Solar cell manufacturing can achieve up to 80% water savings

Scientists from Technical University of Berlin, Rena Technologies, Fraunhofer Institute for Building Physics IBP, and Fraunhofer Institute for Solar Energy Systems ISE have developed an extensive model of water flow within a 5-gigawatt solar cell factory. They tested the implementation of two different strategies for circular water use. The finding reveals that with today's production technologies, it's technically possible to achieve up to 79% water savings and up to 84% wastewater reduction in solar cell production. This allows for the construction of new solar cell factories in locations with less water availability.

The research team analyzed water, wastewater, and material flows for a 5-gigawatt PERC solar cell production. Their results are also beneficial for factories where Heterojunction or TOPCon solar cells are manufactured or being re-equipped for manufacturing, as the wastewater flows for these cell types are very similar. As Peter Brailovsky from Fraunhofer ISE explains, "We analyzed different possibility for water savings and reprocessing based on this production model. We can recommend two approaches: reusing lightly contaminated wastewater (LCR) and 'Minimal Liquid Discharge' (MLD), which involves reusing certain residual substances."

Water savings in solar cell production without additional costs

"The results show that with the MLD scenario, up to 80% of fresh water demand and wastewater in the solar cell factory can be saved," says Jascha Reich, a scientist at Technical University of Berlin, "If the LCR approach is applied, we can achieve up to 40% saving.” At the same time, implementing these savings measures would not impose additional costs on production, but would rather result in slight cost savings. A closed water cycle can significantly reduce the risk of a factory shutdown due to water shortage, such as during heat waves in summer, which could cost up to 1.9 million euros in weekly costs.

Solar cells are already a very sustainable product, according to the scientists. When incorporated into a photovoltaic module, the energy used in its manufacture is paid back in no time. In the case of PV installations in Central Europe, this typically occurs within 1.3 years. "But we shouldn't rest on our laurels," says Jochen Rentsch, Head of Technology Transfer in the field of Photovoltaics at Fraunhofer ISE, "Like everywhere in manufacturing, photovoltaics should also become part of a circular economy."

The advancements in water savings in solar cell manufacturing not only make the production process more sustainable but also enhance the feasibility of setting up factories in regions with limited water resources. Once these highly efficient solar cells are produced, the next crucial step is to effectively store the generated solar energy to ensure a consistent and reliable power supply.

ACE Battery offers state-of-the-art solar energy storage solutions designed to maximize the utility of solar energy. By integrating these storage systems with solar installations, excess energy collected during sunny periods can be stored and used during times of low sunlight, such as nighttime or cloudy days. This ensures a steady energy supply and enhances the overall efficiency and sustainability of solar power systems.

Incorporating ACE Battery’s advanced storage technology allows for optimal use of the electricity generated by solar cells, supporting the transition towards a more sustainable and resilient energy infrastructure. Thus, the combination of water-efficient solar cell manufacturing and effective energy storage solutions represents a significant leap towards a greener and more sustainable future.