3DP.1.3 Fthenakis Valencia 2010

7/27/2019 3DP.1.3 Fthenakis Valencia 2010

1/24

1

Environmental Aspects of Thin Film ModuleProduction and Product Lifetime

Environmental Aspects of Thin Film ModuleProduction and Product Lifetime

Vasilis FthenakisPV Environmental Research Center

Brookhaven National Laboratory

andCenter for Life Cycle Analysis

Columbia University

Invited Plenary Presentation at the 25th European Photovoltaic SolarEnergy Conference, Valencia, September 9, 2010

email: [email protected]

web: www.pv.bnl.gov

www.clca.columbia.edu


2/24

2

PV Sustainability CriteriaPV Sustainability Criteria

Photovoltaics are required to meet the need for abundant

electricity generation at competitive costs, whilst conserving

resources for future generations, and having environmentalimpacts lower than those of alternative future energy-

options

Sustainability Metrics:

Low Cost

Resource Availability

Minimum Environmental Impact


3/24

3

Thin-Film PV -The Triangle of SuccessThin-Film PV -The Triangle of Success

Low Cost

Affordability in a

competitive world

Affordability in aAffordability in a

competitive worldcompetitive world

ResourceAvailability

LowestEnvironmental Impact

Cd in CdTe & CIGS

NF3 in a-Si/mc-Si

Cd in CdTe & CIGSCd in CdTe & CIGS

NFNF33 in ain a--SiSi/mc/mc--SiSi

Tellurium in CdTe

Indium in CIGS

Germanium in a-SiGe


4/244

Tellurium for PV* from Copper SmeltersTellurium for PV* from Copper Smelters

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

2010 2020 2030 2040 2050 2060 2070 2080 2090 2100

Te(

MT/yr)

Tellurium Availability for PV* (MT/yr)

Low

High

Global Efficiency of Extracting Te from anode slimes increases to 80% by 2030 (low scenario);

90% by 2040 (high scenario)* 322 MT/yr Te demand for other uses has been subtracted

Fthenakis, Renewable & Sustainable Energy Reviews, 2009


5/245

Te Availability for PV:Primary + RecycledTe Availability for PV:Primary + Recycled

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

2010 2020 2030 2040 2050 2060 2070 2080 2090 2100

Te(

MT/yr)

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

2

Te(

MT/yr)

2010 2020 2030 2040 2050 2060 2070 2080 2090 2100

Tellurium Availability for PV (MT/yr)

Low

HighRecycling every 30-yrs

10% loss in collection10% loss in recycling

Recycling every 30Recycling every 30--yrsyrs10% loss in collection10% loss in collection10% loss in recycling10% loss in recycling


6/246

Assumptions for Thin-Film PV GrowthAssumptions for Thin-Film PV Growth

PV Type Efficiency (%)

2008 2020

Conservative Most

likely

Optimistic

CdTe 10.8 12.3 13.2 14

CIGS 11.2 14 15.9 16.3

a-Si-Ge 6.7 9 9.7 10


Update 2010


7/247

Assumptions for Thin-Film PV GrowthAssumptions for Thin-Film PV Growth

PV Type Efficiency (%)Efficiency (%)Efficiency (%) Layer Thickness (m)

200820082008 202020202020 2008 2020

ConservativeConservativeConservative MostMostMost

likelylikelylikely

OptimisticOptimisticOptimistic Conservative Mostlikely

Optimistic

CdTe 10.810.810.8 12.312.312.3 13.213.213.2 141414 3.3 2.5 1.5 1.

CIGS 11.211.211.2 141414 15.915.915.9 16.316.316.3 1.6 1.2 1. 0.8

a-Si-Ge 6.76.76.7 999 9.79.79.7 101010 1.2 1.2 1.1 1.



8/248

CdTe PV Annual Production ConstraintsCdTe PV Annual Production Constraints

CdTe PV (GW/yr)

Most likely

Optimistic

Conservative0

50

100

150

200

250

2010 2020 2030 2040 2050 2060 2070 2080 2090 2100

CdTePV(GW/yr)

Conservative

Most likely

Optimistic

Production can increasewith direct miningstarting at ~2015


9/249

CIGS Material-based Growth Constraints*CIGS Material-based Growth Constraints*

CIGS PV (GW/yr)

0

50

100

150

200

250

2010 2020 2030 2040 2050 2060 2070 2080 2090 2100

CIGSPV(G

W/yr)

Conservative

Most likely

Optimistic

* 1/2 of In production growth is allocated to PVFthenakis, IEEE PVSC, June 23, 2010


10/24


11/2411

CdTe PV Product Life Accidental ReleasesCdTe PV Product Life Accidental Releases

PV Roof-top fires

Negligible emissions during fires

Fthenakis, Renewable and Sustainable Energy Reviews, 2004,

Fthenakis et al., Progress in Photovoltaics, 2005

Based on standard protocols by the ASTM and ULExpert Peer reviews by:

BNL, US-DOE, 2004

EC-JRC, 2004German Ministry of the Environment, (BMU), 2005

French Ministry of Ecology, Energy, 2009

Based on standard protocols by the ASTM and ULExpert Peer reviews by:

BNL, US-DOE, 2004

EC-JRC, 2004German Ministry of the Environment, (BMU), 2005

French Ministry of Ecology, Energy, 2009


12/2412

CdTe PV Fire-Simulation Tests: XRF AnalysisCdTe PV Fire-Simulation Tests: XRF Analysis

-4

-3.5

-3

-2.5

-2

-1.5

-1

-0.5

0

0 10000 20000 30000

Cd(counts)

position(mm)

-4.5

-4

-3.5

-3

-2.5

-2

-1.5

-1

-0.5

0

0 10000 20000 30000

Cd(counts)

position(mm

-8

-7

-6

-5

-4

-3

-2

-1

0

0 5000 10000

Cd(counts)

position(mm

XRF-micro-probing

Cd Distribution in PV Glass

1000 C, right end of sample

XRF-micro-spectroscopy -Cd Mapping in PV Glass

1000 C, Section taken from middle of sample

Heat

Fthenakis, Fuhrman, Heiser, Lanzirotti, Fitts and Wang, Progress in Photovoltaics, 2005


13/24

13


Leaching from shuttered modules 10 mm fragments -Rain-worst-case scenario- leached Cd concentration in the

collected water is no higher than the German drinking water concentration.

(Steinberger, Frauhoffer Institute Solid State Technology, Progress in Photovoltaics, 1998)

< 4 mm fragments Leached Cd exceeds the limits for disposal in inert landfill but

is lower than limits for ordinary landfills

(Okkenhaug, Norgegian Geotechnical Institute, Report, 2010)

Uncontrolled dumping of CdTe-moduleswill result in greater environmental riskscompared with disposal in approvedlandfill sites

Uncontrolled dumping of CdTe-moduleswill result in greater environmental riskscompared with disposal in approvedlandfill sites


14/24

14


Leaching from shuttered modules 10 mm fragments -Rain-worst-case scenario- leached Cd concentration in the

collected water is no higher than the German drinking water concentration.

(Steinberger, Frauhoffer Institute Solid State Technology, Progress in Photovoltaics, 1998)

< 4 mm fragments Leached Cd exceeds the limits for disposal in inert landfill but

is lower than limits for ordinary landfills

(Okkenhaug, Norgegian Geotechnical Institute, Report, 2010)

< 2 mm fragments CdTe PV sample failed California TTLC and STLC tests

(Sierra Analytical Labs for the Non-Toxic Solar Alliance, 2010)

All PV modules would fail the California tests

c-Si for Ag, Pb, and Cu (ribbon),

CIGS for Se; a-Si marginally for Ag

Eberspacher & Fthenakis, 26th IEEEPVSC,1997; Eberspacher 1998

All PV modules would fail the California tests

c-Si for Ag, Pb, and Cu (ribbon),CIGS for Se; a-Si marginally for Ag

Eberspacher & Fthenakis, 26th IEEEPVSC,1997; Eberspacher 1998

We advocate for all PV modules tobe recycled at the end of their lifeWe advocate for all PV modules tobe recycled at the end of their life


15/24

15

The Triangle of SuccessThe Triangle of Success

Low Cost

Recycling

LowestEnvironmental Impact

ResourceAvailability


16/24

16

Atmospheric Cd Emissions from the Life-Cycle of CdTe PV ModulesReference CaseAtmospheric Cd Emissions from the Life-

Cycle of CdTe PV ModulesReference Case

Process (g Cd/ton Cd*) (% ) (mg Cd/GWh)

1. Mining of Zn ores 2.7 0.58 0.02

2. Zn Smelting/Refining 40 0.58 0.303. Cd purification 6 100 7.79

4. CdTe Production 6 100 7.79

5. CdTe PV Manufacturing 0.4* 100 0.52*

6. CdTe PV Operation 0.05 100 0.067. CdTe PV Recycling 0.1* 100 0.13*

TOTAL EMISSIONS 16.55

Plus 200 mg Cd/GWh fromfossil fuels in the electricitymix in the life-cycle of CdTePV

Plus 200 mg Cd/GWh fromfossil fuels in the electricitymix in the life-cycle of CdTePV

Fthenakis V. Renewable and Sustainable Energy Reviews, 8, 303-334, 2004* 2009 updates


17/24

17

Total Life-Cycle Cd Atmospheric EmissionsTotal Life-Cycle Cd Atmospheric Emissions

3.7

0.3

44.3

0.90

10

20

30

40

50

0.4 0.7 0.6 0.2

bbon

-Si

mon

o-Si

mc-Si

CdT

eCoal

Natural

Gas O

il

Nuclear

gCd/GWh

ri

Fthenakis and Kim, Thin-Solid Films, 515(15), 5961, 2007

Fthenakis, Kim & Alsema, Environ. Sci. Technol, 42, 2168, 2008


18/24

18

GHGs Used in PV Module ManufacturingGHGs Used in PV Module Manufacturing

Substance Source

CF4 c-Si surface etching

C2F6 c-Si reactor cleaning

SF6 a-Si/nc-Si reactor cleaningNF3 a-Si/nc-Si reactor cleaning

Weiss et al (2008), Nitrogen trifluoridein the global atmosphere, GeophysicalResearch Letters, 2008

PV: climate killer?

The NF3 storyPhoton Magazine, December 2008

PV: climate killer?

The NF3 storyPhoton Magazine, December 2008


19/24

19

NF3 Emissions in a-Si/nc-Si PV Life-CyclesNF3 Emissions in a-Si/nc-Si PV Life-Cycles

Analysis based on detailed data from

Air Products NF3 Production

Applied Materials NF3 Use in PV

Qualitative information from Kanto Denka - NF3 Production Oerlikon NF3 Use in PV


20/24

20

Trends in NF3 Production and Emission FactorsTrends in NF3 Production and Emission Factors

NF3 Emission Factor Relative to Global Production 2000 2008

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

2000 2001 2002 2003 2004 2005 2006 2007 2008

Global NF3 Manufacturing Capacity (Metric tons)

0

1000

2000

3000

4000

5000

6000

7000

8000

1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

Source: R. Ridgeway, Air Products


21/24

21

Emission Trends in NF3 ManufacturingEmission Trends in NF3 Manufacturing

Known NF3 Emission Factors

0.0%

0.1%

0.2%

0.3%

0.4%

0.5%

0.6%

0.7%

0.8%

NF3 Dryer

Losses

NF3 Reactor

Losses

NF3 Liquifier

Losses

NF3 Analytical

Losses

All Other Vents

EmissionFactors(%)

Mar-09

Apr-10

Target

Source: R. Ridgeway, Air Products

NF3 E i i M t i T i lNF3 E i i M t i T i l


22/24

22

NF3 Emission Measurements in Typicala-Si and tandem Si PV FabsNF3 Emission Measurements in Typicala-Si and tandem Si PV Fabs

Factory Source avg NF3Conc(ppm)

DRE

(%)

Emission

Factor

(%)A Applied Materials 1.0 99.98 0.02

B Applied Materials 8.5 99.90 0.1

C Applied Materials 27.5 99.75 0.25

D Third Party 2.0 99.98 0.02

E Third Party 8.6 99.90 0.1

F Third Party 11.0 99.87 0.13Average 99.89 0.11

For average U.S. insolation (1800 kWh/m2/y) NF3 life-cycle emissions add 2 - 7 g/kWh of CO2-eq


23/24

23

ConclusionConclusion

Thin-film PV can reach very high rates of growth withoutbeing impaired from material availability issues.

Recycling spent modules will become increasinglyimportant in resolving cost, resource, and environmental

constraints to large scales of sustainable growth.

The controlled use of NF3 in the a-Si/nc-Si PV industry willnot alter the environmental benefits of PV replacing fossilfuels if best practices are adopted globally.

Email: [email protected]

www.pv.bnl.gov


24/24

24

AcknowledgmentAcknowledgment

Support from US-DOE, Solar Technologies Program Jeff Britt - Global Solar Jun Ki Choi, Huyng Chul Kim BNL Daniel Clark, Mehran Moalem Applied Materials Al Compaan U. Toledo Xunming Deng Xunlight Subhendu Guha - Uni-Solar D.R. Nagaraj - Cytec Funsho Ojebuoboh, Alex Heard, Dave Eaglesham, Tim Mays, Lisa Krueger

-First Solar Robert Ridgeway Air Products Jim Sites Colorado State U. Bill Stanbery -HelioVolt Marc Suys, 5NPlus

Bolko von Roedern NREL Ken Zweibel George Washington U.

email: [email protected]: www.pv.bnl.gov

3DP.1.3 Fthenakis Valencia 2010

Documents

Transcript of 3DP.1.3 Fthenakis Valencia 2010