3DP.1.3 Fthenakis Valencia 2010
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Transcript of 3DP.1.3 Fthenakis Valencia 2010
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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
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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
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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
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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
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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
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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
Fthenakis, Renewable & Sustainable Energy Reviews, 2009
Update 2010
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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.
Fthenakis, Renewable & Sustainable Energy Reviews, 2009
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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
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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
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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
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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
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CdTe PV Product Life Accidental ReleasesCdTe PV Product Life Accidental Releases
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
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CdTe PV Product Life Accidental ReleasesCdTe PV Product Life Accidental Releases
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
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The Triangle of SuccessThe Triangle of Success
Low Cost
Recycling
LowestEnvironmental Impact
ResourceAvailability
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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
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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
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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
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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
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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
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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
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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
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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
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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