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Policy Department A: Economic and Scientific Policy ____________________________________________________________________________________________ Energy efficiency and environmental performance The efficiency of mono-crystalline PV panels ranges from 13 to 20%. The upper level has been achieved by SunPower and is based on a PV panel consisting of 96 single cells with a capacity of 333 MW. The cell efficiency amounts to about 23% [SunPower 2009]. Today, the energy payback times vary between <2 years (Southern Spain, Southern Portugal) and 5 years (Northern Sweden). In the major part of the EU the energy payback time amounts to 2 to 4 years [Jungbluth 2007]. Detrimental environmental impacts can occur during the production of solar panels in the various process stages. The production of pure silicon via the trichlorosilane (HSiCl3) route can lead to emissions of chlorinated compounds into air and water (e.g. toxic substances like SiH2Cl2, AsCl3, PCl3 and POCl3). Emissions of toxic substances (HF, SiF4) and strong greenhouse gases such as SF6 (GWP: 22,800 g CO2 equivalent/g) and PFCs can occur during the production process of wafers and photovoltaic cells. Foreseen developments and research areas Research and development areas are the improvement of existing processes for the production of solar grade silicon and the development of new processes with lower energy consumption and less usage of hazard substances. - Wacker in Germany is developing a trichlorosilane (HSiCl3) fluidized bed process which has a lower energy consumption than the conventional Siemens HSiCl3 process. It is expected that the energy consumption can be reduced to less than one third of the value of the conventional HSiCl3 process. This implies that it is below 50 kWh per kg solar grade silicon (probably electricity, probably including the upstream production of metallurgical silicon). The decomposition of trichlorosilane produces hydrochloric acid, so exhaust gas treatment is necessary [REFOCUS 2004]. - “Muto Silicon” in Taiwan developed a process for the production of solar grade silicon from upgraded metallurgical silicon using the SiF4 route instead of the HSiCl3 route. NaF which is formed in the process is toxic. Therefore, recycling of the NaF is important. The advantage of this process is the lower electricity consumption (120 kWh per kg including Na and metallurgical Si manufacture) compared to the conventional process via HsICl3 route. The production costs of the Muto Silicon process are indicated with 17 to 20 US$ per kg of solar grade silicon compared to about 35 US$ per kg via the Siemens process using the HSiCl3 route. Open issues are the handling of the reactive Na and the long term stability of the process to produce silicon with sufficient purity [Photon 5/2009]. - Elkem Solar in Norway is developing a process for the metallurgical refining of metallurgical grade silicon to solar grade silicon (so-called upgraded metallurgical grade silicon (UMG-Si). The electricity consumption is indicated with 10-30 kWh per kg of solar grade silicon (probably including metallurgical silicon production) [REFOCUS 2004] [Elkem 2007]. This is a significant reduction compared to the range of 75-130 kWh of electricity per kg (probably including metallurgical silicon production) found for the production of electronic grade silicon via the conventional Siemens HSiCl3 process [Elkem 2007]. Furthermore the handling with harmful substances like HSiCl3 and SiCl4 (a by-product from the process) can be avoided. IP/A/ITRE/ST/2009-11 & 12 8 PE 440.278PDF Image | Policy Department Renewable Technologies
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