Within the first eighteen months of SOLMAE project implementation, quite positive progress towards achieving its strategic objectives has been achieved.
Namely, the three different use cases and business models were defined for decentralized energy systems based on second-life PV modules and EV batteries. Those are agrivoltaics setup including a battery (led by KU LEUVEN), at least three Plug-in PV setups including a battery system (led by SUN), and a Roof-top PV system with battery storage in a low-income community (led by W4E).
This work laid basis to prepare for the start preparation of demonstration of the three different use cases and business models for decentralized energy systems based on second life PV modules and EV batteries. Moreover, aspects of technical and economic conditions necessary for successful and replicable demonstrations are being explored and discussed.
Sourcing PV modules and EV batteries for the SOLMATE demonstrators and defining associated qualification protocols also took place. This included: Identification of PV modules or PV components batches done by SOREN and for EV batteries by W4E, followed by characterisation, qualification and selection of PV modules (CERTISOLIS and CEA), and for EV batteries by W4E. Adapted Energy Management System (EMS) is being developed by REVOLTA and W4E.
Focus on development of a qualification sequence for the second life PV modules enables to have PV batches fully characterized to highlight possible relations between defects and performance and to propose a light but adequate protocol. PV modules that successfully pass the tests will be divided according to the requirements of the SOLMATE demonstrators.
Specifically for the EV batteries focus, progress was made towards establishing the processes for sourcing end-of-life (EoL) EV batteries, assessing their condition, and determining their suitability for second-life applications through standardized characterization, testing, and qualification procedures. To this end, W4E developed a sequence of quick testing activities for anomaly detection as the first screening step. These preliminary tests were designed to quickly identify batteries with critical safety or functional issues before proceeding to more detailed assessments. Additional checks such as visual inspection for physical damage, connector and casing integrity assessments, polarity verification, and self-discharge rate tests were also carried out. Together, these tests allowed W4E to quickly flag unsafe or defective EV batteries, preventing further handling of units that could pose hazards or fail early in a second-life application. The second step involved a comprehensive State of Health (SoH) estimation to evaluate the remaining usable capacity and performance of the EV batteries. Further dynamic load profile tests were performed to simulate real-world operating conditions, along with temperature monitoring to identify abnormal thermal behaviour.
SOLMATE also started with the development of automated technologies for the on-site inspection and characterization of EoL PV modules, and the robotic sorting and dismantling of EoL PV modules.
Specifically, automated drone-based technologies for the inspection and characterization of end-of-life (EoL) PV modules were developed, in line with testing and certification protocols. This included drone-inspection workflow definition, with which it is possible to assign a quality label to each individual PV panel in a cost-effective and automated manner; Development of region-specific drone operational API in compliance with European Union Aviation Safety Association (EASA) regulations; and Integration of API for VITO-IFLIGHT communication.
Regarding the robotic system for sorting and dismantling EoL PV modules (expected to improve currently used PV panels on the market that are manually dismantled and sorted), progress done includes the design and engineering for dismantling and sorting PV modules from system-level concepts, detailed mechatronic design for the dismantling unit and required end-of-arm tooling, in parallel with preparing functional dismantling unit (under construction and ongoing) as well as integrating capability for antimony detection (XRF equipment based) in PV modules.
Work progressed on sorting EoL PV panels depending on their antimony content using XRF analyses so that the panels containing antimony can be processed in industrial PV recycling lines separately from the panels not containing antimony. Several samples of different PV panels were analysed. The results of first analyses showed only few samples were antimony free. Additionally, other potential end-users were identified for a potential use of such glass in the cement matrix of manufactured concrete as a substitute to sand, and in the ceramic industry.
