Periodic Reporting for period 2 - RESILEX (Resilient Enhancement for the Silicon Industry Leveraging the European matriX)
Periodo di rendicontazione: 2023-12-01 al 2025-05-31
Silicon is one of the few critical raw materials used in most of the strategic renewable energy applications: improving its value chain is of major importance for the EU’s resilience, as this material is used in several key sectors, from batteries to PV & ICT, and it’s not easily replayable without serious loss of end performance or increase of cost.
Today, only 32% of the Silicon used in Europe is produced within the EU, in a global market dominated by China. The core activity of RESiLEX is to strengthen each part of the Silicon value chain, through the technological improvement of all its processes, from the extraction and transformation of the raw material up to the optimization and recycling of PV modules, and the reuse of Silicon for Lion Batteries. RESiLEX targets the sourcing and reuse of other critical raw materials for the green transition as well as to minimise their use in newly designed PV panels.
The project goal is to demonstrate several industry-driven innovative solutions (TRL6-7), aiming at sustainable and resilient critical raw material value chains in Europe.
Today, only 32% of the Silicon used in Europe is produced within the EU, in a global market dominated by China. The core activity of RESiLEX is to strengthen each part of the Silicon value chain, through the technological improvement of all its processes, from the extraction and transformation of the raw material up to the optimization and recycling of PV modules, and the reuse of Silicon for Lion Batteries. RESiLEX targets the sourcing and reuse of other critical raw materials for the green transition as well as to minimise their use in newly designed PV panels.
The project goal is to demonstrate several industry-driven innovative solutions (TRL6-7), aiming at sustainable and resilient critical raw material value chains in Europe.
The main achievements for each activity of the project are:
1/ Recovery of critical raw materials from mining wastes and wastewater: Partner CETAQUA first characterized the samples of acidic and solid waters from the mining demonstration site to determine which points are of greater interest to recover critical materials. In parallel, we designed two treatment trains to recover valuable metals from wastewater and mining waste, respectively. The first is located at CETAQUA facilities and consists of a non-ferrous metal recovery unit followed by an adsorption module with a final crystallizer. The second is located at THARSIS facilities and consists of a thermal waste valorization unit. These treatment trains are now operational, and the demonstration and techno-economic analysis of the process are ongoing.
2/ Sustainable silicon production: RESILEX has demonstrated a sustainable silicon recycling process at lab and medium scales. NTNU developed a circular method using aluminothermic reduction of quartz fines, refining silicon from recycled sources like Si-kerf and slag. This process achieved 97.79% purity at 100 kg scale. Further refining through directional solidification and Czochralski (Cz) growth led to 3N–5N purity, with 5N in the ingot’s core. CEA produced three 30 kg Cz ingots using up to 12% recycled silicon, achieving dislocation-free growth. One ingot was sliced into 700 wafers for WP4. Life Cycle Assessments (LCAs) are ongoing to evaluate carbon footprint reductions compared to global averages.
3/ Sustainable, eco-designed solar cells & modules: An industrial SHJ solar cell process was developed, eliminating indium via aluminum zinc oxide (PVD) and reducing silver through copper-based screen-printing. This led to just a 1.4% efficiency loss compared to the reference. Additional SHJ cells with 72% less indium and copper metallization (via printing and plating) achieved high performance with efficiency ≥25%. Initial Life Cycle Costing showed a 10% cost reduction, with potential for more savings through new materials. Early LCA results show a 46% carbon footprint cut by replacing alumina frames with wood and using polymer-glass alternatives for front covers.
4/ Silicon recycling from PV modules: In RESILEX, silicon material out of Silicon cells recovered from PV panels (provided by Recma and ENVIE2E) will be used to make batteries and/or new Silicon wafers. The technical specifications to meet the targets of the recycling process is now finalised. The design of the upgraded process is done. Results at small-scale already validated the possibility to reuse Silicon for anodic material. For wafers use, a higher purity is needed (9N). The demonstrator will be started up before Q4 2025.
5/ Development of high-efficiency Si composite for Li-ion batteries: RESiLEX developed and optimized the process allowing the production of Si/C composite at pilot-scale with a production capacity exceeding 1 Kg per week (MS9). Furthermore, as detailed in the Deliverable D6.3 and briefly described in T6.3 RESiLEX has successfully accomplished the SO5 by preparing the 20 multi-layer pouch cells. These cells incorporate 10 wt.% Si/C composite sent by ULIEGE-GREEnMat, designated as MS9 (T6.2) at the anode side achieving a capacity exceeding 2 Ah. Electrochemical testing is currently underway at CEA and is scheduled to start shortly at CSEM.
6/ Multi-faceted Impact assessment & EU policy recommendations: The perimeter of analysis and assessment of the different pilots have been defined and the first version of the RESiLEX Policy Platform where policy recommendations will be released has been launched. The stakeholder questionnaire remains open to gather further inputs to draft RESiLEX’s recommendations. A policy brief with recommendations for the EC has been developed between RESILEX and 5 other Horizon-funded projects focused on sustainability of the production of PV panels
1/ Recovery of critical raw materials from mining wastes and wastewater: Partner CETAQUA first characterized the samples of acidic and solid waters from the mining demonstration site to determine which points are of greater interest to recover critical materials. In parallel, we designed two treatment trains to recover valuable metals from wastewater and mining waste, respectively. The first is located at CETAQUA facilities and consists of a non-ferrous metal recovery unit followed by an adsorption module with a final crystallizer. The second is located at THARSIS facilities and consists of a thermal waste valorization unit. These treatment trains are now operational, and the demonstration and techno-economic analysis of the process are ongoing.
2/ Sustainable silicon production: RESILEX has demonstrated a sustainable silicon recycling process at lab and medium scales. NTNU developed a circular method using aluminothermic reduction of quartz fines, refining silicon from recycled sources like Si-kerf and slag. This process achieved 97.79% purity at 100 kg scale. Further refining through directional solidification and Czochralski (Cz) growth led to 3N–5N purity, with 5N in the ingot’s core. CEA produced three 30 kg Cz ingots using up to 12% recycled silicon, achieving dislocation-free growth. One ingot was sliced into 700 wafers for WP4. Life Cycle Assessments (LCAs) are ongoing to evaluate carbon footprint reductions compared to global averages.
3/ Sustainable, eco-designed solar cells & modules: An industrial SHJ solar cell process was developed, eliminating indium via aluminum zinc oxide (PVD) and reducing silver through copper-based screen-printing. This led to just a 1.4% efficiency loss compared to the reference. Additional SHJ cells with 72% less indium and copper metallization (via printing and plating) achieved high performance with efficiency ≥25%. Initial Life Cycle Costing showed a 10% cost reduction, with potential for more savings through new materials. Early LCA results show a 46% carbon footprint cut by replacing alumina frames with wood and using polymer-glass alternatives for front covers.
4/ Silicon recycling from PV modules: In RESILEX, silicon material out of Silicon cells recovered from PV panels (provided by Recma and ENVIE2E) will be used to make batteries and/or new Silicon wafers. The technical specifications to meet the targets of the recycling process is now finalised. The design of the upgraded process is done. Results at small-scale already validated the possibility to reuse Silicon for anodic material. For wafers use, a higher purity is needed (9N). The demonstrator will be started up before Q4 2025.
5/ Development of high-efficiency Si composite for Li-ion batteries: RESiLEX developed and optimized the process allowing the production of Si/C composite at pilot-scale with a production capacity exceeding 1 Kg per week (MS9). Furthermore, as detailed in the Deliverable D6.3 and briefly described in T6.3 RESiLEX has successfully accomplished the SO5 by preparing the 20 multi-layer pouch cells. These cells incorporate 10 wt.% Si/C composite sent by ULIEGE-GREEnMat, designated as MS9 (T6.2) at the anode side achieving a capacity exceeding 2 Ah. Electrochemical testing is currently underway at CEA and is scheduled to start shortly at CSEM.
6/ Multi-faceted Impact assessment & EU policy recommendations: The perimeter of analysis and assessment of the different pilots have been defined and the first version of the RESiLEX Policy Platform where policy recommendations will be released has been launched. The stakeholder questionnaire remains open to gather further inputs to draft RESiLEX’s recommendations. A policy brief with recommendations for the EC has been developed between RESILEX and 5 other Horizon-funded projects focused on sustainability of the production of PV panels
The expected results and potential impacts are:
1/ Recovery Treatment train demonstrated at Tharsis mine and replicated in 5 other Europan mines.
2/ Demonstration and development of a carbon-free sustainable process in Norway for producing Silicon and Silicon alloys suitable for solar applications.
3/ Demonstration of eco-designed solar cells (such as CRM-free solar cells and Silicon wafers from revalorized Silicon wastes)
4/ Scaled-up PV dismantling line in Toulouse by Comet, Recma and Envie2E, reducing the EU’s demand for primary materials and hence lessening its reliance on imported CRM.
5/ Scaled-up production of nanopowders for battery applications to replace graphene anode in Li-ion batteries by high-energy density Silicon-carbon composite anodes.
6/ EU policy recommendations through an open-source platform, eg. promoting the Integration of Silicon to the Carbon Border Adjustment Mechanism (CBAM).
1/ Recovery Treatment train demonstrated at Tharsis mine and replicated in 5 other Europan mines.
2/ Demonstration and development of a carbon-free sustainable process in Norway for producing Silicon and Silicon alloys suitable for solar applications.
3/ Demonstration of eco-designed solar cells (such as CRM-free solar cells and Silicon wafers from revalorized Silicon wastes)
4/ Scaled-up PV dismantling line in Toulouse by Comet, Recma and Envie2E, reducing the EU’s demand for primary materials and hence lessening its reliance on imported CRM.
5/ Scaled-up production of nanopowders for battery applications to replace graphene anode in Li-ion batteries by high-energy density Silicon-carbon composite anodes.
6/ EU policy recommendations through an open-source platform, eg. promoting the Integration of Silicon to the Carbon Border Adjustment Mechanism (CBAM).