline silicon rod is crushed to obtain a polycrystalline silicon crushed mass.
- the size of the polycrystalline silicon crushed mass is preferably at least 90% by mass, and the major axis length is preferably in the range of 2 to 160 mm. In this range, it is generally divided according to the particle size, specifically, at least 90% by mass is in the range of 90 to 160 mm in major axis length, and at least 90% by mass is in the major axis length.
- Impurities derived from raw materials and peripheral devices are mixed into the polycrystalline silicon rod during the manufacture of the polycrystalline silicon rod. This is called bulk contamination.
- the polycrystalline silicon crushed mass is subjected to post-treatment steps such as crushing, classification, cleaning, transportation, packaging, etc. In each process of the above, contact with equipment and handling members causes further various metal contamination. These metals adhere to the surface of polycrystalline silicon and are further incorporated into the oxide film formed on the surface and remain. This is called surface contamination.
- the target elements of the surface metal concentration of the polycrystalline silicon crushed mass are 14 elements of Na, Mg, Al, K, Ca, Cr, Fe, Ni, Co, Cu, Zn, W, Ti and Mo. Can be mentioned.
- the polycrystalline silicon crushed mass according to the present invention has the above-mentioned surface metal concentration of 15.0 pttw or less.
- the surface metal concentration is more preferably 7.0 to 13.0 pttw. Since the surface metal concentration is so low, it is useful as a raw material for manufacturing a single crystal silicon rod by the CZ method for cutting out a single crystal silicon wafer having few defects.
- the polycrystalline silicon crushed mass according to the present invention has a low surface metal concentration, and particularly a low copper concentration of 0.30 pttw or less.
- a low surface metal concentration As mentioned above, if copper remains in the metal, it is a metal that easily causes deterioration of electronic circuit performance and reliability, but on the other hand, hydrofluoric acid, which is a general-purpose active ingredient of cleaning liquid, has a sufficient cleaning effect. Since it is a metal that is difficult to exhibit, the value of the polycrystalline silicon crushed mass of the present invention having a sufficiently low surface copper concentration is great.
- the surface copper concentration is particularly preferably 0.20 pttw or less.
- the lower limit of the surface copper concentration is usually 0.05 pttw, preferably 0.10 pttw.
- the surface concentration of copper which is difficult to remove with the cleaning liquid containing hydrofluoric acid, is as low as 0.30 pttw or less, and is compatible with this.
- the surface iron concentration and the surface zinc concentration are also reduced to 2.00 pttw or less in terms of the total concentration. That is, the surface copper concentration is difficult to reduce, but it can be reduced to the desired degree by cleaning with an alkaline aqueous solution containing hydrogen hydrogen, which is applied in Patent Document 2.
- the cleaning liquid exhibits alkaline water, it becomes difficult to keep the surface metal concentrations of the iron and zinc low.
- the surface copper concentration is low, but also the surface iron concentration and the surface zinc concentration are also low.
- the total concentration of iron and zinc is more preferably 1,80 pttw or less.
- the lower limit of the total concentration of the surface iron concentration and the surface zinc concentration is usually 0.60 pttw, preferably 1.00 pttw.
- the iron concentration is preferably 1.25 pttw or less, and more preferably 1.00 pttw or less.
- the lower limit of the surface iron concentration is usually 0.50 pttw, preferably 0.80 pttw.
- the zinc concentration is preferably 0.75 pttw or less, and more preferably 0.60 pttw or less.
- the lower limit of the surface zinc concentration is usually 0.10 pptw, preferably 0.20 pttwpptw.
- the crushed polycrystalline silicon lump according to the present invention preferably has a nickel concentration of 0.30 pttw or less, and more preferably 0.20 pttw or less.
- the lower limit of the surface nickel concentration is usually 0.05 pttw, preferably 0.10 pttw.
- the lower limit of the total surface metal concentration and the lower limit of the surface copper, iron, zinc, and nickel concentrations may be in the above ranges. ..
- the surface metal concentration of the above-mentioned polycrystalline silicon crushed mass refers to a value measured by the following method. That is, in the metal concentration analysis on the surface of the crushed polycrystal silicon lump to be measured, the surface of the crushed polycrystal silicon lump is decomposed and removed, and each metal element in the obtained sample liquid is inductively coupled plasma mass spectrometry (ICP-MS). ) Is a method of analysis and quantification. Specifically, about 400 g of polycrystalline silicon crushed mass is transferred to 500 ml of clean Teflon (registered trademark) beaker, and 100 ml of the solution (50% by mass-HF: 10 ml, 70% by mass-nitric acid: 90 ml) is added to 25.
- Teflon registered trademark
- Extraction was performed at ° C. for 15 minutes.
- the liquid content in the Teflon beaker and the surface of the polycrystalline silicon crushed mass were washed with 100 ml of ultrapure water, and the cleaning solution was transferred to a clean Teflon beaker to prepare a surface extract of the polycrystalline silicon crushed mass.
- the surface extract of the polycrystalline silicon crushed mass was evaporated to dryness, 3.5% by mass-nitrate aqueous solution was added, the volume was adjusted to 20.0 ml, and ICP-MS measurement was performed, and Na, Mg, Al, K, Ca, Cr were performed. , Fe, Ni, Co, Cu, Zn, W, Ti, and Mo were obtained, and the values were calculated as the concentration values per total weight of the crushed polycrystalline silicon mass.
- the method for producing the crushed polycrystalline silicon lump having a clean surface is not limited, but if a suitable production method is shown, the method is as follows. That is, (A) Crushing process of polycrystalline silicon rod, (B) First cleaning in which the crushed lump of the obtained polycrystalline silicon rod is brought into contact with an aqueous solution for first cleaning containing hydrogen peroxide and hydrofluoric acid and having an acid content other than hydrofluoric acid of 3% by mass or less. Process, (C) A second cleaning step of contacting the cleaned product of the polycrystalline silicon crushed mass that has undergone the first cleaning step with a second cleaning aqueous solution composed of fluorine. It is a method including. According to this method, the surface contamination received by (a) the crushing step can be highly cleaned within the range specified by the present invention in the subsequent cleaning steps (b) to (c). Become.
- the CZ method polycrystalline silicon rod may be crushed to the desired size according to a conventional method using a breaking tool.
- these destructive tools include mechanical impact tools such as jaw crushers, roll crushers, and hammer mills, as well as manual hammers.
- WC / Co alloy is usually used even among hard metals.
- the content of tungsten carbide is preferably 78 to 90% by mass, more preferably 80 to 88% by mass, and the content of cobalt is preferably 10 to 22% by mass, more preferably. It is 12 to 20% by mass.
- the crushed mass obtained is preferably classified into the crushed mass having the size.
- the first cleaning step the crushed lump of the polycrystalline silicon rod obtained in the above step (a) is brought into contact with the first cleaning aqueous solution for cleaning.
- the first cleaning aqueous solution contains hydrogen peroxide and hydrofluoric acid.
- Hydrofluoric acid aqueous solution is a strong acidic solution, has strong metal solubility, and ionizes many metals.
- iron and zinc are also removed in the ionized state, and reattachment to the silicon surface is suppressed.
- metal impurities incorporated in it can also be removed.
- the first cleaning aqueous solution contains hydrogen peroxide
- the hydrogen peroxide is more oxidized than the copper. Since the reduction potential is high, the copper ions dissolved in the first cleaning aqueous solution are not reduced even when they come into contact with silicon and remain in an ionic state, and are well prevented from being reattached to the surface of the crushed mass.
- the hydrofluoric acid concentration is preferably 1.0 to 20.0% by mass, preferably 2.0 to 10.0% by mass, in consideration of the high effect of lowering the surface metal concentration. It is more preferable to have it.
- the hydrogen peroxide contained in the hydrofluoric acid aqueous solution is preferably 1.0 to 10.0% by mass, preferably 2.0 to 7.0% by mass, from the effect of lowering the surface copper concentration. Is more preferable.
- the first cleaning aqueous solution may contain an acid other than hydrofluoric acid.
- Acids other than hydrofluoric acid are, for example, inorganic acids such as hydrochloric acid and sulfuric acid, and organic acids such as acetic acid and oxalic acid. If an acid other than hydrofluoric acid is contained, the metal solubility of hydrofluoric acid may be impaired. Therefore, the content thereof is 3% by mass or less, preferably 1% by mass, based on the total mass of the first aqueous solution for cleaning. % Or less, and it is more preferable that it is not substantially contained.
- the rest other than the above is water.
- water used for the first cleaning aqueous solution it is naturally preferable to use water having a low metal content, and ultrapure water is usually used.
- the cleaning method may be to bring the polycrystalline silicon crushed mass into contact with the first aqueous solution for cleaning.
- a first cleaning aqueous solution may be sprayed on the crushed polycrystalline silicon mass.
- a method of immersing the polycrystalline silicon crushed lump in the first cleaning aqueous solution is adopted.
- the immersion tank a box-shaped structure or the like may be appropriately used. In the dipping, it is preferable to bring the crushed polycrystalline silicon lumps into contact with each other while swinging, and the swinging method is not particularly limited, and examples thereof include vertical movement and swing movement.
- Cleaning in the first cleaning process can also be performed in multiple stages.
- the concentration of hydrofluoric acid and the concentration of hydrogen peroxide in the cleaning aqueous solution at each stage may be the same or different.
- the temperature of the first cleaning aqueous solution is not particularly limited, but is preferably 5 to 40 ° C, more preferably 10 to 30 ° C.
- the contact time between the first washing aqueous solution and the polycrystalline silicon crushed mass is usually 1 to 20 minutes, preferably 2 to 15 minutes.
- Second cleaning step the cleaning product of the polycrystalline silicon crushed lump obtained in the above (b) first cleaning step is brought into contact with the second cleaning aqueous solution for cleaning.
- the second cleaning aqueous solution consists of a fluorine nitric acid aqueous solution.
- Hydrofluoric acid is a mixed acid of hydrofluoric acid and nitric acid.
- metal impurities adhering to the surface of the polycrystalline silicon lump of silicon and incorporated in the oxide film formed on the surface are satisfactorily removed including the copper, iron and zinc. can.
- Some metal impurities are embedded in the silicon surface layer due to the impact of a hammer when crushing a polycrystalline silicon rod and the vibration of a sieve during classification. The metal impurities embedded in these surface layer portions cannot be completely removed by the cleaning in the above (b) first cleaning step, and a trace amount remains.
- the hydrofluoric acid aqueous solution of the second cleaning aqueous solution in the second cleaning step has a high solubility of the above-mentioned metal impurities by the hydrofluoric acid aqueous solution and a new action of removing the oxide film by nitric acid. It also has an oxide film forming action. Therefore, in the second cleaning step, the surface layer portion is etched on the surface of the polycrystalline silicon crushed mass while the removal of the oxide film and the formation of the oxide film proceed at the same time. Thus, the metal impurities embedded in the surface layer portion of the crushed lumps that could not be removed in the first cleaning step (b) are highly removed, and the polycrystalline silicon crushed lumps are obtained in the clean surface state.
- the hydrofluoric acid concentration is preferably 0.1 to 3.0% by mass, preferably 0.2 to 2.5% by mass, in consideration of the high effect of lowering the surface metal concentration. Is more preferable.
- the nitric acid concentration is preferably 40 to 70% by mass, more preferably 50 to 70% by mass, because of its high solubility on the surface of the crushed material.
- water having a low metal content As a matter of course, it is preferable to use water having a low metal content as the water used for the second cleaning aqueous solution, and ultrapure water is usually used.
- the cleaning method in the second cleaning step the same method as in the contact between the polycrystalline silicon crushed mass and the first cleaning aqueous solution in the above (b) first cleaning step can be used.
- the cleaning liquid is consumed by the reaction with silicon, so it is preferable to add or replace the cleaning liquid as necessary.
- Cleaning in the second cleaning process can also be performed in multiple stages.
- the hydrofluoric acid concentration and the nitric acid concentration of the washing aqueous solution at each stage may be the same or different.
- the temperature of the aqueous cleaning solution is not particularly limited, but is preferably 0 to 70 ° C, more preferably 5 to 40 ° C, and particularly preferably 10 to 30 ° C.
- the etching allowance on the surface of the polycrystalline silicon crushed material may be appropriately determined according to the size and shape of the polycrystalline silicon to be cleaned and the amount of contamination in the crushing step.
- the etching allowance is preferably 1 to 15 ⁇ m, more preferably 3 to 13 ⁇ m.
- the contact time between the aqueous solution of fluorine nitric acid and the crushed polycrystalline silicon mass it is usually 1 to 20 minutes, preferably 2 to 15 minutes.
- the etching allowance of the polycrystalline silicon crushed mass means the amount (thickness) of silicon removed by etching, and as will be described later, the polycrystalline silicon small piece etched together with the polycrystalline silicon crushed mass. The value obtained by the weight difference before and after etching of the group.
- the third cleaning step is performed because metal impurities may be dissolved at a considerably high concentration in the cleaning liquid after the (c) second cleaning step, and the step is completed.
- a part of the metal impurities contained in the cleaning liquid may be taken in a small amount again in the oxide film newly formed on the surface of the polycrystalline silicon crushed mass. That is, the crushed polysilicon is again brought into contact with a third cleaning aqueous solution containing hydrogen peroxide and hydrofluoric acid to remove metal impurities incorporated in the new oxide film.
- the details of cleaning in the third cleaning step are the same as in the above (b) first cleaning step.
- the preferred embodiment of the third washing aqueous solution is also the same as that of the first washing aqueous solution.
- the aqueous solution containing hydrogen peroxide and hydrofluoric acid discharged after the third washing step (d) has the same liquid composition as the first washing step (b) in the upstream step of washing, and the liquid composition is the same. Considering the cleanliness required for the cleaning liquid used in the first cleaning step, it is in a sufficiently acceptable state, and it is efficient to reuse it in this step. That is, the cleaning liquid discharged from the third cleaning step may be circulated in the first cleaning step and reused as a part or all of the first cleaning aqueous solution.
- the polycrystalline silicon from which the oxide film has been removed in the third cleaning step can gradually form an oxide film in the atmosphere.
- the oxide film gradually formed in the atmosphere forms non-uniformly on the surface of polycrystalline silicon, which may take in contaminants. Therefore, (e) in the fourth cleaning step, by forming an oxide film on the surface of the crushed mass in advance by the action of nitric acid, the uptake of pollutants in the atmosphere is further suppressed. Since the metal impurities have already been highly removed by the cleaning steps (b) to (d), there is almost no possibility that the metal impurities will remain in the oxide film formed in the fourth cleaning step.
- the details of cleaning in the fourth cleaning step are the same as in the above (c) second cleaning step.
- the preferred embodiment of the fourth washing aqueous solution is also substantially the same as that of the second washing aqueous solution, but the concentration of hydrofluoric acid may be low in the fourth washing step because the oxide film remains. Therefore, the hydrofluoric acid concentration in the fourth aqueous solution for cleaning may be slightly lower than that in the second aqueous solution for cleaning from the viewpoint of retaining the surface oxide layer and reliably removing metal impurities.
- the fourth washing step is divided into two or more washing steps with different concentrations of hydrofluoric acid, and in particular, a washing aqueous solution having a reduced hydrofluoric acid concentration is used in order to ensure that the oxide film remains in the subsequent washing.
- a washing aqueous solution having a reduced hydrofluoric acid concentration is used in order to ensure that the oxide film remains in the subsequent washing.
- the etching allowance on the surface of the polycrystalline silicon crushed material in the fourth cleaning step is preferably 0.5 to 10 ⁇ m, and the total etching allowance is 30 ⁇ m together with the etching allowance in the second cleaning step (c). It is preferable that the range does not exceed.
- the fluorinated aqueous solution discharged after the fourth washing step (e) has the same liquid composition as the second washing step (c) in the upstream washing step, and is used in the second washing step. Given the cleanliness required of the second cleaning aqueous solution, it is in a sufficiently acceptable state and therefore it is efficient to reuse it in this step. That is, the cleaning liquid discharged from the fourth cleaning step may be circulated in the second cleaning step and reused as a part or all of the second cleaning aqueous solution.
- a large amount of silicon fine powder is usually attached to the surface of the polycrystalline silicon rod crushed mass obtained in the step (a). Since these silicon fine powders not only contain a large amount of impurities but also (b) impair the detergency in the first cleaning step, it is preferable to remove them as much as possible before using them in (b) the first cleaning step. Specifically, it is preferable to preliminarily contact the polycrystalline silicon crushed mass with pure water or ultrapure water before contacting it with the first cleaning aqueous solution to remove the silicon fine powder adhering to the surface.
- a water washing step may be included between each washing step and / or after the washing is completed.
- the washing step it is possible to suppress the carry-in of the washing liquid to the next step, and it is also effective from the viewpoint of removing the contaminants adhering to the surface of the polycrystalline silicon crushed mass.
- washing with water may bring water into the next step and reduce the concentration of the cleaning component in the cleaning liquid, thereby reducing the ability of the cleaning liquid to remove metal impurities. From this point of view, the washing step may be omitted.
- the water used in the cleaning step it is preferable to use purified water having a small amount of metal impurities contained in the water, and it is more preferable to use ultrapure water.
- a drying step may be included after the final washing step of the above-mentioned polycrystalline silicon crushed mass. This makes it possible to remove the water adhering to the surface of the polycrystalline silicon crushed mass.
- the drying method include natural drying, aeration drying, heat drying, vacuum drying and the like. As the drying method, a plurality of methods may be combined. Further, cooling may be performed at the same time as drying.
- the polycrystalline silicon crushed lumps obtained as described above are preferably stored in a resin bag to form a polycrystalline silicon crushed lump package.
- a resin material such as polyethylene, polypropylene, polyvinyl chloride, or nylon can be used for the resin bag.
- the shape of the bag is not particularly limited as long as it can accommodate the polycrystalline silicon crushed mass and can be sealed.
- etching allowance and the amount of surface metal contamination of the polycrystalline silicon crushed mass are the values obtained as follows.
- Etching allowance for crushed polycrystalline silicon A group of 50 polycrystalline silicon pieces, which are cubes with a side of about 7 mm, were prepared for measuring the etching allowance . The total mass of the polycrystalline silicon small pieces in a dry state was measured in advance, and the particles were housed in a polytetrafluoroethylene (PTFE) net and subjected to washing together with the crushed polycrystalline silicon lumps. Next, the total mass of the polysilicon small pieces after the cleaning treatment is measured, and the thickness of the removed surface layer (etching allowance) is measured based on the mass difference before and after the cleaning treatment and the total surface area of the polysilicon small pieces. ) was calculated.
- PTFE polytetrafluoroethylene
- the surface extract of the polycrystalline silicon crushed mass was evaporated to dryness, 3.5% by mass-nitrate aqueous solution was added, the volume was adjusted to 20.0 ml, and ICP-MS measurement was performed, and Na, Mg, Al, K, Ca, Cr were performed. , Fe, Ni, Co, Cu, Zn, W, Ti, Mo, and the mass of each surface metal was measured. The measured value of each surface metal mass was divided by the mass of the polycrystalline silicon crushed mass before extraction, and evaluated as the content per unit mass (pptw) of the polycrystalline silicon crushed mass. As the ICP-MS measuring device, "8900" manufactured by Agilent was used. Four measurements were performed in each Example and Comparative Example, and the average value was calculated.
- Example 1 ⁇ (A) Crushing process> A polycrystalline silicon rod is manufactured in a reduction reaction furnace by the Siemens method, air passed through a HEPA (High Efficiency Particulate Air) filter is introduced into the furnace, the furnace is opened to the atmosphere, and the polycrystalline silicon rod is used in the furnace. I took it out.
- the polycrystalline silicon rod taken out is a hammer whose striking part is made of a tungsten carbide / cobalt alloy (tungsten carbide content 82% by mass, cobalt content 18% by mass), and at least 90% by mass has a major axis. It was crushed so as to be a crushed mass having a length in the range of 10 to 120 mm.
- the polycrystalline silicon crushed mass obtained through the above cleaning method was stored in a resin bag after measuring the amount of surface metal contamination.
- Table 1 shows the measurement results of the amount of surface metal contamination.
- the total etching allowance in the table includes the thickness of the oxide film removed in the first cleaning step and the third cleaning step in addition to the etching allowance in the second cleaning step and the fourth cleaning step.
- Example 2 (D) The cleaning liquid discharged in the third cleaning step (the third cleaning aqueous solution containing hydrogen hydrogen in a concentration of 3% by mass and hydrofluoric acid in a concentration of 5% by mass) is reused in the above (b) first cleaning step.
- the polycrystalline silicon crushed mass was washed by the same method as in Example 1 above. Table 1 also shows the results of measuring the amount of surface metal contamination of the obtained crushed polycrystalline silicon.
- Example 3 (B) A cleaning aqueous solution containing hydrogen hydrogen at a concentration of 3% by mass and hydrofluoric acid at a concentration of 5% by mass used in the first cleaning step and (d) third cleaning step, each containing 5 hydrogen.
- Polycrystalline silicon crushed lumps were washed by the same method as in Example 1 except that the aqueous solution was changed to an aqueous solution containing 5% by mass and 5% by mass of hydrofluoric acid.
- Table 1 also shows the results of measuring the amount of surface metal contamination of the obtained crushed polycrystalline silicon.
- Example 4 (C) A second cleaning aqueous solution having a hydrofluoric acid concentration of 3% by mass and a nitric acid concentration of 66% by mass, which is used in the second cleaning step, has a hydrofluoric acid concentration of 5% by mass and a nitric acid concentration of 63% by mass.
- Cleaning of the polycrystalline silicon crushed mass is carried out by the same method as in Example 1 above, except that the aqueous solution is changed to an aqueous solution for cleaning and the etching allowance of the polycrystalline silicon crushed mass in this cleaning step is changed to 10 ⁇ m. went.
- Table 1 also shows the results of measuring the amount of surface metal contamination of the obtained crushed polycrystalline silicon.
- Example 5 The polycrystalline silicon crushed mass was washed by the same method as in Example 1 except that the washing time in the first washing step was changed from 3 minutes to 10 minutes. Table 1 also shows the results of measuring the amount of surface metal contamination of the obtained crushed polycrystalline silicon.
- Comparative Example 1 The first cleaning aqueous solution containing 3% by mass of hydrogen peroxide and 5% by mass of hydrofluoric acid used in the first cleaning step and (d) third cleaning step is 5% by mass, respectively.
- the polycrystalline silicon crushed mass was washed by the same method as in Example 1 except that it was changed to an aqueous hydrofluoric acid solution.
- Table 1 also shows the results of measuring the amount of surface metal contamination of the obtained crushed polycrystalline silicon.
- Comparative Example 2 As the first cleaning step, the same operation as in the second cleaning step (c) of Example 1 was carried out using an aqueous solution of hydrofluoric acid having a hydrofluoric acid concentration of 3% by mass and a nitric acid concentration of 66% by mass as a cleaning liquid.
- the first cleaning step (b) of Example 1 is carried out using a 2% by mass tetramethylammonium hydroxide (TMAH) aqueous solution containing hydrogen peroxide at a concentration of 2% by mass as a cleaning solution. I did the same operation as.
- TMAH tetramethylammonium hydroxide
- the same operation as the first cleaning step was carried out using a hydrofluoric acid aqueous solution having a hydrofluoric acid concentration of 2% by mass and a nitric acid concentration of 67% by mass as a cleaning liquid, and the cleaning step was completed. Except for the above, the polycrystalline silicon crushed mass was washed by the same method as in Example 1. Table 1 also shows the results of measuring the amount of surface metal contamination of the obtained crushed polycrystalline silicon.
- Comparative Example 3 As the first cleaning step, (b) first cleaning step of Example 1 except that a cleaning aqueous solution having a hydrochloric acid concentration of 8% by mass, a hydrogen peroxide concentration of 3% by mass, and a hydrofluoric acid concentration of 5% by mass was used. I did the same operation as. Next, as the second cleaning step, the same operation as in the second cleaning step (c) of Example 1 was performed except that a cleaning aqueous solution having a hydrofluoric acid concentration of 3% by mass and a nitric acid concentration of 65% by mass was used.
- Example 1 the same operation as in the third cleaning step (d) of Example 1 was performed except that a cleaning aqueous solution having a hydrochloric acid concentration of 8% by mass and a hydrogen peroxide concentration of 3% by mass was used. Except for the above, the polycrystalline silicon crushed mass was washed by the same method as in Example 1. Table 1 also shows the results of measuring the amount of surface metal contamination of the obtained crushed polycrystalline silicon.
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Abstract
Description
a)多結晶シリコンロッドの破砕工程
b)得られた多結晶シリコンロッドの破砕塊をフッ硝酸水溶液と接触させる第一洗浄工程
c)第一洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、過酸化水素を含むアルカリ水溶液と接触させる第二洗浄工程
d)第二洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、フッ硝酸水溶液と接触させる第三洗浄工程
を含んでなる、多結晶シリコン破砕塊の製造方法を提案している(特許文献2)。即ち、特許文献2の方法によれば、上記フッ硝酸水溶液による第一洗浄工程に続けて、第二洗浄工程として、過酸化水素を含むアルカリ水溶液による洗浄を施すことにより、タングステンやコバルトによる表面汚染が大きく低減された多結晶シリコン破砕塊が得ることができている。そして、この方法によれば、上記タングステンやコバルト以外の表面金属も多くは良好に低減でき、その総濃度は15.0pptwであり、上記銅濃度も実施例では0.30pptw以下に低下できている。
1.前清浄化:25+/-5℃で水と共にHF5質量%、HCl8質量%およびH2O23質量%を含有するHF/HCl/H2O2水溶液で20分間の酸洗。シリコンの腐蝕による剥削は、約0.02μmであった。
2.22℃で5分間の洗浄。
3.主要な清浄化:水と共にHF3質量%およびHNO365質量%を含有するHF/HNO3水溶液中での8℃で5分間の腐蝕。腐蝕による剥削は、約12μmであった。
4.22℃で5分間の洗浄。
5.22℃で水と共にHCl8質量%およびH2O22質量%を含有するHF/HCl/H2O2水溶液で5分間の親水性化。
6.22℃での洗浄。
7.80℃で等級100の最も純粋な空気での乾燥。
さらに、該表面金属濃度のうち、鉄及び亜鉛の合計濃度が2.00pptw以下であることを特徴とする多結晶シリコン破砕塊を提供する。
(a)多結晶シリコンロッドの破砕工程、
(b)得られた多結晶シリコンロッドの破砕塊を、過酸化水素およびフッ酸を含み、フッ酸以外の酸の含有量が3質量%以下である第一洗浄用水溶液と接触させる第一洗浄工程、
(c)第一洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、フッ硝酸からなる第二洗浄用水溶液と接触させる第二洗浄工程、
を含んでなる、前記製造方法も提供する。
本発明に係る多結晶シリコン破砕塊は、多結晶シリコンロッドを破砕し分級して得られる。上記多結晶シリコンロッドは、製造方法が制限されるものではないが、通常は、シーメンス法によって製造されたものが対象になる。ここで、シーメンス法とは、トリクロロシランやモノシラン等のシラン原料ガスを加熱されたシリコン芯線に接触させることにより、該シリコン芯線の表面に多結晶シリコンをCVD(Chemical Vapor Deposition)法により気相成長(析出)させる方法である。
斯様に表面が清浄な多結晶シリコン破砕塊は、その製造方法が制限されるものではないが、好適な製造方法を示せば、以下の方法になる。即ち、
(a)多結晶シリコンロッドの破砕工程、
(b)得られた多結晶シリコンロッドの破砕塊を、過酸化水素およびフッ酸を含み、フッ酸以外の酸の含有量を3質量%以下である第一洗浄用水溶液と接触させる第一洗浄工程、
(c)第一洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、フッ硝酸からなる第二洗浄用水溶液と接触させる第二洗浄工程、
を含んでなる方法である。この方法によれば、(a)破砕工程までに受けた表面汚染が、続く(b)~(c)の洗浄工程で、前記本発明が規定する範囲に、高度に清浄化させることが可能になる。
多結晶シリコンロッドの破砕工程は、CZ法多結晶シリコンロッドを、破壊具を用いて常法に従い、前記所望の大きさに破砕すれば良い。これら破壊具は、手動式のハンマーの他、ジョークラッシャー、ロールクラッシャー、ハンマーミル等の機械式衝撃工具が挙げられる。これら破壊具の材質は、硬質金属の内でも、通常、WC/Co合金が使用される。WC/Co合金において、炭化タングステンの含有量は好適には78~90質量%、より好適には80~88質量%で、コバルトの含有量は好適には10~22質量%、より好適には12~20質量%である。
第一洗浄工程では、上記(a)工程で得られた多結晶シリコンロッドの破砕塊を、第一洗浄用水溶液と接触させ、洗浄する。第一洗浄用水溶液は、過酸化水素とフッ酸とを含む。フッ酸水溶液は強い酸性溶液であり、強い金属溶解性を有し多くの金属をイオン化させる。補足すれば、斯様に酸性溶液であるため、鉄及び亜鉛も、上記イオン化したままの状態で除去され、シリコン表面への再付着は抑制される。また、多結晶シリコン表面の酸化膜の除去性も有する為、これに取り込まれた金属不純物も除去できる。
第二洗浄工程では、上記(b)第一洗浄工程で得られた多結晶シリコン破砕塊の洗浄物を、第二洗浄用水溶液と接触させ、洗浄する。第二洗浄用水溶液はフッ硝酸水溶液からなる。フッ硝酸は、フッ酸と硝酸との混酸である。前記第一洗浄工程では、シリコンの多結晶シリコン破砕塊の表面に付着及び該表面に形成された酸化膜に取り込まれている金属不純物が、前記銅、さらには鉄及び亜鉛も含めて良好に除去できる。金属不純物の中には、多結晶シリコンロッドの破砕時のハンマーによる衝撃や、分級時の篩による振動により、シリコン表面層に埋入しているものもある。そして、これらの表層部に埋入する金属不純物は、上記(b)第一洗浄工程での洗浄では完全には除去できずに、微量が残留している。
以上の洗浄により、表面金属濃度が、前記説明した状態に低減された多結晶シリコン破砕塊が製造可能であるが、その表面の清浄性を一層に高めるためには、更に追加して、
(d)第二洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、過酸化水素およびフッ酸を含み、フッ酸以外の酸の含有量が3質量%以下の第三洗浄用水溶液と接触させる第三洗浄工程、を施すのが好ましい。
さらに、上記多結晶シリコン破砕塊の製造方法では、更に追加して、
(e)第三洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、フッ硝酸からなる第四洗浄用水溶液と接触させる第四洗浄工程、を実施するのが好ましい。
前記(a)工程で得られた多結晶シリコンロッド破砕塊の表面には、通常、シリコン微粉が多く付着している。これらシリコン微粉は不純物を多く含むばかりか、(b)第一洗浄工程での洗浄性を阻害する為、可能な限り除去してから、(b)第一洗浄工程に供するのが好ましい。具体的には、多結晶シリコン破砕塊を第一洗浄用水溶液に接触させる前に、純水や超純水に予備接触させ、表面に付着したシリコン微粉を取り除くことが好ましい。
エッチング代測定用として一辺が約7mmの立方体である多結晶シリコン50個から成る多結晶シリコン小片群を用意した。多結晶シリコン小片群の乾燥状態の総質量を事前に測定しておき、ポリテトラフルオロエチレン(PTFE)製ネット内に収めた状態で、多結晶シリコン破砕塊と共に洗浄に供した。次に、洗浄処理後の多結晶シリコン小片群の総質量を測定し、洗浄処理前後の質量差と該多結晶シリコン小片群の全表面積をもとに、除去された表面層の厚み(エッチング代)を算出した。
多結晶シリコン破砕塊約400gを500mlの清浄なポリテトラフルオロエチレン製ビーカーに移し、溶解液100ml(50質量%-HF:10ml、70質量%-硝酸:90ml)を加えて25℃で15分間の抽出を行った。上記ビーカー中の液分、及び多結晶シリコン破砕塊の表面を超純水100mlを用いて洗った洗浄液を、清浄なポリテトラフルオロエチレン製ビーカーに移し多結晶シリコン破砕塊の表面抽出液とした。係る多結晶シリコン破砕塊の表面抽出液を蒸発乾固させ、3.5質量%-硝酸水溶液を加え20.0ml定容化しICP-MS測定を行い、Na、Mg、Al、K、Ca、Cr、Fe、Ni、Co、Cu、Zn、W、Ti、Moの各表面金属質量を測定した。この各表面金属質量の測定値を、抽出前の多結晶シリコン破砕塊の質量で除することにより、多結晶シリコン破砕塊の単位質量当たりの含有量(pptw)として評価した。なお、ICP-MSの測定装置は、Agilent社製「8900」を使用した。各実施例及び比較例で4回の測定を行い、平均値を算出した。
<(a)破砕工程>
還元反応炉内でシーメンス法により多結晶シリコンロッドを製造し、炉内に、HEPA(High Efficiency Particulate Air)フィルタを通した空気を導入した後、炉を大気開放し、前記多結晶シリコンロッドを炉外に取り出した。取り出した多結晶シリコンロッドを、打撃部の材質が、炭化タングステン/コバルト合金(炭化タングステンの含有量82質量%、コバルトの含有量18質量%)からなるハンマーで、少なくとも90質量%が、長径の長さ10~120mmの範囲である破砕塊であるように砕いた。
得られた多結晶シリコン破砕塊の約5kgを、過酸化水素を3質量%、フッ酸を5質量%の濃度で含む第一洗浄用水溶液と接触させる第一洗浄工程に供した。即ち、多結晶シリコン破砕塊5kgを樹脂製のカゴに入れ、これを前記第一洗浄用水溶液が収容された洗浄槽に浸漬した。浸漬は20℃の液温下3分間行われた。
上記(b)第一洗浄工程後、洗浄槽より多結晶シリコン破砕塊を取り出し、超純水(液温20℃)が収容された水洗槽に3分間浸漬させた。水洗後、洗浄槽より多結晶シリコン破砕塊を取り出し送風乾燥した。(c)第二洗浄工程を行う前に水洗を行うことにより(b)第一洗浄工程で用いたフッ酸及び過酸化水素の第二洗浄工程への混入を防ぐことができる。
続いて、(b)第一洗浄工程を経た前記多結晶シリコン破砕塊の洗浄物を、フッ酸濃度が3質量%で、硝酸濃度が66質量%のフッ硝酸水溶液である第二洗浄用水溶液と接触させる第二洗浄工程に供した。即ち、多結晶シリコン破砕塊5kgを樹脂製のカゴに入れ、これを50質量%弗酸と70質量%硝酸を1:14の体積比で混合した第二洗浄用水溶液が収容された洗浄槽に浸漬した。浸漬は20℃の液温下、多結晶シリコン破砕塊のエッチング代が9μmに測定される時間で行われた。なお、(c)第二洗浄工程の洗浄槽には、エッチング代測定用の多結晶シリコン小片群も収容し、この洗浄でのエッチング代の測定を行った。
上記(c)第二洗浄工程後、洗浄槽より多結晶シリコン破砕塊を取り出し、超純水(液温20℃)が収容された水洗槽に3分間浸漬させた。水洗後、洗浄槽より多結晶シリコン破砕塊を取り出し送風乾燥した。(d)第三洗浄工程を行う前に水洗を行うことにより(c)第二洗浄工程で用いたフッ硝酸、特に硝酸の(d)第三洗浄工程への混入を防ぐことができる。
続いて、(c)第二洗浄工程を経た前記多結晶シリコン破砕塊の洗浄物は、(d)第三洗浄工程として、再度、(b)第一洗浄工程と同じく、過酸化水素を3質量%、フッ酸を5質量%の濃度で含む第三洗浄用水溶液を洗浄液とした洗浄に供した。洗浄操作の詳細は、(b)第一洗浄工程と同様とした。
上記d)第三洗浄工程後、洗浄槽より取り出した多結晶シリコン破砕塊は、前記b)第一洗浄工程後の水洗工程と同じく、水洗及び送風乾燥した。
続いて、(d)第三洗浄工程を経た前記多結晶シリコン破砕塊の洗浄物を、フッ酸濃度が2質量%で、硝酸濃度が67質量%のフッ硝酸水溶液である第四洗浄用水溶液と接触させる第四洗浄工程に供した。即ち、多結晶シリコン破砕塊5kgを樹脂製のカゴに入れ、これを50質量%弗酸と70質量%硝酸を1:20の体積比で混合した第四洗浄用水溶液が収容された洗浄槽に浸漬した。浸漬は20℃の液温下、多結晶シリコン破砕塊のエッチング代が3μmに測定される時間で行われた。なお、第四洗浄工程でも洗浄槽には、エッチング代測定用の多結晶シリコン小片群も収容し、この洗浄でのエッチング代の測定を行った。
上記(e)第四洗浄工程後、洗浄槽より取り出した多結晶シリコン破砕塊は、前記b)第一洗浄工程後の水洗工程と同じく、水洗及び送風乾燥した。
(d)第三洗浄工程で排出された洗浄液(過酸化水素を3質量%、フッ酸を5質量%の濃度で含む第三洗浄用水溶液)を、前記(b)第一洗浄工程に再使用する以外は、前記実施例1と同様の方法により、多結晶シリコン破砕塊の洗浄を行った。得られた多結晶シリコン破砕塊について、表面金属汚染量を測定した結果を表1に併せて示した。
(b)第一洗浄工程及び(d)第三洗浄工程で使用する、過酸化水素を3質量%、フッ酸を5質量%の濃度で含む洗浄用水溶液を、夫々に、過酸化水素を5質量%、フッ酸を5質量%含む洗浄用水溶液に変更する以外は、前記実施例1と同様の方法により、多結晶シリコン破砕塊の洗浄を行った。得られた多結晶シリコン破砕塊について、表面金属汚染量を測定した結果を表1に併せて示した。
(c)第二洗浄工程で使用する、フッ酸濃度が3質量%で、硝酸濃度が66質量%の第二洗浄用水溶液を、フッ酸濃度が5質量%で、硝酸濃度が63質量%の洗浄用水溶液に変更して、この洗浄工程での多結晶シリコン破砕塊のエッチング代が10μmになるように変更する以外は、前記実施例1と同様の方法により、多結晶シリコン破砕塊の洗浄を行った。得られた多結晶シリコン破砕塊について、表面金属汚染量を測定した結果を表1に併せて示した。
(b)第一洗浄工程における洗浄時間を、3分間から10分間に変更する以外は、前記実施例1と同様の方法により、多結晶シリコン破砕塊の洗浄を行った。得られた多結晶シリコン破砕塊について、表面金属汚染量を測定した結果を表1に併せて示した。
(b)第一洗浄工程及び(d)第三洗浄工程で使用する、過酸化水素を3質量%、フッ酸を5質量%の濃度で含む第一洗浄用水溶液を、夫々に、5質量%フッ酸水溶液に変更する以外は、前記実施例1と同様の方法により、多結晶シリコン破砕塊の洗浄を行った。得られた多結晶シリコン破砕塊について、表面金属汚染量を測定した結果を表1に併せて示した。
第一洗浄工程として、フッ酸濃度が3質量%で、硝酸濃度が66質量%のフッ硝酸水溶液を洗浄液として用いて、前記実施例1の(c)第二洗浄工程と同じ操作をした。
次いで、第二洗浄工程として、過酸化水素を2質量%の濃度で含む、2質量%テトラメチルアンモニウムヒドロキシド(TMAH)水溶液を洗浄液として用いて、前記実施例1の(b)第一洗浄工程と同じ操作をした。
さらに、第三洗浄工程として、フッ酸濃度が2質量%で、硝酸濃度が67質量%のフッ硝酸水溶液を洗浄液として用いて上記第一洗浄工程と同じ操作をし、洗浄工程を終えた。
上記以外は、前記実施例1と同様の方法により、多結晶シリコン破砕塊の洗浄を行った。得られた多結晶シリコン破砕塊について、表面金属汚染量を測定した結果を表1に併せて示した。
第一洗浄工程として、塩酸濃度が8質量%、過酸化水素濃度が3質量%、フッ酸濃度が5質量%の洗浄用水溶液を用いた以外は、実施例1の(b)第一洗浄工程と同じ操作をした。
次いで、第二洗浄工程として、フッ酸濃度が3質量%で、硝酸濃度が65質量%の洗浄用水溶液を用いた以外は、実施例1の(c)第二洗浄工程と同じ操作をした。
さらに、第三洗浄工程として、塩酸濃度が8質量%、過酸化水素濃度が3質量%の洗浄用水溶液を用いた以外は、実施例1の(d)第三洗浄工程と同じ操作をした。
上記以外は、前記実施例1と同様の方法により、多結晶シリコン破砕塊の洗浄を行った。得られた多結晶シリコン破砕塊について、表面金属汚染量を測定した結果を表1に併せて示した。
Claims (10)
- 表面金属濃度が15.0pptw以下であり、該表面金属濃度のうち、銅濃度が0.30pptw以下である多結晶シリコン破砕塊であって、
さらに、該表面金属濃度のうち、鉄、及び亜鉛の合計濃度が2.00pptw以下であることを特徴とする多結晶シリコン破砕塊。 - 表面金属濃度のうち鉄濃度が1.25pptw以下である、請求項1記載の多結晶シリコン破砕塊。
- 表面金属濃度のうち亜鉛濃度が0.75pptw以下である、請求項1又は請求項2記載の多結晶シリコン破砕塊。
- さらに、表面金属濃度のうちニッケル濃度が0.30pptw以下である、請求項1~3のいずれか一項に記載の多結晶シリコン破砕塊。
- 前記表面金属濃度がNa,Mg,Al,K,Ca,Cr,Fe,Ni,Co,Cu,Zn,W,TiおよびMoの合計濃度である、請求項1~4のいずれか一項に記載の多結晶シリコン破砕塊。
- (a)多結晶シリコンロッドの破砕工程、
(b)得られた多結晶シリコンロッドの破砕塊を、過酸化水素およびフッ酸を含み、フッ酸以外の酸の含有量が3質量%以下である第一洗浄用水溶液と接触させる第一洗浄工程、
(c)第一洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、フッ硝酸からなる第二洗浄用水溶液と接触させる第二洗浄工程、
を含んでなる、請求項1記載の多結晶シリコン破砕塊の製造方法。 - さらに、追加して
(d)第二洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、過酸化水素およびフッ酸を含み、フッ酸以外の酸の含有量が3質量%以下である第三洗浄用水溶液と接触させる第三洗浄工程、
が行われてなる、請求項6記載の多結晶シリコン破砕塊の製造方法。 - (d)第三洗浄工程を行うに際して、該(d)第三洗浄工程で排出された第三洗浄用水溶液を、前記b)第一洗浄工程の第一洗浄用水溶液の一部または全部として再使用する、請求項7記載の多結晶シリコン破砕塊の製造方法。
- さらに、追加して
(e)第三洗浄工程を経た多結晶シリコン破砕塊の洗浄物を、フッ硝酸からなる第四洗浄用水溶液と接触させる第四洗浄工程、
が行われてなる、請求項7または請求項8記載の多結晶シリコン破砕塊の製造方法。 - (e)第四洗浄工程を行うに際して、該(e)第四洗浄工程で排出された第四洗浄用水溶液を、前記(c)第二洗浄工程の第二洗浄用水溶液の一部または全部として再使用する、請求項9記載の多結晶シリコン破砕塊の製造方法。
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JP7018553B1 (ja) | 2022-02-10 |
EP4186859A1 (en) | 2023-05-31 |
KR20230043974A (ko) | 2023-03-31 |
KR102643428B1 (ko) | 2024-03-06 |
US20230294996A1 (en) | 2023-09-21 |
CN115989192B (zh) | 2024-02-02 |
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