Design for RE-Solar

Design for RE-Solar

This traditional research and development REMADE proposal is to create a framework that addresses the knowledge gaps of RE-SOLAR design. The proposed framework will offer impact projections for future PV panel waste streams (globally and for the US) based on predictions of global PV growth, provide LCA of various PV designs, and demonstrate new concepts and innovation for the design of an industrial scale PV recycling plant. The proposal is a continuation of Project 18-01-DE-07.

Upon completion, this project will deliver PV in a circular economy (PV ICE) version 1.0.0 software tool with the capability to analyze embodied energy and equivalent carbon dioxide emissions given changes in Si PV technologies, new PV technologies such as tandem cells and perovskites, and effects of changing raw material sourcing or increasing recycled material in manufacturing; The tool will also be used to analyze reduced material consumption and the effect of open-loop versus closed-loop recycling on future CO2 emissions, energy, waste streams, and material economic value. This project will reduce primary feedstock by 1.08 million metric tons (MMT), 26.6 PJ energy reduction, 1.34 MMCO2e. Assumptions based on preliminary results of the exploratory project.

Project Team:
University of Pittsburgh, University of California-Irvine (UCI), National Renewable Energy Laboratory (NREL), First Solar, Alfred University, Yale University, Sunnking, Inc., Aluminum Association, Electronic Recyclers International (ERI)

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21-01-DE-5028

Remanufacturing of Surface-Hardened Steel Components by Ultrasonic Surface Modification

Remanufacturing of Surface-Hardened Steel Components by Ultrasonic Surface Modification

This project seeks to develop practical repair techniques to recover nominal ‘as-new’ fatigue life in used or worn surface-hardened steel components by i) forging closed preexisting microcracks, ii) introducing beneficial compressive residual stresses (CRS) deeper than conventional shot peening, and iii) generating a nanocrystalline microstructure at the surface. Surface repairs based on UIT (a form of high-frequency needle peening) will be developed for a range of usage-induced damage conditions that are commonly found in these components, but for which there is a lack of practical repair methods.

Project Team:
Rochester Institute of Technology (RIT), Caterpillar, Inc., University of Pittsburgh (PITT)

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20-01-RM-4012

Non-Destructive In-process Assessment of Thermal Spray Repairs

Non-Destructive In-process Assessment of Thermal Spray Repairs

Thermal spray process inspection is currently lot-based which can result in the rejection of entire lots of parts due to process variation. This project will focus on development of non-destructive in-process evaluation of thermal spray to minimize reject rates of good parts.

Project Team:
Rochester Institute of Technology, University of Pittsburgh, Caterpillar Inc.

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18-01-RM-11

Development of an Industrially Relevant RE-SOLAR Design Framework

Development of an Industrially Relevant RE-SOLAR Design Framework

Solar modules are creating a major surge in e-waste because inadequate attention is focused on designing for recycling or reuse. This project provides a design framework of high-efficiency modules that can be economically recycled, recovered, remanufactured, and/or reused.

Project Team:
University of Pittsburgh, University of California-Irvine, National Renewable Energy Laboratory, First Solar

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18-01-DE-07