Periodic Reporting for period 2 - CUSTOM-ART (DISRUPTIVE KESTERITES-BASED THIN FILM TECHNOLOGIES CUSTOMISED FOR CHALLENGING ARCHITECTURAL AND ACTIVE URBAN FURNITURE APPLICATIONS)
Berichtszeitraum: 2022-03-01 bis 2023-08-31
CUSTOM-ART aims at developing the next generation of building and product integrated photovoltaic modules (BIPV and PIVP respectively), based on earth-abundant and fully sustainable thin film technologies. CUSTOM-ART will develop advanced BIPV and PIPV products (flexible and semi-transparent solar modules), based on earth abundant kesterite materials which are at the forefront of emerging inorganic thin film technologies. By combining advanced strategies for materials properties management, with customized modules design in a circular economy approach, two types of products will be developed including flexible PV modules (polymer and steel supports) and semi-transparent (polymer). CUSTOM-ART will bring these technologies from TRL4-5 up to TRL7, demonstrating very competitive conversion efficiencies (20% at cell and 16% at module level) and durability (over 35 years), at a reduced production cost (< 75 €/m2), contributing to ensure the full sustainability and competitiveness of the European BIPV and PIPV Industry.
The work performed since the beginning of the project and the main results achieved so far are summarised in the following points:
• Optimisation of processes for highly efficient kesterite solar cells. Main results obtained include the demonstration of monograin solar cells with 14% active area certified efficiency (10.2% total area efficiency) and the demonstration of microcrystalline thin film solar cell with 12.6% total area efficiency (w/o) ARC), as well as the demonstration of the thin film microcrystalline process scalability (up to 10x10 cm2) with good process uniformity;
• Encapsulation, durability and reliability: The testing methods to quantify the performances of non-encapsulated devices have been defined. Non encapsulated devices show good stability results in different technologies (including monograin and thin film microcrystalline cells) and substrates (glass, steel) with best devices from each technology showing degradations below 5% after 1000 hours in dry environment. Reversible adhesives with target activation temperature have also been developed, and the encapsulation process for flexible modules has been accomplished with good selection of epoxy formulation and primer;
• Modules fabrication: Main results include i) the demonstration of all solution processes front contact achieving all targets defined in the project (< 10/sq resistance, transparency > 85% and material costs reduction > 50%); ii) successful transfer of thin film microcrystalline processes from glass substrate to flexible (steel) substrate, with cell device efficiencies similar to values achieved on glass substrate; and iii) the demonstration of monolithically interconnected modules with relative efficiency loss ≤ 20% versus cell efficiency;
• Demonstration in 2 business scenarios: BIPV and PIPV: Activities developed up to M36 include the development of specific designs for BIPV products (modular façade element with PV lamellas, solar tiles) and PIPV products (solar bench, lights room), and the definition of metrics and Key Performance Indicators for outdoor testing sites. First module prototypes have been installed at AYESA testing site for 12 months monitoring under real operational conditions;
• Cost analysis, recycling, LCA and societal acceptance: Main results achieved include: i) the development of LCA analysis of both monograin and thin film microcrystalline technologies and benchmark with current industrial CIGS technology; ii) the development of the LCC model. First estimations of EPBT give results already in line with those from dominant Si technology (around 2.07 years and 0.75 years for monograin and microcrystalline CZTS technologies at 1700 kWh/m2, respectively, in front of 1.0 -1.5 years reported for Si), in spite of the lower device efficiency; and iii) the definition of the better routes and processes for kesterite solar modules recovery, for both polymer-based and steel-based kesterite devices. Recycling processes have been demonstrated at lab level, with recovery yields of 88%-100%;
• Dissemination and communication activities: Custom-Art has created a webpage of the project and the project logo, project templates, a promotional video, project brochures and an e-newsletter issue have been produced and released at social media. Custom-Art has also developed an intense scientific dissemination campaign that has included participating in the more relevant international conferences from the field (with 86 contributions, including 14 invited contributions), and the publication of 29 papers in relevant high impact scientific journals;
• Exploitation activities have included the identification of the Foreground, Background and KER of the project. An overall analysis of the BIPV/PIPV market (external and internal factors, industry rivalry and stokeholds) accompanied by a commercialization plan and a review of the exploitation activities were carried out at the 1st project period, and have been revised and updated in M35.
• Optimisation of processes for highly efficient kesterite solar cells. Main results obtained include the demonstration of monograin solar cells with 14% active area certified efficiency (10.2% total area efficiency) and the demonstration of microcrystalline thin film solar cell with 12.6% total area efficiency (w/o) ARC), as well as the demonstration of the thin film microcrystalline process scalability (up to 10x10 cm2) with good process uniformity;
• Encapsulation, durability and reliability: The testing methods to quantify the performances of non-encapsulated devices have been defined. Non encapsulated devices show good stability results in different technologies (including monograin and thin film microcrystalline cells) and substrates (glass, steel) with best devices from each technology showing degradations below 5% after 1000 hours in dry environment. Reversible adhesives with target activation temperature have also been developed, and the encapsulation process for flexible modules has been accomplished with good selection of epoxy formulation and primer;
• Modules fabrication: Main results include i) the demonstration of all solution processes front contact achieving all targets defined in the project (< 10/sq resistance, transparency > 85% and material costs reduction > 50%); ii) successful transfer of thin film microcrystalline processes from glass substrate to flexible (steel) substrate, with cell device efficiencies similar to values achieved on glass substrate; and iii) the demonstration of monolithically interconnected modules with relative efficiency loss ≤ 20% versus cell efficiency;
• Demonstration in 2 business scenarios: BIPV and PIPV: Activities developed up to M36 include the development of specific designs for BIPV products (modular façade element with PV lamellas, solar tiles) and PIPV products (solar bench, lights room), and the definition of metrics and Key Performance Indicators for outdoor testing sites. First module prototypes have been installed at AYESA testing site for 12 months monitoring under real operational conditions;
• Cost analysis, recycling, LCA and societal acceptance: Main results achieved include: i) the development of LCA analysis of both monograin and thin film microcrystalline technologies and benchmark with current industrial CIGS technology; ii) the development of the LCC model. First estimations of EPBT give results already in line with those from dominant Si technology (around 2.07 years and 0.75 years for monograin and microcrystalline CZTS technologies at 1700 kWh/m2, respectively, in front of 1.0 -1.5 years reported for Si), in spite of the lower device efficiency; and iii) the definition of the better routes and processes for kesterite solar modules recovery, for both polymer-based and steel-based kesterite devices. Recycling processes have been demonstrated at lab level, with recovery yields of 88%-100%;
• Dissemination and communication activities: Custom-Art has created a webpage of the project and the project logo, project templates, a promotional video, project brochures and an e-newsletter issue have been produced and released at social media. Custom-Art has also developed an intense scientific dissemination campaign that has included participating in the more relevant international conferences from the field (with 86 contributions, including 14 invited contributions), and the publication of 29 papers in relevant high impact scientific journals;
• Exploitation activities have included the identification of the Foreground, Background and KER of the project. An overall analysis of the BIPV/PIPV market (external and internal factors, industry rivalry and stokeholds) accompanied by a commercialization plan and a review of the exploitation activities were carried out at the 1st project period, and have been revised and updated in M35.
The expected results of the project are structured in the following specific objectives:
• SO1: To develop and test 2 enhanced configurations of CZTS modules conceived by the perfect combination of earth-abundant materials to demonstrate the fulfilment of KPIs directly linked with the technological competitiveness of the technology: Efficiency (20%), high-stability and lifetime (>35 years; 95%); reliability and reproducibility (less than 10% variation in key parameters); recyclability (85%) by the end of the project;
• SO2: To apply a set of cost reduction strategies to achieve a highly competitive manufacturing cost target of <40 c€/Wp (polymer and steel substrate configurations). Both approaches will guarantee reducing by 20% the current manufacturing costs of competing thin-film technologies;
• SO3: To assembly and test 4 module prototypes, as a full system, in 2 Business Cases where the role of PV technologies is considered vital for the final products of the end-users: AYESA as construction and engineering firm expert in BIPV and KWS as urban furniture manufacturer expert in PIPV. This approach will allow us to demonstrate technical feasibility through an exhaustive monitoring and assessment of selected KPIs in a relevant environment;
• SO4: To introduce novel circular economy strategies to ensure a high-recycling target (≥ 85%) that guarantee the development of a sustainable PV solutions and to demonstrate its environmental, social and economic impact by the development of a full LCA and LCC;
• SO5: To boost the European PV industry through the commitment of substantial investments in manufacturing plants especially in the cell/module assembly stages. To that end, it is needed to ensure its long-lasting sustainability, minimising the dependence of non-European raw materials thanks to promotion of local earth-abundant materials.
• SO6: To update and refine the current feasibility study and business plan as a “strategic tool” to get a smooth market penetration and proper orientation of the future products and services in 2024.
• SO1: To develop and test 2 enhanced configurations of CZTS modules conceived by the perfect combination of earth-abundant materials to demonstrate the fulfilment of KPIs directly linked with the technological competitiveness of the technology: Efficiency (20%), high-stability and lifetime (>35 years; 95%); reliability and reproducibility (less than 10% variation in key parameters); recyclability (85%) by the end of the project;
• SO2: To apply a set of cost reduction strategies to achieve a highly competitive manufacturing cost target of <40 c€/Wp (polymer and steel substrate configurations). Both approaches will guarantee reducing by 20% the current manufacturing costs of competing thin-film technologies;
• SO3: To assembly and test 4 module prototypes, as a full system, in 2 Business Cases where the role of PV technologies is considered vital for the final products of the end-users: AYESA as construction and engineering firm expert in BIPV and KWS as urban furniture manufacturer expert in PIPV. This approach will allow us to demonstrate technical feasibility through an exhaustive monitoring and assessment of selected KPIs in a relevant environment;
• SO4: To introduce novel circular economy strategies to ensure a high-recycling target (≥ 85%) that guarantee the development of a sustainable PV solutions and to demonstrate its environmental, social and economic impact by the development of a full LCA and LCC;
• SO5: To boost the European PV industry through the commitment of substantial investments in manufacturing plants especially in the cell/module assembly stages. To that end, it is needed to ensure its long-lasting sustainability, minimising the dependence of non-European raw materials thanks to promotion of local earth-abundant materials.
• SO6: To update and refine the current feasibility study and business plan as a “strategic tool” to get a smooth market penetration and proper orientation of the future products and services in 2024.