Greening the digital diamonds
During the launch of the India Semiconductor Mission (ISM), the Prime Minister described chips as our “digital diamonds.” He emphasised that India’s smallest chip will soon drive the world’s biggest change. The launch of SEMICON INDIA 2025 marked a pivotal moment for India in its journey to become a major semiconductor manufacturing hub, following recent advancements in defense manufacturing.
India’s semiconductor mission is not limited to establishing a single fabrication facility or producing just one type of chip. Instead, it aims to create a robust semiconductor ecosystem that will make the nation self-reliant and globally competitive. With the introduction of the India Semiconductor Mission and the Production-Linked Incentive (PLI) scheme, the semiconductor industry is projected to grow to $100 billion by 2030, aiming to capture a significant share of the anticipated $1 trillion global market.
The semiconductor industry creates a wide range of employment opportunities, from design to manufacturing, while also generating indirect jobs in the regions where manufacturing units are established. Moreover, the industry not only generates jobs but also enhances innovation across academic institutions by driving technological advancements and fostering creative opportunities for the talent pool. More than 60000 students have availed the benefits of the talent development programme supported by the government.
Chip manufacturing process
The creation of semiconductor devices involves transforming silicon and other raw materials through a complex manufacturing process that can take months to complete. Semiconductor manufacturing, or the fabrication of integrated circuits (ICs), includes the assembly of transistors and other components that form the backbone of modern electronic devices. The manufacturing process encompasses several chemical and photographic steps to convert a silicon wafer into functioning electronic circuits.
1. Wafer fabrication
The foundation of semiconductor devices is silicon wafers. The process begins with a pure silicon crystal, known as an “ingot,” which is sliced into thin wafers and polished for smoothness. Polishing is crucial as it removes impurities and scratches, providing a high-quality surface for chip fabrication. Contamination at this stage can lead to defects in the final product. After polishing, a layer of conducting or semiconducting materials is deposited onto the wafer, a step known as “deposition.”
2. Photoresist coating
Once the wafer is prepared, its surface is coated with a photoresist, a light-sensitive material that alters the chemical properties of the wafer for circuit printing. There are two primary types of photoresists based on their reaction to ultraviolet (UV) light: positive and negative. In positive photoresist, exposed areas become soluble after UV exposure, while negative photoresists harden upon exposure.
3. Lithography
After applying the photoresist, the wafer is ready for circuit printing through a process called photolithography. The wafer is exposed to UV light in photolithography equipment, where light passes through a mask that contains the circuit blueprint, imprinting the design onto the photoresist-coated wafer.
4. Etching
Following the pattern printing, the etching process removes excess materials from the surface of the wafer. Precision and careful control are vital during this step to avoid damaging the chip structure.
5. Ion implantation
Ion implantation incorporates impurities, such as arsenic or phosphorus ions, to impart semiconducting properties to the silicon wafers. Heat treatment is then applied to activate the ions and create micro-transistors. The photoresist serves to block ions from entering areas that could lead to defects and is subsequently removed through ashing or chemical processes.
6. Assembly and packaging
The semiconductor manufacturing process may take up to 26 weeks, from design inception to final production. The concluding stage involves separating the wafer into individual chips (dicing) and bonding them onto a substrate. A metal container with a cooling system is then placed over the chip to prevent overheating, preparing the chip for operational use.
Throughout the semiconductor manufacturing process, several additional steps, including testing and inspecting the chips, are essential. However, manufacturers often encounter challenges such as:
- Product quality: Maintaining high product quality becomes increasingly challenging as semiconductor products advance and demand escalates.
- Defects: Various stages, from assembly to testing, can introduce defects that are difficult to detect, especially given the size and complexity of each chip.
- Cost: Rising costs associated with semiconductor manufacturing processes, driven by innovative technologies and supply shortages, complicate efforts for manufacturers to achieve profitable revenue levels.
The intricate process of semiconductor manufacturing significantly affects our electricity and water resources and involves careful waste disposal. This reality calls for a transformation toward greener practices and the adoption of clean energy, ultimately championing sustainability. Power semiconductors are at the forefront of this vital mission.
Also Read: Beyond imports: How India can build its own industrial strength in heavy machinery
Benefits of renewable energy in semiconductor manufacturing
At the forefront, harnessing renewable sources—such as solar, wind, and hydroelectric power—is vital for dramatically reducing carbon emissions tied to semiconductor production. Around 10 major semiconductor units are already being under development in India. By distancing themselves from fossil fuels, the semiconductor manufacturing companies can lower greenhouse gas emissions and actively participate in the critical battle against climate change.
Additionally, renewable energy sources offer a more dependable and stable approach to energy security and cost management. Unlike the volatile swings of fossil fuel prices, solar and wind energy provide consistent operational costs, empowering semiconductor manufacturers to take charge of their long-term energy expenditures. This reliability fosters a vision of a brighter, more sustainable future.
The next pivotal step, following the efficient storage of renewable energy, is its seamless distribution to end-users. Semiconductors are the backbone of this transformation, ensuring the smooth flow of electricity across power grids and effectively using the energy generated and stored from renewable sources. From balancing loads in smart grids to stabilising high-voltage transmission, semiconductor technologies are crucial in reshaping renewable energy into a dependable and scalable solution for our global energy demands.
Conclusion
In innovative grid systems, semiconductor components—such as IGBTs and MOSFETs—serve essential roles in voltage regulation and power conversion. Wide bandgap semiconductors, like GaN and SiC, excel in managing high power levels and operating at elevated frequencies, making them ideally suited for overseeing expansive energy distribution networks. Furthermore, the advanced semiconductors seamlessly integrate energy storage within grids, ensuring stability and an uninterrupted supply, even during peak demand periods.
As India advances toward its goal of becoming a premier semiconductor hub, companies within this sector are increasingly can assess the integration of clean energy solutions, such as solar energy, hybrid systems, and Battery Energy Storage Systems (BESS). The achievements of leading manufacturing entities in textiles, steel, pharmaceuticals, and various other industries, particularly those driven by Prozeal Green Energy Limited, provide a valuable framework for these semiconductor firms. By leveraging the expertise in project execution and executing well-structured operations and maintenance protocols, Prozeal Green Energy exemplifies how businesses can take a leading role in the renewable energy sector, thereby contributing to the development of a more sustainable and environmentally responsible future.
