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

Transcription

1 1 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

2 Content Importance of Eco-manufacturing Strategies for enhanced process efficiency Repurposing of waste products Environmental impact 2

3 Importance of Eco-manufacturing Market outlook for the next decades: cumulative installed capacity worldwide based on different scenarios *The evolution of PV waste in Europe, May 2013, Sandt Consulting and European Centre for the Recycling of Solar Energy (CERES). Photo: [PVCYCLE] 3

4 Importance of Eco-manufacturing Expected resource consumption and savings by 2030 (in Megatonnes). (Note: worldwide silver resources in 2014 belong to 0.52 Mt.) 4 *Assumptions: high-ren scenario, market 100% c-si, no technological improvements from today to 2030

5 General approach Maximising resource and process efficiency Introducing design for repair, reuse and recycling 5

6 6 Eco-Solar roadmap

7 Recovery & reuse during Si-ingot crystallisation Argon purge gas recycling 3-5 million m 3 of argon are used per 1GWp of silicon wafer output Recycling systems from the Semiconindustry to refined and expanisve Alternative solutions based on chemical looping combustion Reusable crucibles based on advanced Si 3 N 4 ceramics 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 Objective: Recycling rate > 95% 7

8 Recovery & reuse of Si-kerf-loss Treatment of spent Fixed Abrasive Sawing (FAS) slurry 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 Sifeedstock or other high end markets Si-powder Si-granules Si-pellets mc-si sc-si 8 Anode material in Lithium Ion batteries

9 Remanufacturing & resource efficiency in cell processing Silver Solar cell architectures Cell-doctor Interconnection schemes Metallization pastes that contain less silver Objective: 66% savings of silver Current solar cell design DI-Water 9 de-ionised water is used in several cleaning steps Objective: 90% recycling rate

10 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 Aluminum frameless module 60% less aluminium 10

11 REPURPOSING OF WASTE PRODUCTS High pure graphite Ceramic tiles Living Lab Establishment of Pan Industrial Material Reuse Opportunities Steel wires Glass Broken cells 11

12 Environmental impact Preliminary LCI baseline of the module production Carbon footprint 12 *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.

13 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 Martin.Bellmann@sintef.no