FRELP

Full Recovery End Life Photovoltaic


Presentazione progetto “Frelp By Sun” alla fiera Ecomondo/KeyEnergy di Rimini

Nel 2015 la SASIL S.r.l., con i partners Stazione Sperimentale del Vetro (SSV) e PVCycle, aveva sviluppato il progetto “FRELP” per il recupero integrale di pannelli fotovoltaici a fine vita.
In seguito alla esigua quantità di pannelli disponibili, la Sasil aveva abbandonato il progetto.
Nel 2019 la TIALPI S.r.l., società partecipante alla Sasil S.r.l. attraverso la Minerali Industriali S.r.l., ha stretto un accordo con Sasil S.r.l. per poter riprendere e sviluppare il progetto FRELP.
Inoltre, TIALPI ha integrato il progetto con alcune migliorie e con l’inserimento del prototipo, in un edificio in classe A e con copertura fotovoltaica tale da permettere l’autonomia energetica per la prima fase del progetto, che comporta il recupero e la valorizzazione dell’89% in peso dei pannelli, vale a dire: alluminio, vetro e connettore.
La TIALPI S.r.l. sarà presente a Ecomondo/KeyEnergy a Rimini dal 5 al 8 novembre 2019, presso lo stand numero 065 nel padiglione B7, per illustrare il nuovo progetto “Frelp By Sun”.
A questo link può trovare l’intervista sul progetto rilasciata al portale di informazione online RiEnergia:
Per info:
Vera Ramon – amministratore unico di TIALPI S.r.l. – 349.7942009 –
e-mail: frelpbysun@gmail.com

Lodovico Ramon – Responsabile R&D di TIALPI S.r.l. – 347.2264964

TIALPI-FrelpBySun.jpg
Logo FrelpBySun.jpg

 


Technical Progress – september 2015

September 2015

The test phase was completed in July 2015 and at the beginning of October the progress report will be presented to the European Commission.

On September 25, 2015 was held at the Laghetto Gabella of Curino a seminar to present the progress of the project. At this link you can download the conference presentations and see some photos of the day.

The initial phases of the project were as follows:

I-    Posting mechanical robot of aluminum profiles, connectors, glass and sandwiches (RAC + REV)

II-   Pyrolysis Eva II to recover the silicon metal and other metals (PES)

III-  Leaching acid by filtration to separate the silicon from other metals (ALF)

IV-   Electrolysis IV to recover copper and silver and neutralization treatment of acid water (OME)

At the end of the trial, because of the presence of fluorinated plastic in the sandwich, it had to abandon the pyrolysis process, which would have resulted in emissions of fluorine with the fuels cracking, and it is opted for the incineration of the sandwich, to be performed at a external company that has already given an initial availability of maximum (Phase TES).

In practice, the results of the experiment possible to confirm the validity of the initial project, with the only variant of incineration instead of pyrolysis.

They have already been pre-built prototypes of some components of Phase I, and now, on the basis of the overall results obtained in the trial, would like to start the realization of the complete project, for which the use of acquiring:

  • the waste code for the conferment of the panels;
  • the code for the treatment of residues of the bottom of the treatment of waste to energy;
  • the authorization to the construction of the pilot plant, and in particular of phases III and IV, as for phase I is of purely mechanical treatments, while the phase III is an operation to make the outside.

The ultimate impact expected from this project is shown schematically in the following mass flow:

FRELP MASS FLOW (15.09.15)

and can be thus summarized:

every 1.000 kg of input panels are obtained:

–          180 kg of aluminum metal to sell on the market;

–          10 kg of connectors to give the WEEE;

–          700 kg of white glass of high quality for sale on the market;

–          36,5 kg of silicon metal to be recovered by filtration after leaching and for sale in the metallurgical sector;

–          1,67 kg of copper and silver recovered at cathodes electrolysis and for sale on the market;

–          120 kg of calcium nitrate in aqueous solution to the silo to be used as fertilizer in agriculture;

The total yield of these components is 93% and the loss is represented by 6% from plastics intended for combustion and residual recovered metals as hydroxides.

By contrast, we have the following environmental impact:

  • 20 kg: production of hydroxides of various metals (tin, aluminum, lead, zinc) to be disposed of in landfill as waste;
  • 2 kg: NOx emissions to the anode of the electrolysis (to be verified);
  • 5 kg: production (at the waste to energy plant) of ash resulting from the reduction in special fluorine with sodium bicarbonate and/or calcium carbonate, at the waste to energy plant (to be verified).

It must be said that there is currently no industrial technology that allows to achieve a yield of 93% and that the problem of disposing of the photovoltaic panels will have a major impact as early as 2017.

The pilot plant which is planned will have the processing capacity of 1 t/hour of photovoltaic panels to a maximum of 8.000 t/year.

According to forecasts in the draft, submitted for approval to the Province of Biella the 29th September 2015, the plant should be active from 2017.


Press release – FRELP PROJECT CONFERENCE 25.09.2015

Sasil S.p.A., Stazione Sperimentale del Vetro and PV Cycle are working on a 4 years project to test and demonstrate the application of innovative technologies for integral recycling of end-of-life PV  panels, mono and poly-crystalline in an economically and viable way.

The partnership wished to share with stakeholders the first important milestone achieved: having found the technological solutions for every step of the treatment process and translated into a technically and economically feasible industrial process design.

To this end, on the 25th of September, a conference took place at the visitors centre of Laghetto Gabella in Curino (Biella, Italy), in the past a feldspar mine transformed in a prestigious natural area.

During the conference have been proposed four solutions with low environmental impact for the recovery of the following components:

  • Automatically recovery of aluminum profiles;
  • Recovery of high quality extra clear glass, to be employed in hollow and flat glass industry, implying very significant energy and CO2 emission saving in the glass melting process;
  • Recovery of (metallic) silicon, to be employed as ferrosilicon in iron silicon alloys, thus saving important energy cost and CO2emission  for the production of primary silicon;
  • Recovery of silver by electrolysis.

The actual situation concerning the collection of end-of-life PV panels has been illustrated by PV Cycle’s Olmina Della Monica. It appears that the conferment of such panels saw a significant drawback since 2012 when incentives in Europe for the substitution of old panels were strongly reduced. This drawback is expected to imply a delay in the need for technologies for their disposal with several years.

PV_CYVLE Olmina Della Monica

Gian Andrea Blengini of the JRC – Institute for Environment and Sustainability presented the life cycle assessment performed on the FRELP process, showing the important improvements that can be achieved with respect to actually available technologies. He highlighted as well the important contribution the project can offer to the EU Draft Ecodesign Working Plan 2016, identifying the constraints that actual product design imply for the full recovery of the panels and that could be improved by producers. As such, in particular the use of fluorine content in the panel’s back-sheet should be abandoned to permit an environmentally and economically optimal recovery process.

JRC ISPRA Gian Andrea Blengini

Lodovico Ramon, project manager of FRELP, then illustrated the objectives of the project and the 4 phases of the treatment process that will be piloted next year. He extensively revealed the environmental achievements that are expected, as well as the employment opportunities that would derive from exploitation of the treatment process.

SASIL Lodovico Ramon

At this point, and before presenting more in detail the main technologies to be experimented, Sandro Hreglich of the Stazione Sperimentale del Vetro explained in detail how PV panels are constituted, underlining the high variability of the materials involved and their respective amounts. The explanation made clear which materials can be recovered (glass, silver, alumina, silicon) and what are the main difficulties to do so.

SSV Sandro Hreglich

After the coffee break Sasil consultant Piero Ercole explained in detail the various technologies studied, simulated and trialed to separate the glass from the polymer-based adhesive encapsulation layer (called EVA) and showed the identified best technology translated into a pre-prototype that offered excellent results. He proceeded with an exposure of the further treatment of this EVA, originally foreseen to be submitted to pyrolysis, but, due to environmental constraints, at last transformed in ashes by means of controlled combustion. This process was trialed by the Stazione Sperimentale del Combustibile.

SASIL Dott. Piero Ercole

Lastly, Stefano Ceola explained the audience how from these ashes metals will be recovered.

SSV Stefano Ceola

Next step of the project regards the realisation of prototype equipment to trial the findings on a significant scale (1 ton PV panels per hour). The construction is expected to be performed during 2016 after obtainment of the needed authorisations, while pilot operation is foreseen in 2017.

Frelp Conference 2015

Si ringrazia @MicheleGiorgioPhotography per le foto.

 

DOWNLOAD HERE THE PRESS RELEASE

 

Qui di seguito è possibile scaricare i pdf delle presentazioni dei relatori durante la conferenza:

1- PV CYCLE – Olmina DELLA MONICA – Collection, selection, distribution of EOL PV panels

2- CE DG-JRC – Gian Andrea BLENGINI – Treatment process of EOL PV panels

3- SASIL – Lodovico RAMON – FRELP Project presentation

4- SSV – Sandro HREGLICH – Characterization and variability of EOL PV panels

5- SASIL – Piero ERCOLE – PV panel glass detachment

6- SASIL – Piero ERCOLE – Controlled pyrolysis-combustion of sandwich

7- SSV – Stefano CEOLA – Metals recovery from ashes from controlled combustion

 

For further information:

Lodovico Ramon, managing director Sasil S.p.A.

l.ramon@sasil-life.com

Tel: 39015985261
Fax: 39015985980

http://www.frelp.info

http://www.sasil-life.com


PhotoLife (LIFE13 ENV/IT/001033) another project for recovery end-of-life PV panels

http://www.photolifeproject.eu/

PhotoLife (LIFE13 ENV/IT/001033) is an EU LIFE+ co-funded project with the aim of recovery of glass and main values from end life Photovoltaic panels. Scope of the project is the construction of a pilot plant and the experimentation of the innovative process for the full recovery of different kind of PV panels. Eco Recycling is Coordinator of the project, the designer and the builder of the pilot plant. The project has been started at 1 June 2014.

 

Actually processes were developed and patented for manual recovery of specific type of panels, and in particular for crystalline Si or CdTe.

The proposed project will instead focus on a hydrometallurgical approach (avoiding high temperature and energy-consuming treatments), using conventional equipments easily available for common waste collectors, and comprehending all the commercial types of photovoltaic panels: crystalline Si (45-50% of the total market is represented by polycrystalline and 35% by monocrystalline), amorphous Si (5-8% of the market), Cd-Te (8-9%) , CIS and CIGS (2%).

PhotoLife project will aim:

  • to demonstrate in pilot scale the technical feasibility of an innovative process (developed on the base of laboratory scale experiments) for the automated and simultaneous treatment of the three main kinds of photovoltaic panels (crystalline Si, amorphous Si, Cd-Te)
  • to characterize the pilot plant products (glass and metals)
  • to determine the overall economic feasibility of the pilot plant process accounting also for the recovery of electronic equipment (printed circuit boards and other electronic equipment) and plastic

PhotoLife Project has been developed according to the following actions:

1- Elaboration of the existing data

  • B1 Analysis of HTR lab results
  • B2 Estimation of the market trend
  • B3 Preliminary economic feasibility

2- Photovoltaic panels retrieval and characterization

  • B4 Photovoltaic panels retrieval and classification
  • B5 Retrieved panel characterization

3- Process and plant design and realization

  • B6 Process design
  • B7 Pilot plant design (including offer request)
  • B8 Pilot plant construcion (including site preparation and autorization request)

4- Pilot plant experiments

  • B9 Disassembling and physical treatment: optimization using Si- and CdTe- based panels
  • B10 Chemical treatment: optimization usng Si- CdTe-based panels
  • B11 Wastewater treatment: optimization
  • B12 Experiments using innovative photovoltaic panels
  • B13 Product Characterization

5- Economic Analysis

  • B14 Economic analysis and management strategies

6- Lab scale tests with innovative photovoltaic panels (CIS and CIGS)

  • B15 Physical pretreatment and chemical treatment of innovative photovoltaic panels

7- Monitoring phase

  • C1 Environmental assessment of the project impact
    • C1.1 Monitoring of environmental impact
    • C1.2 LCA
    • C1.3 Preliminary environmental impact assessment and financial prevision for the future full s
  • C2 Assessment of socio-economic impacts

8- Dissemination phase

9- Management phase


25.09.2015 FRELP CONFERENCE: A recovery process for all usefull materials from end-of-life PV panels

25 September 2015

Conference FRELP project

Sasil S.p.A. (Brusnengo), with SSV – Stazione Sperimentale del Vetro (Murano)  and PV Cycle (Brussels), have the honor to invite all interested to the conference: ‘A RECOVERY PROCESS FOR ALL USEFULL MATERIALS FROM END-OF-LIFE PV PANELS’, to be held September 25 in Curino (BI).

Here you can download the conference program and the brochure of the project:

CONFERENCE PROGRAM – 25.09.2015

BROCHURE – August 2015

When: 25 september 2015

Where: Laghetto Gabella, Curino (BI)  – map

Info & registrations:

Vera Ramon
Sasil S.p.A.
tel. 015-985261
cell. 349-7942009
e-mail: eventi@sasil-life.com
web: www.sasil-life.com


Technical Progress – may 2015

May 2015

Completion, at the Stazione dei Combustibili, of the emission tests relating to the pyrolysis and combustion of the sandwich of EVA (action 4). Preliminary data confirm the presence of fluoride so important, which precludes the use of pyrolysis and thus lead to the forced choice of incineration. We will receive the full report by mid-June and will enter as a supplement to deliverable “B4”.

It was contacted a company that works in the field of incineration of waste, with a furnace large enough for our purpose, and that is available to do two campaigns per year of incineration on providing our sandwiches, so that they can return to us the residual ash for subsequent treatment of leaching and electrolysis to be carried out in Sasil. For the transfer from the incinerator of Sasil sandwiches we have already identified the code, and we are evaluating the return code to Sasil according to the final report of the Stazione dei Combustibili.

We are completing the preparation of about 10 kg of ash from sandwiches to provide the company “Darsa”, that will handle the supply of the electrolysis, to make additional checks on the characteristics of the recovered metals and the quality of the eluates to be treated to recover the hydroxides and calcium nitrate. The preparation consists in reducing the sandwich powder oxidized with sizes less than 100 microns, such as to permit efficient acid attack. Darsa will, depending on the needs of electrolysis, to look for the right conditions of acid attack, simulating as closely as possible to the scheme of flow developed by Sasil.


Technical progress – February 2015

February 2015

SUMMARY OF THE WORK DONE IN DECEMBER 2014 AND JANUARY 2015

With reference to the information contained in the report of November 2014, there are two important changes: the first one refers to an alternative to the expected pyrolysis process (action B4) and the second one to the methodology applied for electrolysis (action B5).

 

Action B4 – Why the alternative to the expected pyrolysis process

In the control phase of the emissions of gases from the pyrolysis of the sandwich it has been noted the presence of traces of fluoride. Although the first analysis of the backsheet had not shown these values, more accurate tests have established that about 50% of the panels include a microlayer of fluorinated plastic. Given that the Sasil’s pyrolysis equipment is not authorized for the treatment of fluorinated plastics, we have considered an alternative process to incinerate the sandwich, as the treatment of the fumes generated by the combustion is much simpler and does not imply unknown technological processes. It is a widespread process and normally it is applied downstream of the incineration plant. Moreover,a lower consumption of nitric acid in the process of leaching related to to the incineration combustion was found. Therefore it was decided to investigate this incineration process considering the possibility to treat all the sandwiches, regardless of whether or not they contain fluorinated plastic.

 

Even though this choice can represent a disadvantage if considered in terms of energy efficiency only, still it must be taken into account that the incineration of combustion, unlike the pyrolysis, allows to treat 100% of the panels, and not only those without fluorinated plastics, thus avoiding to send to landfill 50% of previously treated sandwich. Furthermore, the incineration from combustion allows a considerable saving of HNO3 (25%). Also we have considered the option of treating the sandwiches of fluorinated plastic with a technology patented by a company of Novara, but we have estimated that the industrialization of such a system is very complex and it also has to do with solvents which, however, have a certain environmental impact.

In conclusion, we are researching an industrial incinerator capable of ensuring this intermediate step, between detachment of sandwich (Action B3) and the successive steps of leaching and electrolysis (action B5), and thus replacing the pyrolysis (action B4). In terms of environmental impact, the disadvantage of having to transfer on the outward (by the SASIL establishment to the incinerator) about 770 t / year of sandwich, and in return (by the incinerator to the SASIL establishment) about 300 t / year of ashes, it is compensated by the lower use of nitric acid and the consequent lower consumption of calcium hydroxide, with relative lower production of calcium nitrate in solution. This alternative to pyrolysis involves a modification of the development program of the FRELP project that, at this stage, will not include any longer the adaptation and use of the existing Sasil pyrolysis plant when performing B4 action. But it will have to rely on an external incinerator to reduce to ashes the sandwich by heat treatment.

Optimization process of chemical recovery: characterization of the ashes before leaching.

After the thermal cracking, the ashes are separated by sieving with a mesh sieve (ASTM 3 mm). Subsequently, the small pieces of metal, probably coming from the disintegration of the metal grid during thermal cracking, are carefully removed by hand. This represents about 30% of weight of ash, with respect to the initial weight of the plastic sheet, after the detachment of the glass. The obtained material is shown below:

Caratterizzazione delle ceneri prima della lisciviazione

Action B5 – METHODOLOGY OF ELECTROLYSIS

In December 2014 and January 2015 the experiments carried out by Darsa with samples of ash resulting from the pyrolysis in laboratory have allowed to get closer to the completion of the last stage of the recovery process for the electrolysis of metals, particularly silver and copper. From these experiences it emerges that the process has a high recovery yield, close to 95%, but requires constant power conditions in order to calibrate the control parameters of the electrolysis. In particular it is necessary, in the acid solution, to minimize the presence of free nitric acid, and to act with additions of silver, copper, aluminum and various metals fairly constant. We will have to intensify such tests on significant quantities of ashes (few kg), in order to mediate the presence of metals and thus obtaining a calibration of electrolysis aimed at constant recoveries and efficiencies that will lead to an enhancement of the functional selectivity. In order to minimize the use of nitric acid for leaching, we have also considered the use of a concentrator to fractional distillation before the electrolysis phase. The solution of this problem with electrolysis in function of leaching, for the recovery of copper and silver, will be the subject of further investigation in the next three months, jointly by Sasil and SSV for what refers to leaching, and by Darsa for electrolysis.

 

Description of the pilot test in Darsa

The goal of the pilot test was to find the best condition for the collection of silver from the solution of nitric acid for galvanic deposition, performed with the Electro-winning DEW M 100 that works with a constant value of Ampere and with various concentrations and pH of the solution.

Apparecchiatura per test pilota

A – solution of nitric acid | B – Electro-winning system | C – Carbon Cathode | D – Recovery of silver

 

 

Next steps

It is expected to conclude the last tests of electrolysis at Darsa by April. Meanwhile, in order to obtain a precise comparison between the various options that allow a final decision on the most suitable strategy, several LCA about technically feasible scenarios will be prepared. Subsequently we should proceed to the submission of a project amendment (in May), so that it can be completed by the presentation of the mid-term report expected by the end of July.

Mass Flow FRELP PROJECT

 

 


Technical progress – November 2014

November 2014

SUMMARY OF WORK SINCE THE START OF THE PROJECT UNTIL NOVEMBER 30, 2014

This report summarizes the actions B1-B2-B3-B4-B5-B6-B7, and C1-C2-D1-D2 that have been developed over the period considered.

With reference to the following description, are explained some definitions used in the text of the report:

BACKSHEET: the photovoltaic panel behind the surface exposed to the sun and consists of plastic material in polyester or chlorinated or fluorinated compounds.

SANDWICH: is the set of glass + backsheet + eva + wafer of silicon metal.

SILICON WAFER: is the heart of the photovoltaic panel that converts sunlight into electricity.

PLOT: series of connectors generally in aluminum that connect the various wafers to bring the generated current to the connector of the panel.

WARP: number of connections perpendicular to the plot, on the surface of the wafer exposed to the sun, which generally consist of a glass frit containing silver.

IM: unexpected

OB: objectives

RA: expected results

IP: progress indicators

 

Action B1

It’s the action carried out by the partner PV CYCLE who oversaw the procurement of samples of panels used for the characterization of the same and for testing the process in subsequent actions.

IM/1: due to the variability of the panels characterized by PV Cycle will get an additional sample to have more data for the comparison.

OB/1: procure the panels at the beginning and then the sample panels for tests on prototypes developed during the project.

RA/1: to provide 20 panels 1 x 1,67 m sufficiently diversified to have average data of composition to be used in the actions B2-B3-B4-B5.

IP/1: supply of panels for characterization took place October 15, 2013 and for testing expected by December 2015.

Action B2

The action was developed by SSV and consisted of the complete characterization of the sample panels received by PV CYCLE.

Based on these results, Sasil began the work of development of various process technologies provided by the project.

IM/2: the quality of the panels is variable depending in particular on the quality of the backsheet, which may contain chlorinated and fluorinated plastics that require a different approach in the pyrolysis phase.

OB/2: fully characterize the various panels and in particular to determine the metals present in the wafer to modulate the actions of acid attack and pyrolysis.

RA/2: provide useful indications on the most suitable technology for the recovery of the various components that constitute the photovoltaic panel.

IP/2: the close cooperation between Sasil and SSV has allowed a remarkable synergy that has allowed to proceed according to the flow chart provided by the project and to have immediately useful results to Sasil to optimize the subsequent actions of its competence.

Action B3

The problem of the separation of the glass from the sandwich was solved brilliantly by Sasil with a method that has been the subject of patent application filed in September 2014. This system plans to remove the glass from the sandwich in a qualitative way with a progression of 1 cm per second.

The pre-prototype is able to process strips of the panel (obviously devoid of aluminum profiles and the connector) of the width of 250 mm, equal to ¼ of the total width of the panel.

It has been tested and is still being optimized, in particular in relation to the quality of the backsheet, the variability of which required an additional modulation on the positioning of the source of infrared, not initially provided by the patent.

It is during the optimization phase, the system for continuous bonding of the panels, prior to insertion in the detachment device, so as to give continuity to the system.

The final prototype will be sized to handle continuously about 22 panels/hour, the standard size of 1000 x 1660 mm.

The heat treatment preliminary to the detachment was made with a mixed system for medium and short wave infrared, assisted by a maintenance phase with diathermic oil.

The separation occurs by means of a device with a high frequency knife button and modulated in amplitude and speed.

On the glass recovered in the millimeter size was noted at times the presence of the organic black parts, due to the adhesion to the glass of the seals on the edge of the panel.

Furthermore, on the fine fractions of glass, less than a millimeter, however constituents only 5% of the stemmed glass, has occurred the incidental presence of silicon metal coming from the silicon wafer.

To overcome these two drawbacks, Sasil adopted a unique technology of optical treatment, after a sieving to 1 mm. Practically a channel of optical separator treats the fraction> 1 mm containing organic compounds, and a channel treats separately the fraction <1 mm to remove residual silicon metal from the glass.

IM/3: the greater difficulty involved the search of the optimal thermal system that would allow a temperature differential between “EVA” and glass, flaking, and this was done through a detailed analysis of the behavior in curing of the heated EVA, so as to ensure a margin of work sufficiently wide to allow the detachment at temperatures close to the temperature of crosslinking without reaching the same cross-linking.

This work was developed brilliantly by SSV.

The choice of infrared system was made after evaluating the option laser and microwave, with the advice of CNA respectively of Sesto Fiorentino and of the University of Rome Tor Vergata.

RA/3: the solution of the pre-prototype, including the section of optical separation, allowed to remove any unknown for the actual design of the prototype that is in an advanced stage of selection.

IP/3:

– Achievement of 97% of recovery of pure glass;

– Power consumption less than 50 kWh/t of the panel;

– Excellent level of homogeneity and particle size of the recovered glass;

– Very low level of emissions on warming phase and within the limits of the law; in any case, such emissions test will be repeated once developed the system of heat sealing of the panels prior to insertion into the car behind.

– Prototype in definitive design phase according to the operational directions of the pre-prototype.

Action B4

This action has been carried out by Sasil and SSV according to a similar pattern, ie with pyrolysis treatment in batches, but with use of different gases (argon for SSV, nitrogen for SASIL).

The temperature conditions were the same even if it is seen that, according to analysis thermo-ponderal, already at 450 °C all organic compounds pyrolise completely.

As it was not possible to do is to obtain significant results on the quality of fuels obtained as the instrumentation provided for the analysis will be available at the SSV only in January 2015. In any case, the pyrolysis has provided the ashes sufficient, from the point of view of quality and quantity, for the subsequent acid etching process, object of the action 5.

Before the process of acid leaching (Action B5) the ashes were milled and screened under 0,5 mm obtaining residue subgrid free from metal particles, and a overscreen consisting predominantly of particles of aluminum and other metal conductors.

In fact, the advantage of this process is to break the silicon metal, which is very fragile, and leave intact the metals, which are elastic and with a particular grinding technique for compression tend to flatten and not to break, thereby enhancing their recovery by sieving .

With regard to the analysis of plastics from pyrolyze (polyester, Tedlar, PVC) as constituents of the backsheet, the data so far available on the 20 types of panels have provided a frequency of about 30% of fluorinated plastic and/or chlorinated on the total of panels examined.

This is an aspect that should be investigated further as it will be a decision about the treatment of the panels with the presence of chlorinated or fluorinated plastic as you can choose two options:

A- treat the sandwich before the pyrolysis, with a technology patented by an Italian company who has already made some tests with positive results with the goal of separating the organic solvent in the autoclave, the backsheet from the rest of the sandwich, so sent for disposal fluorinated or chlorinated plastics. This is to avoid sending in pyrolysis chlorine and/or fluorine (note that the weight of the backsheet accounts for only 1,5% of the total weight of the panel).

B- Studying, downstream of the pyrolysis, a system that inerted the fluorinated and/or chlorinated compounds that are generated in phase induced heating, in order to knock them down as fly ash, with a scrubbing at the end of the process of condensation of the fuel generated by the process of thermal cracking in an inert environment.

RA/4: from laboratory tests showed that the pyrolysis at 600°C is able to completely demolish the organic compounds present in the sandwich and not to produce carbon residues on the residual ashes, formed only from silicon metal, glass and metals. Therefore are evaluating the most effective system for use in the discontinuous pyrolyzer present in Sasil, and that choice will be made in March 2015 based on the results of the analysis that will SSV fuels recovered from pyrolysis.

IP/4: the quality of the residual ash has already been judged as optimal as a function of the subsequent step of acid attack hot and electrolysis.

Action B5

This action has been divided into two sections:

– section of acid attack;

– electrolysis section.

The acid etching was conducted with different modes and different topologies of acids and bases but in the end the best results are obtained with nitric acid.

This choice was carefully evaluated also in function of the environmental impact because of the main drawback of this technology is that, however, we must eventually neutralize a residual acid polluted in part by metals.

However we have already achieved an environmentally sustainable because, by means of the killing with calcium hydroxide, is possible to obtain a calcium nitrate that, for the low content of residual metals may still be used in agriculture as a nitrogen fertilizer.

In any case, this aspect is still being in analytic investigation phase because the electrolysis process that generates acid residues to be salified is still under development and will be completely defined by the month of March 2015. Thus, even the environment appearance will be further investigated.

RA/5: through a first acid leaching is possible to obtain a good quality of metal silicon as residue of acid solubilization of ashes. This quality can be further improved through a basic attack with KOH that dissolves any residue from the oxidation of silicon.

The final choice of whether or not this additional operation depends on the market value of more or less pure silicon and this market survey is being developed on the basis of samples significant that we are producing with experimental tests on large quantities.

IP/5: indicators for the quantity and quality of silicon recovered from the leaching of metals recovered by electrolysis and fertilizer from salification acid residues were positive both in terms of energy consumption and environmental impact, and value of the end products .

An important issue that we have yet to investigate is the recovery of the residual glass present together with the metal silicon as filtered of the acid and alkaline attack, or acid attack alone, for which we are still evaluating gravimetric, centrifugal and chemical-physical systems.

In conclusion:

– the recovery of the metal silicon is total (no problems of oxidation to SiO2);

– the silver recovery is total at the cathode of the electrolysis;

– the recovery of lead and copper is total at the cathode together with the silver;

– the recovery of aluminum is partial to the cathode because a part remains in solution and is then salified with calcium hydroxide but without incompatibility problems as fertilizer.

Since at the cathode of spongy graphite will be present different metals in minor amounts compared to silver, it will do so to orient the electrolysis in a way as to leave in solution those metals which do not give problems in the residual nitrate salts, and to retain at the cathode the heavy metals which may still be selectively removed by melting at different temperatures in the final process of recovery of the metals contained in the spongy cathode of graphite.

Action B6

The design of the robot system for the separation of aluminum profiles and the connector is already well under way and does not reserve any problems because it uses standard robots, adapted to the particular function required.

Action B7

The design of the prototype for the system of separation of the glass from the sandwich is in an advanced planning stage, based on the experience made on the pre-prototype already in operation for months.

The only problem yet to be determined is the bonding system of the panels once released from aluminum and the connector, to insert in the apparatus of detachment of glass from EVA which needs continuity of operation.

At first it seemed that the simple drawing of a tape on the two edges of the sandwich (backsheet side) was enough but then it is seen that, in phase of continuity of the process, the heat reached of the backsheet causes the detachment of the junction in the point dedicated to the inclusion in the apparatus of detachment at knife button.

It’s already found alternative means of a heat sealing tape itself but we are evaluating with a producer of backsheet the material type best suited to speed the operation automatically and avoid delays in the ongoing process, which would lead to discontinuities in the production of sandwich to start at pyrolysis.

Action C1

The monitoring of the environmental impact is constantly followed by both Sasil that SSV and is based on that monitoring that we make the design decisions to be taken in the development of the prototypes that need to perform the functions required of the various actions.

Action C2

The LCA study is done jointly by SSV and SASIL with free advice of ISPRA, Research Institute for Environmental Protection, which, being very interested in the development of this project, entered it as a reference project among the various options with the recovery of photovoltaics.

A first draft of the environmental impact assessment has already been completed on the basis of the results from the various actions carried out so far and, by January 2015, will be updated in line with subsequent tests to be carried out.

Action D1

As regards the general Dissemination, SSV has prepared a mailing list to send the newsletter (at the time, one for the month of June and one for October).

With regard to international conferences, this year there have been two important conferences simultaneously on 23 September to which Sasil and SSV participated by presenting the project FRELP:

Both have attracted much interest because, in the recovery of the panels with silicon technology, there are currently no active treatment processes at industrial level; also at the level of research is still in the recovery phase little selective for the enhancement of the individual components.

Action D2

SASIL has prepared a NOTICE BOARD with the description of the project (objectives, actions and results) and a TECHNICAL SCHEME precisely with the outline of the project.

SASIL also updated regularly on his website a special page devoted to the project FRELP (http://www.sasil-life.com/index.php?option=com_content&view=article&id=85&Itemid=83&lang=it) and preparing two sections: one dedicated to the technical advances of the project and one to download newsletters, press releases and presentations of the conference.

In order to come to meet the request of the Commission to improve the site and given the technical limitations of its current location by the end of the year will be built a website specifically dedicated only to the FRELP project, made over to the SASIL website that enclosed already updates and sections of FRELP.