Environmental Health and Safety

Transcription

1 Environmental Health and Safety Vasilis Fthenakis, Ph.D. Senior Chemical Engineer/Principal Investigator Charlie Kim, Ph.D., Materials Engineer/LCA Specialist Wenming Wang, Ph.D., Metallurgical Engineer, Recycling Specialist National Photovoltaic (PV) EHS Research Center Brookhaven National Laboratory DOE Solar Energy Technologies Program Peer Review Denver, CO, April 17-19,

2 Objectives Preserve the safe and environmentally friendly nature of PV and minimize EH&S risks and associated costs, to ensure the public support and economic viability of PV systems. Identify potential EH&S barriers of PV materials, processes, or applications and define strategies to overcome such barriers, with proactive research and rigorous industry outreach. Maintain the EH&S Research Center as the world s best source on PV EH&S, providing accurate information related to EH&S issues and perceptions. Relevance Minimization of EH&S risks and costs is paramount for achieving the program s 2020 goal of $0.06/KWh while having the support of the public is a prerequisite for existence and growth that could support this price. The EH&S work also supports DOE s strategic mission objectives: Reducing adverse environmental impacts associated with energy production, delivery, and use. Helping industry shift from waste management to resource efficiency and pollution prevention 2

3 FY06 Main Activities HAZARD/ENVIRONMENTAL ASSESSMENT ($180K) Life Cycle Analysis (LCA) of Amonix Concentrating PV GHG emissions in solar electric and nuclear power life cycles Energy Payback, GHG emissions, and external costs of PV (mc-si, pc-si, ribbon, CdTe) Environmental metrics of roof-top and ground-based PV HAZARD MANAGEMENT CdTe PV Recycling: Recovery of 99.98% pure Cd at projected cost of 0.1 /W Silane storage safety analysis INDUSTRY OUTREACH Assistance to First Solar, Unisolar, DayStart Tech and others INFORMATION DISSEMINATION/ COMMUNICATIONS Answered several requests from agencies, business and media Organized an MRS symposium on LCA Published and presented extensively PROJECT MANAGEMENT/ REVIEWS / ASSISTANCE ($90K) ($39K) ($52K) ($39K) 3

4 Major Accomplishments Determined Energy Payback Times (EPBT), GHG and toxic emissions from PV Conducted comparative assessment of GHG emissions in PV and nuclear life cycles Optimized Cd recovery from defect/spent CdTe PV modules Spearheaded international collaborations on LCA and recycling Led expert workshops by the EU-JRC, BMU and the IEA 4

5 Presentation Overview Life Cycle Analysis Greenhouse Gas Emissions Energy Payback Times (EPBT) Toxic Emissions Recycling Silane Safety Risk Estimates Future Directions 5

6 GHG Emissions from Life Cycle Energy of Electricity Production -ExternE & Australian Coal Association Research Programs Comparison of Energy Technologies: Major Studies CO2-eq.(g/kWh) ExternE, Germany 2003 ACARP, Australia Coal Gas CC PV, mc-si Nuclear 6

7 GHG Emissions from Life Cycle Energy of Electricity Production BNL et al. Estimates 1400 GHG (g CO2-eq./kWh) Materials Operation Transportation Fuel Production Coal (Kim and Natural Gas Petroleum Dale 2005) (Kim and Dale(Kim and Dale 2005) 2005) Nuclear (Baseline - Fthenakis and Kim, 2007 PV, CdTe (Fthenakis and Kim 2005) PV, mc-si, (Fthenakis and Alsema, 2006) 7

8 LCA of BOS of Tucson Electric s Springerville, AZ, PV plant GHG emissions (g CO2-eq./ kwh) BOS part production Transportation Plant Construction Administrative Disposal BOS Total Frame Total Energy Payback Times This is a 70% improvement from previous BOS designs (e.g., Sienna, Italy) years Springerville, AZ U.S. Average Mason, Fthenakis, Hansen, and Kim, Energy Pay-Back and Life Cycle CO2 Emissions of the BOS in an Optimized 3.5 MW PV Installation, Progress in Photovoltaics,

9 Energy Payback Times (EPBT) Crystal Clear & BNL Studies Insolation: 1700 kwh/m2-yr 3.0 EPBT (Years) BOS Frame Frameless Module Ribbon-Si 11.5% Multi-Si 13.2% Mono-Si 14.0% CdTe 9% Based on data from 12 US and European PV manufacturers -Alsema & de Wild, Material Research Society, Symposium vol. 895, 73, dewild & Alsema, Material Research Society, Symposium vol. 895, 59, Fthenakis & Kim, Material Research Society, Symposium vol. 895, 83, Fthenakis & Alsema, Progress in Photovoltaics, 14, 275,

10 Energy Payback Times Effect of Si Slurry Recycling Insolation: 1700 kwh/m2-yr 3.0 EPBT (Years) BOS Frame Frameless Module 0.0 Ribbon-Si 11.5% Multi-Si 13.2% Mono-Si 14% CdTe 9% -Alsema, de Wild & Fthenakis, 21 st EU-PV Conference, Aug., Fthenakis & Alsema, Progress in Photovoltaics, 14, 275,

11 Life Cycle GHG Emissions Europe Insolation: 1700 kwh/m2-yr CO2-eq (g/kwh) BOS Frame Frameless Module 0 Ribbon 11.5% Multi-Si 13.2% Mono-Si 14% CdTe 9% 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, Accelerated Publication, 14, 275,

12 Life Cycle GHG Emissions Phoenix, AZ g CO2-eq./kWh Ribbon 11.5%, PR=0.8 Multi-Si 13.2%, PR=0.8 Mono-Si 14.0%, PR= CdTe 9%, PR=0.8 Amonix HCPV, mono-si 18%, PR=0.7 Concentrator Module Tracker/Foundation Other BOS Frame Module Normalized for Phoenix, AZ. Insolation = 2370 kwh/m2/yr for longitude optimal, = 2480 kwh/m2/yr for direct normal with 2-axis tracker. Kim & Fthenakis, IEEE WCPEC, May 11, 2006

13 Recycling of Cd and Te from Spent CdTe PV Modules Recycling of Spent Electrolyte PV Module Fragments Leach Device H 2 SO 4 H 2 O 2 Removal of Cu from Liquid Using Resin A Column I Cu Column II Cu Removal of Cd and Fe from Liquid Using Resin B Column I Cd, Fe Column II Cd, Fe Effluent Solution (Te) Spent H 2 SO 4 Solution Glass Slurry Elution of Column A Elution of Column B Selective Precipitation Tellurium Filtration Facility Leachate Solution (Te, Cd, Cu, Fe) Elution Solution (Cu) CdSO 4 Cd Metal Clean Glass Cu Recovery (?) 13 Cd Electrowinning Cell

14 Separation of Cd from Te in CdTe Recycling Te, Cd, and Cu (ppm) Te, influent Cd, influent Te, ppm Cd, ppm Cu, ppm Cu, influent Bed Volume Cd separation 99.99% Cd (ppm) Cd effluent concentration <0.3 ppm RESULT: Cd, Te extraction & separation completed at a projected cost of 1 /W p PATENT application #11/421,343 14

15 Cd Recovery by Electrowinning Cadmium Purity of Deposits for Various Inputs % cadmium in deposted sheet A15 B15 C30 D40 E40 Electrolyte 15

16 Cd Electrowinning Estimated Cost Electrowinning Cost Estimates - 10 MW/yr Scrap (5.4 tonne/day) $US per yr $10,000 $9,000 $8,000 $7,000 $6,000 $5,000 $4,000 $3,000 $2,000 $1,000 $0 $9,160 $7,859 $1,300 Capital Operating Total Operating Waste Disposal Maint. Labor Electrodes Supplies Cell Labor Electricity Capital Misc Labor Instrumentation Tanks Pumps Power Supply Electrodes Cell Total Incremental cost of electrowinning = 0.1 /Wp 16

17 Silane Safety Silane Bulk Storage LAYERS OF PROTECTION To Factory Security Fence Pressure Control Deluge Head UV/IR Sensor Crossover Panel Primary Silane Toner Blast Walls Secondary Silane Toner Flow restrictors and pressure transducers for cylinder- and deliverypressures. UV/IR detectors in storage Hybrid sensors in the tools Personnel training/safe procedures are extremely important. The potential for loss is reduced by blast walls, spacing the tanks, having a deluge system, secure, fenced, separation zones. SILANE SAFETY IN AMORPHOUS SILICON AND SILICON NITRIDE OPERATIONS, Dresden, 2006 V..Fthenakis, C. Carlisle and W. Chan Brookhaven National Laboratory, Upton, NY United Solar Ovonic, Auburn Hills, MI 17

18 PV Risks: Studies by Others Oil Lignite Nuclear Man-days lost/ MWyr Natural gas Hard coal Oil Hydro Wind YOLL/GWh Natural Gas Nuclear Methanol Solar Thermal Hydro ExternE German Implementation, 1999 (YOLL= years of life lost ) Wind PV PV Solar energy systems have greater material requirements.., so public risks from emissions will be greater (Inhaber, Science, 1979) Commercial nuclear power is times less risky than PV (Bezdek, Energy, 1993) Lignite Hard coal Maximum fatalities/accident Oil Natural Gas Paul Scherrer Institute (PSI) Report (Hirschberg et al., 2004) Nuclear Hydro Wind PV

19 Estimating Accidental Risks We examined the risks related to the production, distribution and use of hazardous materials used in PV, based on the EPA Risk Management Program (RMP) databases for the U.S. industry 19

20 Hazardous Substances in PV Module Manufacturing (OSHA PSM & EPA RMP) Substance Arsine Boron Trifluoride Diborane Hydrochloric acid Hydrogen Fluoride Hydrogen Selenide Hydrogen Sulfide Phosphine Hydrogen Silane Trichlorosilane Source GaAs MOCVD Dopant a-si dopant Cleaning agent c-si Etchant c-si CIGS selenization CIS sputtering a-si dopant a-si deposition/gaas a-si deposition Precursor - c-si 20

21 Number of Reported Events in the U.S. US-EPA RMP Database ( ) Incident Injuries Death Arsine Boron Trifluoride Diborane Hydrochloric acid Hydrogen Fluoride Hydrogen Selenide Hydrogen Sulfide Phosphine Dichlorosilane Hydrogen Silane Trichlorosilane 21

22 Estimated PV Risks by Chemical Derived from US-EPA RMP Database ( ) 1.E+00 1.E-01 Fatalities Injuries Event/GWyr 1.E-02 1.E-03 1.E-04 1.E-05 1.E-06 HCl HF SiHCl3 c-si (total) a-si (SiH4) Insolation = 1800 kwh/m2/yr; performance ratio =

23 c-si, BNL a-si, BNL 1.E+02 1.E+01 1.E+00 1.E-01 1.E-02 1.E-03 1.E-04 1.E-05 Comparison of Risk Estimates Fatalities Injuries Coal, OECD Coal, non-oecd Oil, OECD Oil, non-oecd NG, OECD NG, non-oecd LPG, OECD LPG, non-oecd Hydro, OECD Hydro, non-oecd Nuclear, OECD Nuclear, non-oecd PV Paul Scherrer Report 23 Event/GWyr

24 Comparisons of Estimated Maximum Consequences Fatalities Coal Oil NG LPG Nuclear (Chernobyl) Nuclear (except Chernobyl) PV, PSI PV, BNL Paul Scherrer Report 24

25 FY 2006 Publications 1. Fthenakis V.M. and Kim H.C., Greenhouse Gas Emissions from Solar Electric and Nuclear Power, A life Cycle Study, Energy Policy, 35, , Fthenakis V.M., et al.,, Emissions and Redistribution of Elements in CdTe PV Modules during Fires, Progress in Photovoltaics: Research and Applications, 13: , Mason J., Fthenakis V.M., Hansen T. and Kim C. Energy Pay-Back and Life Cycle CO2 Emissions of the BOS in an Optimized 3.5 MW PV Installation, Progress in Photovoltaics: Research and Applications, 14, , Fthenakis V.M and Wang W., Extraction and Separation of Cd and Te from Cadmium Telluride Photovoltaic Manufacturing Scrap, Progress in Photovoltaics: Research and Applications, 14: , Fthenakis V.M. and Alsema E., Photovoltaics Energy Payback Times, Greenhouse Gas Emissions and External Costs: 2004-early 2005 Status, Progress in Photovoltaics Research and Applications, 14: , Kim H.C. and Fthenakis V.M, Amonix High-Concentrator Photovoltaic system: Life cycle energy demand and greenhouse gas emissions, Proceedings IEEE 4th World Conference on Photovoltaic Energy Conversion, Hawaii, May 8-12, 2006, pp Fthenakis V.M., Quantifying the life-cycle environmental profile of photovoltaics and comparisons with other electricitygeneration technologies, Proceedings IEEE 4th World Conference on Photovoltaic Energy Conversion, Hawaii, May 8-12, 2006, pp de Wild-Scholten M.J., Alsema E., ter Horst E.W., Bachler M. and Fthenakis V.M., A Cost and Environmental Impact Comparison of Grid-Connected Rooftop and Ground-Based PV Systems, Proceedings 21st European Photovoltaic Solar Energy Conference, Dresden, Germany, 4-8 September 2006, pp Alsema E., de Wild-Scholten M.J. and Fthenakis V.M., Environmental Impacts of PV Electricity Generation - A Critical Comparison of Energy Supply Options, Proceedings 21st European Photovoltaic Solar Energy Conference, Dresden, Germany, 4-8 September 2006, pp Fthenakis V.M., Colli A., Arellano A., Kirchsteiger C., and Ale B., Evaluation of Risks in the life Cycle of Photovoltaics in a Comparative Context, Proceedings 21st European Photovoltaic Solar Energy Conference, Dresden, Germany, 4-8 September 2006, pp Fthenakis V.M., CdTe Photovoltaics: Life-cycle Environmental Profile, Thin Solid Films, in press. 12. Fthenakis V.M. Photovoltaics Life Cycle Analysis, Invited Plenary Presentation, Renewable Energy 2006, Chiba, Japan, October 11, Wang W. and Fthenakis V., Recovery of tellurium from CdTe PV manufacturing scrap and other sources, EPD Congress, TMS (The Minerals, Metals & Material Society, Fthenakis V.M., Carlisle C. and Chan W., Silane Safety in amorphous silicon and silicon nitride operations, Proceedings 21st European Photovoltaic Solar Energy Conference, Dresden, Germany, 4-8 September 2006, Fthenakis V.M., Wang W., Meader A., and Squires K., Recycling of CdTe Photovoltaic Modules: Recovery of Glass, Cadmium and Tellurium, Proceedings 21st European Photovoltaic Solar Energy Conference, Dresden, Germany, 4-8 September 2006, pp Fthenakis V.M., Kim H.C., Emissions from Photovoltaic Life Cycles, Environmental Sciences & Technology, Submitted. 25

26 Future Directions: FY07-09 Key EHS Targets FY07 Industry Outreach/ EHS Vigilance in manufacturing facilities; On-going effort Compare CdS buffer options for CIGS PV Assist industrialization of PV recycling GHG use in c-si etching operations LCA of different manufacturing efficiencies FY08 EHS and LCA production of silicon feedstock Joint studies for increasing material utilization/ decreasing EHS risks and costs in a-si PV manufacturing Dye-sensitized solar cells Life Cycle Analysis Risk-based LCA-based Comparisons of Energy Technologies Collaborative Work FY09 Organic solar cells EHS and LCA Concentrating Solar Power Life Cycle Analyses PV Nanomaterials Toxicity & Life Cycle Analysis Collaborative work 5-yr IEA Task 12- kick off meeting March 16,