Results for “Remanufacturing” — Page 5

DOE OSTI2021

A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis

Solar photovoltaics (PV) are the fastest growing renewable energy technology for clean, inexpensive, and sustainable electricity generation. Along with numerous technical roadmaps to improve system cost, performance and reliability, the PV industry should also plan to handle large volumes of silicon panel waste, which is initially estimated to be ~13 million metric tons (MT) by 2050 in the U.S. alone. Understanding the magnitude of material needs and how material flows throughout the PV panel life cycle could respond to design, operational and different end-of-life (EOL) circular pathways will help transition into a circular, resource-conserving economy. Herein, we introduce a dynamic material flow analysis (DMFA) framework based on electricity generation to quantify time-series stocks and flows of bulk PV materials (e.g., solar glass and aluminum frames) throughout the life cycles of utility-scale silicon PV systems in the U.S. in the period 2000-2100. We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacial, frameless). We found that float glass and aluminum in PV installations would likely reach 100 million MT and 12 million MT by 2100, respectively, in the baseline scenario. The most influential parameters for PV installation and subsequent waste reduction are found to be module lifetime, module efficiency, annual degradation, and material reduction. Module recycling and component remanufacturing were found to be the most effective material circularity strategies for waste minimization. Panel reuse has negligible savings on waste under current module efficiencies compared to replacements with newer generations with higher efficiency. Ongoing trends to produce larger power frameless modules could save 10 million MT of glass and ~9 million MT of aluminum. Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize waste.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis: Preprint

Solar photovoltaics (PV) are the fastest growing renewable energy technology for clean, inexpensive, and sustainable electricity generation. Along with numerous technical roadmaps to improve system cost, performance and reliability, the PV industry should also plan to handle large volumes of silicon panel waste, which is initially estimated to be ~13 million metric tons (MT) by 2050 in the U.S. alone. Understanding the magnitude of material needs and how material flows throughout the PV panel life cycle could respond to design, operational and different end-of-life (EOL) circular pathways will help transition into a circular, resource-conserving economy. Herein, we introduce a dynamic material flow analysis (DMFA) framework based on electricity generation to quantify time-series stocks and flows of bulk PV materials (e.g., solar glass and aluminum frames) throughout the life cycles of utility-scale silicon PV systems in the U.S. in the period 2000-2100. We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacial, frameless). We found that float glass and aluminum in PV installations would likely reach 100 million MT and 12 million MT by 2100, respectively, in the baseline scenario. The most influential parameters for PV installation and subsequent waste reduction are found to be module lifetime, module efficiency, annual degradation, and material reduction. Module recycling and component remanufacturing were found to be the most effective material circularity strategies for waste minimization. Panel reuse has negligible savings on waste under current module efficiencies compared to replacements with newer generations with higher efficiency. Ongoing trends to produce larger power frameless modules could save 10 million MT of glass and ~9 million MT of aluminum. Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize waste.

circular economy↗

DOE OSTI2022

Quantifying Energy Flows in PV Circularity Processes: Preprint

As sustainability and end-of-life management become a hot topic to timely address in the PV community, a proper evaluation of the benefits of circular pathways such as recycling, reuse, and remanufacturing has not been performed holistically beyond material flows or LCA analysis. Energy flows are critical for evaluating energy generation technologies. Previously they have been used to compare renewables to fossil generation and then between PV technologies. This paper brings energy flows to bear on reaching circular pathways for PV. The energy flows to track energy usage, generation, and losses complementary to the mass flows are presented for silicon through the leverage of the PV ICE framework.

circular economy↗

DOE OSTI2023

Enabling Recycling of Composites: Understanding the Impacts of Multiple Thermal Processing Cycles

When considering the utilization of recycled short carbon fiber feedstock materials for advanced manufacturing, understanding the material degradation behavior is essential in determining how many times a composite material can be effectively reprocessed and remanufactured. This study characterizes the degradation behavior of short carbon fiber acrylonitrile butadiene (CF-ABS) that has been reprocessed five times with twin screw extrusion. Parallel plate rheology was completed to observe the degradation in complex viscosity of the recycled feedstock materials. Gel permeation chromatography (GPC) was utilized to characterize the changes in molecular weight distribution of the recycled materials as a result of thermal and mechanical degradation during the re-processing steps. Rheological characterization, GPC, and twin-screw processing data help inform the process optimizations required to process the recycled feedstock material. Successful characterization of the degradation behavior of short fiber composite feedstock materials aids in increased understanding of the lifespan of high value carbon fiber composite materials and aids in process optimization of recycled composite materials.

Walker, Roo↗

DOE OSTI2023

Wind Turbine Blade Repurposing and Recycling: Coupling Repurposing Methods with 3D Printing Technology

Fiber-reinforced thermoplastic composites continue to be implemented in several marketsbecause of their strength capacity and light weight. Especially in the wind industry, wind bladesare made of this material which makes them ideal for wind energy generation, but bladesbecome a problem at end-of-life. Because recycling thermoplastic composites technologiesare still not cost and environmentally effective, research in this space is needed. This paperpresents a case study for coupling repurposed wind turbine blades and 3D printing technology.The purpose is to remanufacture decommissioned wind blades into bus stop roof and seatingsections to then use recycled glass fiber from a decommissioned wind turbine blade to 3Dprint structural and/or fixtures needed in the assembly. We provide an overview of the designprocess, and the development process steps in repurposing and 3D printing the material,delving into key parameters required for a successful implementation.

Henao, Yulizza↗

DOE OSTI2024

Anode Upcycling via Tailored Solvent Treatment

To achieve a truly closed-loop direct recycling process for lithium-ion batteries, all component materials must be recovered. To date, direct recycling method development has primarily focused on the high-value transition-metal cathode materials, while the inherently lower-value graphite has been challenging to recover in a cost-effective manner. However, end-of-life graphite contains a unique engineered value due to the presence of the solid electrolyte interphase (SEI). Growth of the SEI during the cell's active lifetime stabilizes the electronically reactive graphite surface through an irreversible consumption of Li, and thus necessitates both excess lithiation of the cathode and a costly and time-intensive formation procedure during manufacturing. An optimized pre-formed SEI that capitalizes on existing SEI components from end-of-life batteries has the potential to significantly reduce cathode lithiation requirements and eliminate the critical bottleneck of formation cycling during cell remanufacturing. Further, retaining Li at the anode obviates the need for a separate Li leaching and recovery step, improving the overall efficiency of the direct recycling line. In this work, we present a novel approach to "upcycling" spent graphite through use of tailored chemical treatment to remove adverse (i.e., highly resistive and/or poorly passivating) SEI species while retaining beneficially passivating components. We have explored a rational set of solvents spanning a range of polarity, proticity, and molecular size to evaluate structure-property-performance relationships between applied solvent(s), removed and remaining SEI species, and electrochemical response of the resulting graphite product. Further, we have developed and optimized a robust and holistic analysis procedure that couples symmetric-cell electrochemical testing, multi-modal materials characterization, and advanced electrochemical modeling. These analysis results inform a set of correlative metrics for graphite performance relative to both solvent properties and upcycled SEI composition. We demonstrate effective tunability in the residual SEI composition by varying solvent identity and concentration, and report on several promising solvent systems that achieve comparable or performance to pristine graphite.

anode recycling↗

DOE OSTI2024

Recycling of additively printed anisotropic Nd-Fe-B bonded magnets

A high potential cost-effective and environmentally friendly method has been applied for recycling anisotropic Nd-Fe-B bonded magnets. Waste additively printed Hydrogenation-Disproportionation-Desorption-Recombination (HDDR) Nd-Fe-B anisotropic bonded magnet was pulverized into composite powder containing Nd-Fe-B particles and nylon binder through cryomilling at a liquid nitrogen temperature (~77 K) under Ar inert atmosphere. Then, the cryomilled composite powder was warm compacted into a bonded magnet. Further, the magnetic particles were aligned during post-compaction annealing under a magnetic field of 30 kOe. The recycled bonded magnets have a higher density (3% enhancement), but slightly inferior magnetic properties compared to the original magnets, i.e., the magnetic remanence, coercivity and maximum energy product are reduced by 2%, 3% and 8%, respectively. The scanning electron microscopy revealed that some HDDR Nd-Fe-B powder crumbled into fine particles during cryomilling. Powder X-ray diffraction showed a small amount of Nd-oxide impurity in the cryomilled powder. The slightly deteriorated magnetic properties are ascribed to the oxidation of Nd-Fe-B particles due to formation of fresh fracture surface during cryomilling. The approach enables the direct reuse of end-of-life bonded magnets in an economical and environmentally friendly way.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Prioritizing circular economy strategies for sustainable PV deployment at the TW scale

Global decarbonization requires an unprecedented scale-up of photovoltaic (PV) manufacturing and deployment. The material demand and eventual end of life management associated with multi-TW scale deployment poses many challenges. Circular Economy (CE) and it's associated R-Actions (Reduce, Reuse, Recycle) have been proposed to mitigate end of life management and material sourcing concerns. However, CE metrics typically focus on a single product and only consider mass, excluding energy flows. This work leverages the PV in Circular Economy (PV ICE) tool to quantify the deployment, mass, and energy impacts of R-Actions and proposed sustainable PV designs in the context of achieving energy transition deployment goals (75 TW in 2050). 13 module scenarios are established and evaluated across 6 capacity, mass and energy metrics to identify tradeoffs and priorities. We find that increasing module efficiency can reduce near-term material demands up to 30% and improve energy metrics by up to 9%. Material circularity (recycling) can minimize lifecycle wastes and reduce material demands at the cost of higher energy demands. Increasing module lifetime, including reliability improvements and reuse strategies, is effective at reducing both material (>10%) and energy demands (24%). Uniquely, lifetime improvements maximize benefits and minimize the harms across all six metrics while achieving multi-TW scale deployment.

Photovoltaics↗

DOE OSTI2023

A Machine Learning–Based Tire Life Prediction Framework for Increasing Life of Commercial Vehicle Tires

In the commercial freight industry, tire retreading decisions are often conservative due to limited knowledge of a tire’s remaining service life. This practice leads to increased costs and material waste. This paper proposes a machine learning–based approach for estimating tire casing life and retreadability, focusing on usage data rather than wear information. This approach could extend the tire’s lifespan and reduce landfill waste. Data integration from diverse tire casing measurement sources presents challenges, including imbalanced removal data. Our methodology addresses these challenges by using historical inspection, telematics, and finite element modeling (FEM) datasets. We introduce “Tire Casing Energy” as a comprehensive usage input and apply a Variance-Reduction Synthetic Minority Oversampling Technique (VR-SMOTE) for data imbalance rectification. A random forest model is used to estimate the state of the tire casing and the casing removal probability, with Bayesian optimization applied for hyperparameter tuning, enhancing model accuracy. Here, the proposed prediction framework is able to differentiate different truck fleets and tire locations based on their usage parameters. With the aid of this machine learning model, the importance and sensitivity of different tire usage parameters can be obtained, which is beneficial to maximize tire life.

Data balancing↗

DOE OSTI2023

More Than Recycling: How Should We Define Circularity Goals for PV in a Global Energy Transition? Preprint

Energy transition to carbon-free electricity is a crucial pillar of the Circular Economy. Renewable energy reduces environmental impacts and decarbonizes the production of other goods. But, manufacturing renewable energy sources, such as photovoltaic (PV) modules, require energy inputs that are currently carbon intensive. So, how do we decarbonize and circularize these critical technologies to achieve a sustainable energy transition? This work proposes that effective capacity-the installed capacity accounting for degradation rates and failures-is a critical metric to evaluate renewable energy technologies on the path toward circular economy and energy transitions. Our analyses also emphasize the importance of examining a suite of metrics incorporating mass and energy flows to identify potential tradeoffs and inform design or lifecycle management decisions holistically.

bifacial↗

DOE OSTI2023

More Than Recycling: The Importance of Multiple Metrics for a Circular Economy for PV in the Energy Transition

Energy transition to carbon-free electricity is a crucial pillar of the Circular Economy. Renewable energy reduces environmental impacts and decarbonizes the production of other goods. But, manufacturing renewable energy sources, such as photovoltaic (PV) modules, require energy inputs that are currently carbon intensive. So, how do we decarbonize and circularize these critical technologies to achieve a sustainable energy transition? This work proposes that effective capacity-the installed capacity accounting for degradation rates and failures-is a critical metric to evaluate renewable energy technologies on the path toward circular economy and energy transitions. Our analyses also emphasize the importance of examining a suite of metrics incorporating mass and energy flows to identify potential tradeoffs and inform design or lifecycle management decisions holistically.

bifacial↗