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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: [email protected]
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Task 12 PV –EH&STask 12 PV –EH&S
Working together means winning together !