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At least 631 records · Page 35

Task 12 PV Sustainability - Life Cycle Assessment of Crystalline Silicon Photovoltaic Module Delamination with Hot Knife Technology

The objective of this study is to complete a life cycle assessment (LCA) of a novel technology that separates the crystalline silicon (c-Si) photovoltaic (PV) module front glass from the backsheet using hot knife technology. This is known to be the most challenging step in module recycling, where the choice of delamination approach can determine the process selection for the next steps of the recycling process, the economic value of the recovered materials, and environmental performance. The life cycle inventory (LCI) reported here is based on primary data from the technology manufacturer. Different LCIs are established following the cut-off approach and the end-of-life (EOL) approach. The environmental impacts of the hot knife delamination process are analysed based on six indicators, and the main contributors to delamination efforts are identified. For the EOL approach, the potential environmental benefits from the recovered materials are compared to the environmental impacts caused by the delamination process. The functional unit of this analysis is the delamination of 1 kg of used framed c-Si PV modules at the place of installation.

14 SOLAR ENERGY↗

PV Lifetime Project (2021 NREL Annual Report)

DOE's PV Lifetime project was initiated in 2016 with the goal of accurately characterizing the early-life evolution of photovoltaic (PV) field performance. Different PV cell and module technologies result in different initial performance loss rates due to effects like light-induced degradation (LID) and light & elevated temperature-induced degradation (LeTID). To accurately characterize the initial field performance loss requires the use of high-accuracy indoor IV curve measurements at standard test conditions. Therefore, PV modules involved in this study are removed from the field once or twice per year and brought indoors for measurement. Current samples deployed and monitored in this way include Jinko Solar (2016), Trina Solar (2016), Hanwha Q-Cells (2017), Panasonic (2018), LG (2018), Canadian Solar (2018), Mission Solar (2019). More recently, modules from Sunpreme (2019), and LONGi (2020) have been deployed but not yet analyzed. Overall annual performance loss rates are as follows: our first modules to be deployed (Jinko and Trina) have annual median performance loss rate between -0.4%/yr and -0.9%/yr, mainly concentrated in the first year. The QCells mono-PERC and multi-PERC modules have an annual degradation rate of -0.76%/yr and -0.69%/yr respectively, also concentrated in the first year of operation. Panasonic and LG modules displayed negligible performance loss in the past two years, at 0.1%/yr and -0.0%/yr respectively. They also were the only modules with initial IV curve measurements consistently above the nameplate rating. Possibly relatedly, these are also the only two N-type silicon module types analyzed so far. Canadian Solar multi-PERC modules demonstrated a -1.3%/yr degradation rate which actually accelerated in the past year, so this will be a module type to monitor in future years. Mission Solar modules exhibited strong recoverable performance loss, consistent with LeTID susceptibility. (The same is true for the Jinko JKM260 module type). Annual performance loss actually showed improvement in time at +0.3%/yr after 2 years in the field, although the module initially was measured at 3% below nameplate rating. These modules could therefore be experiencing a form of post-LeTID recovery. Initial measurements have been conducted on the next two module types - Sunpreme n-HIT and LONGi bifacial mono-PERC. We will report on initial year-1 performance change for these modules in the next PV Lifetime annual report. For the remaining modules, an additional year of field exposure will provide greater certainty in annual degradation rates, particularly for those with degradation concentrated in the initial year of field deployment.

14 SOLAR ENERGY↗

Protoflight photovoltaic power module system-level tests in the space power facility

Work Package Four, which includes the NASA-Lewis and Rocketdyne, has selected an approach for the Space Station Freedom Photovoltaic (PV) Power Module flight certification that combines system level qualification and acceptance testing in the thermal vacuum environment: The protoflight vehicle approach. This approach maximizes ground test verification to assure system level performance and to minimize risk of on-orbit failures. The preliminary plans for system level thermal vacuum environmental testing of the protoflight PV Power Module in the NASA-Lewis Space Power Facility (SPF), are addressed. Details of the facility modifications to refurbish SPF, after 13 years of downtime, are briefly discussed. The results of an evaluation of the effectiveness of system level environmental testing in screening out incipient part and workmanship defects and unique failure modes are discussed. Preliminary test objectives, test hardware configurations, test support equipment, and operations are presented.

Rivera, Juan C.↗

Protoflight photovoltaic power module system-level tests in the Space Power Facility

Work Package Four, which includes the NASA-Lewis and Rocketdyne, has selected an approach for the Space Station Freedom Photovoltaic (PV) Power Module flight certification that combines system level qualification and acceptance testing in the thermal vacuum environment: the 'protoflight' vehicle approach. This approach maximizes ground test verification to assure system level performance and to minimize risk of on-orbit failures. The preliminary plans for system level thermal vacuum environmental testing of the protoflight PV Power Module in the NASA-Lewis Space Power Facility (SPF) are addressed. Details of the facility modifications to refurbish SPF, after 13 years of downtime, are briefly discussed. The results of an evaluation of the effectiveness of system level environmental testing in screening out incipient part and workmanship defects and unique failure modes are discussed. Preliminary test objectives, test hardware configurations, test support equipment, and operations, are presented.

Rivera, Juan C.↗

Human Health Risk Assessment for Improper Landfill Disposal of End-of-Life CdTe Modules

The present work is a continuation of the 2020 IEA PVPS Task 12 Human Health Risk Assessment Methods for PV Part 3: Module Disposal Risks. The 2020 report performed a human health risk assessment (HHRA) for disposal of a cadmium telluride (CdTe) PV module in an unlined landfill, focusing solely on risks from cadmium. This study extends the 2020 HHRA on CdTe PV, analyzing eleven constituent elements: Cd, Se, Te, Cu, Si, Cr(III), Mo, Sn, Zn, Ni, and Al. The present HHRA was performed through two methods: utilization of the U.S. Environmental Protection Agency's (USEPA) Delisting Risk Assessment Software (DRAS V.4.0) on eight exposure pathways for cancer risk and non-cancer hazards; and comparison of exposure point concentrations to federal standards for groundwater, surface water, air, and soil exposure pathways. Cancer risks and non-cancer hazards posed by elemental leaching through all evaluated exposure pathways, using both methods, were found to be several orders of magnitude below USEPA health-protective thresholds. Cadmium exhibited both the highest risks and lowest uncertainty considering data availability on chemical content, leachate, and federal screening levels.

CdTe↗

Introducing the Baseline Performance Reference (BPR) for Irradiance in PV System Applications

Photovoltaic (PV) reference cells, modules, and arrays respond in a complex manner to the many variables that define their operating environment. PV reference cells for irradiance measurement have similarities but also differences to operational PV modules. For this reason, a more neutral and a well-defined generic PV reference cell is needed, whose characteristics are close enough to most operational PV devices to make stable performance indicators possible but whose characteristics are not necessarily identical to any of them. This poster describes a new well-defined reference quantity for outdoor PV measurements, called the baseline performance reference (BPR).

baseline performance reference↗

Electromagnetic Transient Simulation of Photovoltaic Inverter Using Implicit-Explicit Solver

This paper introduces the implementation of electromagnetic transient (EMT) simulations of a photovoltaic (PV) inverter module using the Implicit-Explicit (ImEx) solver in the Suite of Nonlinear and Differential/Algebraic Equation Solvers (SUNDIALS). This study demonstrates the effectiveness of the ImEx solver in overcoming the challenges inherent in simulating the complex dynamics of PV inverter modules. Furthermore, using SUNDIALS’ ImEx solver module ARKODE for EMT simulation automates key aspects of the process, such as numerical integration, providing substantial benefits including enhanced consistency, faster implementation, reduced human error, and the capability to handle the complexities of advanced numerical integration. By conducting comparative simulations with an implicit method used in commercial software, the research showcases the ImEx solver’s capability in achieving high accuracy and reliability. Results indicate that leveraging the ImEx approach significantly enhances modeling fidelity and reduces simulation setup times, offering a promising tool for the EMT analysis of PV inverter systems in power electronics-dominated power grids.

Choi, Jongchan [ORNL] (ORCID:000000025952455X)↗

Human Health Risk Assessment for Improper Landfill Disposal of End-of-Life CdTe PV

The present work is a continuation of the 2020 IEA PVPS Task 12 Human Health Risk Assessment Methods for PV Part 3: Module Disposal Risks. The 2020 report performed a human health risk assessment (HHRA) for disposal of a cadmium telluride (CdTe) PV module in an unlined landfill, focusing solely on risks from cadmium. This study extends the 2020 HHRA on CdTe PV, analyzing eleven constituent elements: Cd, Se, Te, Cu, Si, Cr(III), Mo, Sn, Zn, Ni, and Al. The present HHRA was performed through two methods: utilization of the U.S. Environmental Protection Agency's (USEPA) Delisting Risk Assessment Software (DRAS V.4.0) on eight exposure pathways for cancer risk and non-cancer hazards; and comparison of exposure point concentrations to federal standards for groundwater, surface water, air, and soil exposure pathways. Cancer risks and non-cancer hazards posed by elemental leaching through all evaluated exposure pathways, using both methods, were found to be several orders of magnitude below USEPA health-protective thresholds. Cadmium exhibited both the highest risks and lowest uncertainty considering data availability on chemical content, leachate, and federal screening levels.

chemicals↗

PV backsheets survey protocol: A framework for geo-spatial field surveys for bulk material characterization and reliability analysis applied across 41 PV systems

As widespread adoption of photovoltaic (PV) technologies continues, understanding the lifetime of modules is paramount to the viability of the industry as an environmentally conscious alternative to traditional energy generation. Although power degradation can affect the total energy production of a module over its lifetime, module safety failures necessitate the removal of a module leading to a loss of not only the particular asset, but the earning potential of the device. Therefore, it is critical to ensure that the components that provide essential safety functions for PV module operate for their entire rated lifetime. PV backsheets provide necessary electrical insulation to the completed device and failure of this component is cause for a immediate removal of the module. Degradation of the PV module backsheet has led to module safety failures in large-scale installations, costing millions of dollars in damages and lost potential revenue. The spatio-temporal degradation of fielded PV modules is important to study in order to identify which modules within installations are experiencing the greatest exposure conditions and in turn have the highest chance of failure. This paper describes a comprehensive field survey protocol developed for monitoring PV module backsheet performance using solely non-destructive methods in commercial PV fields. The protocol establishes a field naming convention, sampling method, data handling requirements, and measurement procedures. By ensuring consistent data collection practices, the field survey protocol enables research groups to obtain data of uniform quality on backsheet performance over multiple years and locations. In this study, the developed protocol was implemented at forty-one PV sites. Eight different types of airside layer backsheet materials including poly(vinylidene fluoride) (PVDF), acrylic PVDF, poly(tetrafluoroethylene-co-hexafluoropropylene-co-vinylidene fluoride) (THV), poly(vinyl fluoride) (PVF), poly(ethylene terephthalate) (PET), fluoroethylene vinyl ether (FEVE), polyethylene naphthalate (PEN), and glass were identified using attenuated total reflection Fourier transform infrared (ATR-FTIR) spectroscopy. The field survey results show that the spatial distribution of degradation indicators are non-uniform within a particular module, individual site, and across site locations. The degradation of PV modules increased in severity for modules mounted at the edge of rows (across a field) and near the junction box (within a module). This study demonstrates the sensitivity of material performance to exposure length across different materials and climates.

14 SOLAR ENERGY↗

What Is a Polyolefin? A Critical Overview of Ethylene Copolymers Used as Solar Photovoltaic Module Encapsulants

In recent years, photovoltaic (PV) encapsulant films marketed as polyolefins (POs), more specifically as PO elastomers (POEs) and thermoplastic POs (TPOs), have gained significant market share and are projected to become the dominant encapsulation films by 2030. Relative to other industries, there are significant misconceptions about the term PO in the PV industry. Both in the scientific literature as well as in sales and advertising, the terms PO, POE, and TPO are often misused to describe the same type of material with comparable properties, while in reality these may each consist of separate material classes. This paper provides a comprehensive literature and market review, to showcase a broad range of PO and other ethylene copolymer encapsulants from recent studies, and discusses the materials' properties to clarify what constitutes a “polyolefin.” In addition, to promote a clearer comparison of encapsulant properties, we propose a two‐dimensional taxonomy to categorize polymers used in module manufacturing, including POs. In terms of improving the reliability of solar PV modules, PO‐based encapsulants have several advantages (including lower water uptake and ion diffusion), but might come with disadvantages too, such as a more complex processing and a higher sensitivity to the storage conditions and shelf life. All this might prospectively impact adhesion properties of the encapsulant to other materials' interfaces (glass, cells etc.) and end‐product quality. Because the track record of field‐deployed PV modules containing PO encapsulants is also limited, we hope to contribute to better material understanding and precision in communication in PV to secure quality.

14 SOLAR ENERGY↗

Extended Accelerated Stress Testing of Lamination-Free Edge-Sealed Photovoltaic Minimodules

Lamination-free minimodules are constructed with silicon solar cells between glass sheets and an edge seal of polyisobutylene and silicone. These samples are stressed using a repeated sequential testing sequence including ultraviolet-containing simulated solar spectrum light exposure at elevated temperature, damp heat, humidity freeze, and thermal cycling adapted from the International Electrotechnical Commission (IEC) TS 63209-2:2022. The minimodule performance throughout the stressing is characterized by flash testing and electroluminescence imaging. Results are compared to conventional laminated minimodules using the same type of solar cells. The lamination-free minimodules experience up to 8% power loss compared to roughly 3% for the laminated versions. However, those losses, dominated by current and fill factor, are caused by glass soiling and busbar ribbon separation on the cells. When glass is replaced and the stressed cells are contacted with probes bypassing the delaminated ribbons, the initial performance is recovered, and overall losses of the lamination-free samples become negligible.

14 SOLAR ENERGY↗

Design and performance oof space station photovoltaic radiators

The design and performance of the Space Station Freedom Photovoltaic (PV) Power Module Thermal Control System radiators is presented. The PV Radiator is of a single phase pumped loop design using liquid ammonia as the coolant. Key design features are described, including the base structure, deployment mechanism, radiator panels, and two independent coolant loops. The basis for a specific mass of 7.8 kg/sqm is discussed, and methods of lowering this number for future systems are briefly described. Key performance paramters are also addressed. A summary of test results and analysis is presented to illustrate the survivability of the radiator in the micrometeoroid and orbital debris environment. A design criterion of 95% probability of no penetration of both fluid loops over a 10 year period is shown to be met. Methods of increasing the radiator survivability even further are presented. Thermal performance is also discussed, including a comparison of modeling predictions with existing test results. Degradation in thermal performance due to exposure to atomic oxygen and ultraviolet radiation in the low Earth orbit environment is presented. The structural criteria to which the radiator is designed are also briefly addressed. Finally, potential design improvements are discussed.

White, K. Alan↗

PV Lifetime Project - 2025 NLR Annual Report

DOE's PV Lifetime project was initiated in 2016 with the goal of accurately characterizing the early-life evolution of photovoltaic (PV) field performance. Different PV cell and module technologies result in different initial degradation rates due to effects like light-induced degradation (LID) and light and elevated temperature-induced degradation (LeTID). To accurately characterize the initial field degradation of maximum power (Pmp) requires the use of high-accuracy indoor IV curve measurements at standard test conditions. Therefore, PV modules involved in this study are removed from the field once or twice per year and brought indoors for measurement under constant temperature and irradiance conditions. Overall annual degradation rates are as follows: our first modules to be deployed (Jinko, Trina, QCells) have annual median degradation rate between -0.4%/yr and -0.5%/yr mainly concentrated in the first year. Mission Solar, LG and Panasonic modules are all displaying modest degradation, better than -0.3% / year. Indeed, Mission Solar fielded modules degraded less than their control modules which remain indoors and un-exposed. This is also true for the LONGi monofacial modules, which had some field degradation, but not as much as the degradation of the indoor control modules. The LONGi bifacial modules on the other hand have degraded more in the field than their monofacial counterparts, although still a modest amount (-0.4 %/yr). Of the four newest module types in the study, only one has had better than average degradation. REC360NP2 (N-type TOPCon) had a slight performance increase over the first year and a half of field deployment. For the other three new module types (plus one older module type), degradation was more rapid. In our study of 16 module types, four have demonstrated degradation faster than -1%/yr: two N-type Heterojunction, one PERC bifacial and one PERC shingled module. The two heterojunction modules in our study are degrading the most rapidly. Sunpreme n-HIT bifacial modules are showing a loss rate around -1.5%/yr, for over -10% total to date. This is largely attributed to loss in front-side Isc. This is distinct from the REC 405AA-Pure modules which have degraded -6.8% in only a year and a half, for an annualized decline of -3.9 %/yr. For this module type, the decline is roughly half in Voc, with the remaining split between FF and Isc. Of the remaining two module types, Prism Solar PERC bifacial has declined -5% total since 2019, although this loss appears to have stabilized in the most recent measurement. The Solaria PowerX-400R Shingled module type has also lost around -3.2% in the first 1.5 years of field deployment. It remains to be seen if these losses will continue with time.

14 SOLAR ENERGY↗

PV Lifetime Project (2024 NREL Annual Report)

DOE’s PV Lifetime project was initiated in 2016 with the goal of accurately characterizing the early-life evolution of photovoltaic (PV) field performance. Different PV cell and module technologies result in different initial degradation rates due to effects like light-induced degradation (LID) and light & elevated temperature-induced degradation (LeTID). To accurately characterize the initial field degradation of maximum power (Pmp) requires the use of high-accuracy indoor IV curve measurements at standard test conditions. Therefore, PV modules involved in this study are removed from the field once or twice per year and brought indoors for measurement under constant temperature and irradiance conditions.

14 SOLAR ENERGY↗

Exploring PV Circularity by Modeling Socio-Technical Dynamics of Modules’ End-of-Life Management

The circular economy (CE) tackles environmental and resource scarcity issues by maximizing value retention in the economy. The concept implies design strategies such as reducing the use of materials or improving products’ durability and end-of-life (EOL) strategies, for example, reusing products and components and recycling materials. With an estimated 80 million tons of global cumulative EOL photovoltaic (PV) modules, applying CE principles to the PV industry could alleviate resource scarcity issues while also providing economic benefits. However, transitioning to a CE may imply changes in organizations and consumer behaviors. In this context, assessment of CE strategies may require accounting for behavioral change, a requirement that methods from complex system science such as agent-based modeling meet. Thus, this paper uses an agent-based modeling (ABM) approach to study circularity in the photovoltaics supply chain. Four types of agents are represented in the ABM: PV owners, installers, recyclers, and manufacturers. Moreover, five possible EOL options – including three CE strategies – are modeled. Departing from traditional techno-economic analysis, the model includes techno-economic factors as well as social factors to model EOL management decisions. Results show that each dollar decrease in the recycling fees improves the recycling rate by roughly 1.1%. However, excluding social factors underestimates the effect that lower recycling prices have on material circularity.

agent-based modeling↗

Exploring PV Circularity by Modeling Socio-Technical Dynamics of Modules' End-of-Life Management: Preprint

The circular economy (CE) tackles environmental and resource scarcity issues by maximizing value retention in the economy. The concept implies design strategies such as reducing the use of materials or improving products’ durability and end-of-life (EOL) strategies such as reusing products and components and recycling materials. With an estimated 80 million tons of global cumulative EOL photovoltaic (PV) modules, applying CE principles to the PV industry could alleviate resource scarcity issues while also providing economic benefits. However, transitioning to a CE may imply changes in organizations and consumer behaviors. In this context, assessment of CE strategies may require accounting for behavioral change, a requirement that methods from complex system science such as agent-based modeling meet. Thus, this paper uses an agent-based modeling (ABM) approach to study circularity in the photovoltaics supply chain. Four types of agents are represented in the ABM: PV owners, installers, recyclers, and manufacturers. Moreover, five possible EOL options – including three CE strategies – are modeled. Departing from traditional techno-economic analysis, the model includes techno-economic factors as well as social factors to model EOL management decisions. Results show that each dollar decrease in the recycling fees improves the recycling rate by roughly 1.1%. However, excluding social factors underestimates the effect that lower recycling prices have on material circularity.

28 EE - Advanced Manufacturing Office (EE-5A)↗

Uniform Mechanical Loading Can Test for Nonuniform Loading Durability

In this work, we present a method to evaluate the equivalency between any module mechanical loading conditions. The method is developed to address the specific failure mode of glass fracture and is based on Weibull analysis and weakest link theory. It considers the varying stress profile across the module to calculate the probability of glass fracture, which is used as the metric of equivalency. An idealized nonuniform loading scheme is employed to demonstrate the method and introduce the concept of the equivalent uniform load factor: a factor applied to the maximum pressure of the nonuniform load to obtain the equivalent uniform load value. It is demonstrated that this factor is less than unity for all nonuniform load cases considered, including snow and various characters of wind loading. These significant results suggest that uniform loading may be reliably, and practically, employed to evaluate photovoltaic module glass for nonuniform loading durability.

14 SOLAR ENERGY↗