Eco-Solar Factory: 40%plus eco-efficiency gains in the photovoltaic - - PowerPoint PPT Presentation

Eco-Solar Factory: 40%plus eco-efficiency gains in the photovoltaic value chain with minimised resource and energy consumption by closed loop systems

M.P. Bellmann, R. Roligheten, G.S. Park, J. Denafas, F. Buchholz, R. Einhaus, I. Lombardi, B. Ehlen,

• K. Wambach, P. Romero, A. Bollar

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Content

• Importance of Eco-manufacturing
• Strategies for enhanced process efficiency
• Repurposing of waste products
• Environmental impact

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Importance of Eco-manufacturing

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*The evolution of PV waste in Europe, May 2013, Sandt Consulting and European Centre for the Recycling of Solar Energy (CERES). Photo: [PVCYCLE]

Market outlook for the next decades: cumulative installed capacity worldwide based on different scenarios

Importance of Eco-manufacturing

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*Assumptions: high-ren scenario, market 100% c-Si, no technological improvements from today to 2030

Expected resource consumption and savings by 2030 (in Megatonnes). (Note: worldwide silver resources in 2014 belong to 0.52 Mt.)

• Maximising resource and process efficiency
• Introducing design for repair, reuse and

recycling

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General approach

Eco-Solar roadmap

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Argon purge gas recycling

• 3-5 million m3 of argon are used per

1GWp of silicon wafer output

• Recycling systems from the Semicon-

industry to refined and expanisve

• Alternative solutions based on

chemical looping combustion

• Objective: Recycling rate > 95%

Reusable crucibles based on advanced Si3N4 ceramics

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Recovery & reuse during Si-ingot crystallisation

• Silica crucibles can be only used once (cracks

after usage (a))

• Up to ~30% to the conversion from poly-Si

to the as-grown ingot

• Objective: > 10 x reuse for Cz and DS

Treatment of spent Fixed Abrasive Sawing (FAS) slurry Anode material in Lithium Ion batteries

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Recovery & reuse of Si-kerf-loss

• Only the coolant is recycled by today
• Separated Si-kerf-loss is landfilled or

used as low grade alloying compound in foundry applications

• No value at the moment is extracted

from this material

• Objective: reduction of Si-waste by

80% due to reutilization as Si- feedstock or other high end markets

Si-powder Si-granules Si-pellets mc-Si sc-Si

Silver Cell-doctor

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Remanufacturing & resource efficiency in cell processing

DI-Water

• Solar cell architectures
• Interconnection schemes
• Metallization pastes that contain less silver
• Objective: 66% savings of silver

Current solar cell design

• de-ionised water is used in several

cleaning steps

• Objective: 90% recycling rate

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Module design for remanufacturing (NICE)

Disassembly "end-of-life" modules for recovery of module components Organics

• EVA for encapsulation
• PVF in backsheets
• 90% less organics
• frameless module
• 60% less aluminium

Aluminum

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REPURPOSING OF WASTE PRODUCTS

High pure graphite Ceramic tiles Steel wires Glass Broken cells Living Lab – Establishment of Pan Industrial Material Reuse Opportunities

Preliminary LCI baseline of the module production Carbon footprint

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Environmental impact

*D. Yue et al., Domestic and overseas manufacturing scenarios of silicon-based photovoltaics: Life cycle energy and environmental comparative analysis, Solar Energy 105:669, 2014.

Technology for a better society

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No. 679692. E-mail: Martin.Bellmann@sintef.no