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International Energy Agency (IEA) PVPS Task 12: Environment, Health and Safety

Vasilis Fthenakis Brookhaven National Laboratory

www.pv.bnl.govColumbia University

www.clca.columbia.edu

with contributions from:Erik Alsema, Utrecht U.

Mariska de Wild-Scholten, ECNKarsten Wambach, SolarWorld

European Industry Association PV Industry Forum22nd EUPVSEC, Milan, Italy, Sept. 5, 2007

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MotivationMotivation

Promote international collaboration on EH&S and sustainabilityFacilitate a common understanding of technical and perceived EH&S issuesDisseminate knowledge to stake holders and

energy-policy decision makers

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JustificationJustificationThe growth of PV is based on the promise of environmentally friendly energy generation and is sustained by the support of the environmentally conscious public Competitive interests try to undermine PV environmental benefits and prospectsWe need to be proactive, ahead of environmental regulationsInternational collaboration is needed as “we are all partners in safety”

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Task 12 Objectives Task 12 Objectives

Quantify the EH&S profiles of PV in comparison to other energy technologiesDefine and address EH&S and sustainability issues that are important for market growth

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Task 12 Technical Experts/Contributors (committed during kick-off meeting, March 16/07, Brussels)

Task 12 Technical Experts/Contributors (committed during kick-off meeting, March 16/07, Brussels)

ECNThe NetherlandsMariskade Wild-Scholten

Deutsche SolarGermanyKarstenWambach

ELKEM SolarNorwayRonnyGlockner

ZSWGermanyOliverSalomon

LBP Stuttgart UniversityGermanyMaiyaShibasaki

Umweltbundesamt GmbHAustriaWernerPolz

ESU-servicesSwitzerlandNielsJungbluth

LBR Stuttgart UniversityGermanyMichaelHeld

Brookhaven National Laboratory

USAVasilisFthenakis

EPIABelgiumEleniDespotou

Utrecht UniversityThe NetherlandsErikAlsema

Company/Organization

CountryFirst NameName

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Task 12 OrganisationTask 12 Organisation

Sub-task 1: Recycling of manufacturing waste and spent modules

Sub task 2: Life cycle assessment

Sub-task 3: EH&S in Manufacturing Facilities

Sub-task 4: Information Dissemination

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Activities /Expertise in Europe (partial list)Activities /Expertise in Europe (partial list)

1. Utrecht/ECN: Energy analyses, risk assessments and LCA’s for PV technology, since 1990;

2. Crystal Clear project – Sustainability and recycling (2004-2008);• crystalline silicon technology – existing and future• up-to-date LCI data collected, published and

analysed3. RESOLVED project – recycling of thin film

modules: LCA study

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Activities /Expertise in Europe (partial list)Activities /Expertise in Europe (partial list)

4. PV CYCLE Aims in:• Supporting recycling research projects,• Defining a voluntary take back and recovery system

for PV modules,• Supporting education and information programs for

owners of PV modules,• Promoting industry-leading sustainable product life

cycle management.

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Planned and Proposed Activities in EuropePlanned and Proposed Activities in Europe

1. Further work within CrystalClear (c-Si) :• Evaluation of new processes• Update of LCI industrial production (-> status 2008)• Use & abatement of fluorinated gases

2. Proposed FP6/FP7 projects• Concentrators• Dye sensitized cells • CdTe• All major cell technologies -Updates

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Activities /Expertise in the United StatesActivities /Expertise in the United StatesLife Cycle Analysis• Greenhouse Gas Emissions• Energy Payback Times (EPBT)• Toxic Emissions

Recycling (Collection Infrastructure, Recovery of Cd, Te, Se, In) Silane SafetyRisk AnalysisComparisons of PV with other energy technologiesSolar energy potential to satisfy all the US energy needs

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SubTask 1 -RecyclingSubTask 1 -Recycling

PVCycleEPIAActivity 1c Collection Infrastructure

Vasilis FthenakisUSActivity 1b Thin-film recycling

Karsten WambachDEUActivity 1a c-Si recycling

NameCountry

LeaderTask 12 PV EH&S

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Highlights of Recycling Research & Implementation

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Module Recycling -Deutsche Solar AGModule Recycling -Deutsche Solar AG

reprocessing

thermal treatment

second lifetime

module assembling

new module

end of life module recovered cells

reprocessed cells

recovered wafers

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Recycling Activities of SolarMaterialRecycling Activities of SolarMaterial

sides of an ingotRecycling of:

• by-products like sides of ingots

• defective semi-finished products like ingots, wafer, cells

• end-of-life modules and modules with transport damage or other defects

modules

defective ingot

cell breakage

wafer breakage

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Recycling of thin-film solar cellsfirst tests

Universität StuttgartInstitut für Kunststoffprüfungund Kunststoffkunde

GaBi

Glass melting

Chemical treatment

Water jet cutting

Ablation, Sanblasting

Hot wire cutting

Thermal Treatment

Crushing & GrindingDismantlingRecycling Steps

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Recycling of Cd and Te from CdTe (Se and In from CIGS) PV Modules

Filtration Facility

Clean Glass

PV Module Fragments

Cd Electrowinning

Cell

Cu Recovery

Column ICu

Column IICu

Column ICd, Fe

Column IICd, Fe

Leach Device

Leachate Solution(Te, Cd, Cu, Fe)

Elution Solution(Cu) CdSO4

Removal of Cu from Liquid Using Resin A

Spen

t H2S

O4

Solu

tion

Glass Slurry

H2SO4H2O2

Cd Metal

Recycling of Spent Electrolyte

Effluent Solution(Te)

Selective Precipitation

Removal of Cd and Fe from Liquid Using Resin B

Elution of ColumnA

Elution of ColumnB

Tellurium

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Separation of Cd from Te in CdTe RecyclingSeparation of Cd from Te in CdTe Recycling

0100200300400500600700800900

1000110012001300

0 2 4 6 8 10 12 14 16 18 20 22Bed Volume

Te, C

d, a

nd C

u (p

pm)

Te , ppm

Cd, ppm

Cu, ppm

Te, influent

Cd, influent

Cu, influent

0.00

0.20

0.40

0.60

0.80

1.00

0 2 4 6 8 10 12 14 16 18 20 22

Cd

(ppm

)

Cd separation 99.99%

Cd effluent concentration <0.3 ppm

RESULT: Cd, Te extraction & separation completed at a projected cost of 1 ¢/Wp

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Separation of Se, In, Cd and Zn in CIGS RecyclingSeparation of Se, In, Cd and Zn in CIGS Recycling

Research in progress

Se

0

100

200300

400

500

600

700

800900

1000

1100

0 2 4 6 8 10 12 14 16 18 20 22

Bed Volume

Se, I

n, C

u, Z

n (p

pm)

Se , ppm In, ppm

Cu, ppm Zn, ppm

Zn, influent

Se, influent

In, influent

Cu, influent

0

400

800

1200

1600

2000

2400

2800

3200

3600

4000

4400

0 2 4 6 8 10 12 14 16 18 20Bed Volume

Se, I

n, C

u, Z

n (p

pm) Se , ppm In, ppm

Cu, ppm Zn, ppm

Zn, influent

Se , influent

In, influent

Cu, influent

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First Solar Module and Manufacturing Scrap Recycling

Pictured in Ohio, March 2007

Recycling Steps•Module/scrap size reduction

•Film removal

•Solid-Liquid separations

•Glass-EVA separation

•Glass rinsing

•Precipitation

•Dewatering

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First Solar Process ResultsFirst Solar Process Results

Clean Glass

Metals rich filter cakeModule (and manufacturing scrap)

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Subtask 2 –Life Cycle AnalysisSubtask 2 –Life Cycle Analysis

Niels Jungbluth SWISSActivity 2i Incorporate data in Ecoinvent

Ronny GlocknerNORWAYActivity 2h Production of Si feedstock

TBD/ Vasilis Fthenakis/Mariska de Wild

SPAIN/US/NLActivity 2g Concentrator PV

Vasilis Fthenakis/Marco RaugeiUS/ITActivity 2f CdTe

Maiya Shibasaki/ Marco RaugeiDEU/ITActivity 2e CIGS

Activity 2d a-Si

Mariska deWild/ Erik AlsemaNLActivity 2c Ribbon c-Si

Erik Alsema/ Mariska deWildNLActivity 2b Mono and multi- c-Si US

Erik Alsema / Niels Jungbluth/ Vasilis Fthenakis

AllActivity 2a Guidelines for common approach

NameCountry

LeaderTask 12 PV EH&S

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Competitive interests try to undermine PV environmental benefits-GHG Emissions -ExternE & Australian Coal Association Research Programs-

Comparison of Energy Technologies: Major Studies

900

400

180

20

900

440

10040

0

200

400

600

800

1000

1200

1400

Coal Gas CC PV, mc-Si Nuclear

CO2-

eq.(g

/kWh)

ExternE, Germany 2003

ACARP, Australia 2001

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0

200

400

600

800

1000

1200

1400

Coal (Kim & Dale2005)

Natural Gas(Kim & Dale

2005)

Petroleum(Kim & Dale

2005)

Nuclear(Baseline -

Fthenakis andKim, 2007

PV, CdTe(Fthenakisand Kim

2006)

PV, mc-Si,(Fthenakis and Alsema, 2006)

GH

G (g

CO

2-eq

./kW

h)

MaterialsOperationTransportationFuel Production

Life Cycle GHG Emissions: BNL/Utrecht/ECN UpdatesLife Cycle GHG Emissions: BNL/Utrecht/ECN Updates

24 24 37

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Energy Payback Times (EPBT): Studies by Others

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Energy Payback Times (EPBT): Studies by Others

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Updated Energy Payback TimesUpdated Energy Payback Times

-Alsema & de Wild, Material Research Society, Symposium vol. 895, 73, 2006-deWild & Alsema, Material Research Society, Symposium vol. 895, 59, 2006-Fthenakis & Kim, Material Research Society, Symposium vol. 895, 83, 2006-Fthenakis & Alsema, Progress in Photovoltaics, 14, 275, 2006

0.0

0.5

1.0

1.5

2.0

2.5

3.0

Ribbon-Si11.5% roof-

top,Europeanproduction

Multi-Si13.2% roof-

top, Europeanproduction

Mono-Si14.0% roof-

top,Europeanproduction

CdTe 8%roof-top,Europeanproduction

CdTe 9%ground-mount,

U.S.production

EPB

T (Y

ears

)

BOS

Frame

Frameless Module

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Man-days lost/ MWyr

0.1

1

10

100

1000

10000

OilNucl

earNatu

ral gas Hydr

o

WindMeth

anol

Solar T

hermal PV

PV Risks: Studies by OthersPV Risks: Studies by Others“Solar energy systems have greater material requirements .., so public risks from emissions will be greater”(Inhaber, Science, 1979)

“Commercial nuclear power is 10-15 times less risky than PV” (Bezdek, Energy, 1993)

Maximum fatalities/accident

110

1001000

10000100000

Lignite

Hard coal Oil

Natural GasNuclear

HydroWind PV

IER Stuttgart, Voβ, 2006

Paul Scherrer Institute (PSI), Hirschberg et al., 2004)

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PV Risks –BNL UpdatePV Risks –BNL Update

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Maximum Consequences per Accident: BNL UpdatePresented at the California Energy Commission Nuclear Issues Workshop,

Sacramento, CA, June 28, 2007

Maximum Consequences per Accident: BNL UpdatePresented at the California Energy Commission Nuclear Issues Workshop,

Sacramento, CA, June 28, 2007

Coal Oil NG LPG

Nuclear

(Chernobyl)

Nuclear

(except

Chernobyl)PV, PSI

Fata

litie

s

434

3000

100

600

125

PV, BNL

2

9000-33000

100

105

104

103

102

101

100

PSI

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Subtask 3- Facility SafetySubtask 3- Facility Safety

Analysis of a silane explosion in a photovoltaic fabrication plant,

AIChE Process Safety Progress, 2006

Guidelines for semi-bulk silane safety,21nd EUPVSEC, Dresden, GR, 2006

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Task 12 PV –EH&S Forthcoming WorkshopsTask 12 PV –EH&S Forthcoming WorkshopsWorkshop on recycling infrastructure in collaboration with PV Cycle

Expert Workshop on Life Cycle Assessment of PV technology

Additional participations are welcome!

“We are all partners in safety”

Email: VMF@BNL.GOV

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Task 12 PV –EH&STask 12 PV –EH&S

Working together means winning together !