Engineering topics
Fthenakis, Vasilis
Publications and source records attributed to Fthenakis, Vasilis.
Updated sustainability status of cadmium telluride thin‐film photovoltaic systems and projections
This paper provides a comprehensive assessment of the up-to-date life-cycle sustainability status of cadmium-telluride based photovoltaic (PV) systems. Current production modules (Series 6 and Series 7) are analyzed in terms of their energy performance and environmental footprint and compared with the older series 4 module production and current single-crystalline Silicon (sc-Si) module production. For fixed-tilt systems with Series 6 modules operating under average US irradiation of 1800 kWh/m 2 /year, the global warming potential (GWP) is reduced from 16 g CO 2eq /kWh in Series 4 systems to 10 CO 2 eq /kWh in Series 6 systems. For operation in US-SW irradiation of 2300 kWh/m 2 /year, the GWP is reduced from 11 to 8 CO 2eq /kWh and for 1-axis tracking systems operating in Phoenix, Arizona, with point-of array irradiation of 3051 kWh/m 2 /year the GWP is reduced to 6.5 CO 2eq /kWh. Similar reductions have happened in all environmental indicators. Energy payback times (EPBT) of currently installed systems range from 0.6 years for fixed–tilt ground–mounted installations at average US irradiation at latitude tilt installations to 0.3 years for one-axis trackers at high US-SW irradiation, considering average fossil-fuel dominated electricity grids with fuel to electricity conversion efficiency of 0.3. The resulting energy return on energy investment (EROI) also depends on the conversion efficiency of the electricity grid and on the operation life expectance. For a 30-year operational life and grid conversion efficiency of 0.3, EROI ranges from 50 (at US average irradiation) to 70 for US-SW irradiation. The EROI declines with increased grid conversion efficiency; for CdTe PV operating in south California with grid conversion efficiency of 49%, the EROI is about 50 and is projected to fall to 30 when the state's 2030 target of 80% renewable energy penetration materializes. Material alternatives that show a potential of further reductions in degradation rates and materials for enhanced encapsulation that would enable longer operation lives have also been investigated. A degradation rate of 0.3%/year, which has been verified by accelerated testing, is assumed in 30-year scenarios; this is projected to be reduced to 0.2%/year in the near-term and potentially to 0.1%/year in the longer term. With such low degradation rates and enhanced edge-sealing, modules can last 40- to 50-years. Consequently, all impact indicators will be proportionally reduced while EROI will increase. This detailed LCA was conducted according to ISO standards and IEA PVPS Task 12 guidelines. Furthermore, the study revealed that the choices of system models, methods and temporal system boundaries can significantly impact the results and points out to the need to include assumptions regarding these choices in the “transparency in reporting” requirements listed in the IEA PVPS Task 12 Guidelines.
Life-cycle costing assessment of back contact doping and encapsulation alternatives for increasing the life expectancy of CdTe PV modules (Final Report)
Contribution of Research to the State-of-Knowledge This research produced comparative sustainability evaluations of back contact doping and encapsulation alternatives considered by First Solar for decreasing degradation and increasing the life of the cadmium telluride (CdTe) photovoltaic (PV) modules. Technical Effectiveness and Economic Feasibility of Methods Investigated A holistic life-cycle-assessment of the alternatives considered for longer module operational lives, showed that they add between 0.2% and 2% to environmental impact indicators at the cradle-to-gate module level, but at the cradle-to-grave system level, alternative materials offer only benefits (i.e., environmental impact indicator decreases) to the public and the environment. Parallel experimental studies at First Solar showed that the use of the considered alternative materials did not impact the effectiveness of the current module recycling separations and material recovery processes. Furthermore, the increment on the module manufacturing cost due to using alternative materials was estimated to be negligible (i.e., >1%) and longer module lives more than compensate cost increases. Specifically, increase of the current warranted module life of 30 years to 50 years, would decrease the levelized cost of electricity (LCOE) from $40/MWh to $24/MWh for utility-scale installations in the US-SW, the economic feasibility of the considered alternatives is assured. Benefit to the Public With decreasing degradation from the current ~0.3%/year of Series 6 modules to less than 0.2%/year, the public will be benefited by longer photovoltaic operational lives, and therefore. In addition, the requirement for end-of-life management is shifted from 30 years to 40 or 50 years, with profound benefits to the public and the environment.
Life-Cycle Analysis of Potentially Longer Life Expectancy CdTe PV Modules
Research on PV module longevity shows that with lower degradation rates and better encapsulation, PV modules can significantly outlast their current life expectancy of 25-30 years. The focus of this study is on alternative CdTe PV module back-contact and encapsulation materials that show the potential of increasing module operation lives from 30 to 40 and 50 years. Life-cycle-analyis shows that some alternative materials may slightly increase cradle-to-gate environmental impacts per m2 of module, but increased operational life more than counterbalances such impacts. The life-cycle carbn footprint of systems operating under average US insolation conditions of 1800 kWh/m2/yr is reduced from 10 gCO2eq/kWh to 6 gCO2eq/kWh when the operation life increases from 30 to 50 yrs. Similar reductions are noted for all life-cycle impact indicators, whereas the EROI of the considered system increases from 67 to 177 as life increases from 30 to 50 yrs.
Realistic operation of two residential cordwood-fired outdoor hydronic heater appliances—Part 1: Particulate and gaseous emissions
This study investigated how heat demand and fuel loading affect the emissions from outdoor wood-fired hydronic heaters by testing two such appliances using an integrated-duty cycle test method. This test included transient operating conditions, such as cold and hot-starts and modulation between 15 and 100% of maximum rated output. Emission values indicate transient operating conditions produce higher emissions than steady state operation. Cold starts resulted in elevated particulate matter emission factors for both appliances; in one case the particulate matter emission factor for this period was >3500 mg/MJ, which represented emissions 20 times the average value. Additionally, when heat demand was cycled—elevated CO emission factors were measured, with values >5000 mg/MJ for both appliances and more than 3 times the appliance averages, respectively. It follows that the appliance average particulate matter emission factors and CO emission factors were not representative of the actual EF values during these transient periods. In contrast, methane emission factors were relatively stable throughout all tested combustion conditions; however, they were much higher than oil-fired appliances are therefore should not be ignored. These findings demonstrate that wood-fired hydronic heater emissions during transient operating conditions can be significantly greater than emissions during steady-state test conditions, such as those used in typical certification tests. Consequently, certification test values for particulate matter and CO emission factors may significantly underestimate the actual emissions of these appliances when operated in a home. Use of integrated duty-cycle test protocols that capture cold-starts and reloading are better for representing in-use operations of wood-fired hydronic heaters and provide more realistic emissions and delivered efficiency measurements.
A solar energy desalination analysis tool, sedat, with data and models for selecting technologies and regions
Abstract There is interest for desalination technologies powered by solar energy as arid areas are typically bestowed with good solar potential. In response to a US DOE call for solar desalination analysis tools, we developed an open-source solar energy desalination analysis tool, sedat , for techno-economical evaluation of desalination technologies and selection of regions with the highest potential for using solar energy to power desalination plants. It is expected that this software will simplify the planning, design, and valuation of solar desalination systems in the U.S. and worldwide. Sedat uses Dash for integrating various layers of large volumes of GIS data with Python-based models of solar energy generation and desalination technologies. It derives time-series of energy generation and water production, with details of plant performance and suggestions for improving the solar-desalination coupling. This paper summarizes the various phases of the tool’s development, presents example results showing the potential, under multiple objectives, of solar desalination in parts of the U.S. southwest, and discusses method details that would be useful for future model development.
GIS-Based Graphical User Interface Tools for Analyzing Solar Thermal Desalination Systems & High-Potential Implementation
This project developed a user-friendly, open-source, software that enables a comparative evaluation of solar thermal desalination technology options and employs geospatial data layers to identify regions of high-potential for solar thermal desalination. This was accomplished by integrating solar models with desalination models and enhancing their utility by providing GIS-based data inputs. The developed Solar Energy Desalination Analysis Tool (SEDAT) enables techno-economical evaluation of desalination technologies and selection of regions with the highest potential for using solar energy to power desalination plants. It simplifies the planning, design, and valuation of solar thermal and solar hybrid desalination systems in the U.S. and worldwide. SEDAT uses Dash for integrating various layers of large volumes of GIS data with Python-based models of solar energy generation and desalination technologies. It derives time-series of energy generation and water production, with details of plant performance and suggestions for improving the solar-desalination coupling. It is a one of-a-kind tool of analysis representing a definitive advancement in the state-of-the-art. Of solar desalination modeling This report summarizes the various phases of the tool’s development, and presents examples of the results.
Life cycle energy demand and carbon emissions of scalable single-junction and tandem perovskite PV
Perovskite photovoltaics reached record efficiencies in the laboratory and, if sustainably commercialized, they would accelerate a green energy transition. Here, this article presents the development of life-cycle inventory material and energy databases of most promising four single-junction and three tandem scalable perovskite systems with assumptions regarding scalable production validated by industry experts. We conducted comprehensive “ex ante” Life Cycle Analysis (LCA) and Net Energy Analysis, analyzing their cumulative energy demand, global warming potential profiles, energy payback times and energy return on investment (EROI). LCA contribution analysis elucidates the most impactful material and process choices. It shows that solution-based perovskite manufacturing would have lower environmental impact than vapor-based methods, and that roll-to-roll (RtR) printing offers the lowest impact. Among material choices, MoOx/Al has lower impact than Ag, and fluorine-tin-oxide lower than indium-tin-oxide. Furthermore, we compare perovskites with commercial crystalline-silicon and thin-film PV, accounting for the most recent developments in crystalline-Si wafer production and differences in life expectancies and efficiencies. It is shown that perovskite systems produced with RtR manufacturing could reach in only 12 years of life the same EROI as that of single-crystalline-Si PV lasting 30-years. This work lays a foundation for sustainability investigations of perovskite large-scale deployment.
Comparative Life Cycle Analysis of Scalable Single-Junction and Tandem Perovskite Solar Cell (PSC) Systems
Efficient, low-cost solar cells based upon perovskites have the potential to transform the US and global energy portfolio and improve energy security if they can be manufactured in an environmentally sustainable manner. However, previous life cycle analyses (LCA) of perovskite solar cells (PSC) used lab recipes to project the environmental impact of industrial PSC production – using materials and processes that may not be representative of industrial productions due to high material waste and complex synthesis – and such studies were limited to a few single-junction technologies. Thus, the goal of this project was threefold: a) to review the most promising for industrial production single-junction and tandem PSC technologies, b) to build life-cycle materials inventories that reflect scalable production of these technologies, and c) to conduct comprehensive life-cycle analysis of these technologies and compare their environmental impact with those of established commercial technologies. In response, this project identified challenges for fabrication transitioning from laboratory to sustainable industrial production, developed life-cycle inventory (LCI) data for scaling to industrial production four promising single-junction and three tandem PSC systems and produced life-cycle-investigations using, as metrics, a complete spectrum of energy, environmental and ecological impact indicators. Special focus was given to the use of lead, silver and indium in PSC. The project used the Life Cycle Assessment (LCA) methodology as standardized by the Society of Environmental Toxicology and Chemistry (SETAC), ISO standards 14040 and 14044, and the International Energy Agency PVPS Task 12 LCA guidelines. LCA allows the calculation of a number of energy and environmental and impact categories, including energy cumulative energy demand (CED), global warming potential (GWP), human toxicity potential (HTP), eco-toxicity potential (ETP), abiotic resource depletion potential (ADP), acidification potential (AP), ozone depletion potential (ODP), photochemical oxidation potential (POP), eutrophication potential (EP). In addition to those, we calculated the Energy Pay-Back Time (EPBT) and the Energy Return On Investment (EROI). We provide LCA impacts for complete perovskite PV systems – including balance of system components – installed at three irradiation levels and considering reference and future potential module efficiencies. Finally, a sensitivity analysis on perovskite lifetime has been performed, considering 10, 20 and 30 years. Contribution analysis of the impacts of each material and layer of PSC shows, that the use of Pb in metalorganic PSC does not result in significant environmental impacts as the major contributions to environmental indicators arise from the use of Ag and encapsulation materials. Solution-based PSC manufacturing was found to be less impactful to the environment than vapor-based fabrication, and roll-to-roll (RtR) printing uses less energy and generates the lowest emissions. PSC produced with RtR manufacturing could reach the same Energy Return on Energy Investment (EROI) as that of crystalline-Si PV within 12 years of life, whereas the most energy demanding spray coating on rigid substrates, would require a 20-yr life to match the EROI of 30-yr lasting silicon PV. This work lays the foundation for sustainability investigations in a comparative context of large-scale production and deployment of PSC. The results of this project have the potential to have a significant impact on the future of PV manufacturing, by providing industry, policy-makers, and academia with insights necessary to choose which, if any, lead-based solar cell life cycles are environmentally sustainable.
Life-cycle environmental impacts of single-junction and tandem perovskite PVs: a critical review and future perspectives
For new technologies, such as perovskite solar cells (PSC), life cycle analysis (LCA) offers a fundamental framework for examining potential environmental, energy and health impacts and mitigation options before large-scale commercialization and for guiding improvements in development and production that further reduce their environmental footprint. However, credible LCA studies require actual process-based material, energy and emissions data, which may not exist before the technologies are commercially produced. Thus, the perovskite LCA literature is based on linear extrapolations of laboratory data. In this paper we critically reviewed the PSC LCA literature, explain the reasoning for a wide divergence of results, and determined which data apply to scalable industrial production, materials and processes. Our investigation probed into the formulation of each layer of a PSC device, and its potential for industrial scale fabrication. We found that electricity use is the main contributor to reported LCA results, explaining the large difference, ranging from 7.78 kWh to 1,460 kWh/m –2 , among various studies. Subsequently, we identified and discuss methodological errors in some of these estimates. In terms of life-cycle toxicity most of the reviewed LCA studies do not attribute any major overall toxicity impact to the presence of lead in the PSC devices. We also reviewed and critiqued studies describing “worst-case” scenarios of accidental release of lead into the environment, and, in spite of statements in those studies, we found them to be inconclusive. Lastly, we discussed end-of-life (EoL) management options for resource recovery and for minimizing environmental impacts.
Energy efficiency and renewable energy utilization in desalination systems
Desalination technologies and industry have advanced significantly in the past two decades to meet the growing freshwater demands stimulated by the compounding issues of both water quality and quantity in many regions of the world. As desalination processes are energy demanding, there have been many efforts dedicated to improve energy-efficiency of the process units, enhance energy conservation and recovery, and increase renewable energy integration in desalination plants. This review article highlights recent key advances and discusses possible venues for further development in desalination energy portfolio to reduce specific energy consumption and, via integration with solar energy, to minimize the environmental footprint associated with freshwater production. First, an overview of current desalination technologies and their energy requirements are presented followed by a discussion on opportunities for improving energy efficiency and energy recovery in both membrane and thermal desalination technologies. Then, various combinations of renewable energy driven desalination plants are discussed with some recent highlights in solar energy driven membrane, thermal and hybrid desalination processes. Technological readiness levels for novel desalination processes, their perceived impact and expected near-future developments in renewable energy integrated desalination technologies are presented. Lastly, the potential for solar driven desalination as a cost-competitive freshwater supply alternative is discussed
Benefits and risks of lead halide perovskite photovoltaics
Photovoltaics (PV) do not emit anything during operation, but, over their life-cycle, emissions are generated from the use of fossil-fuels in the extraction and production of materials and in the manufacturing and installation of PV components and systems. Nonetheless, these emissions are always very small compared to those from conventional combustion-based generators of electricity. The case for CO2 emissions has been well documented; over their lifetime, they range from 10 g CO2-eq / kWh for CdTe PV system installed in high-irradiation (2300 kWh/(m2-yr) locations to 80 g CO2-eq / kWh for Chinese single-crystalline silicon PV systems installed in low-irradiation (1000 kWh/(m2-yr) locations,1 compared to ~1000 g CO2-eq/kWh for electricity from coal. However, in the case of the rapidly emerging lead halide perovskite PV (LHP-PV) technology, concerns are raised regarding the potential of emissions of lead from the life-cycles of LHP-PV, including at their end of life. This warranted an evaluation of lead emissions from PV and comparisons with emissions in other power generation life-cycles.