BermUDa. Lead-free PV module Made in Germany - environmental impact, commercialisation and demonstration of industrial implementation. Final report

In order to improve the sustainability of PV modules, this project focussed on demonstrating the industrial production of a PV module that completely dispenses with lead-containing materials, as well as researching the requirements for parameters and their fluctuations in the production process, as well as possible existing technical challenges. This should improve the ecological footprint of PV modules and contribute to a visible, qualitative differentiation from conventional products from Asia. With regard to the achievable efficiency, performance and long-term stability of the lead-free module, comparable parameters were to be achieved compared to today's standard modules. This was accompanied by a detailed ecological and economic assessment of lead substitution in PV modules. In addition, the demonstration as part of the project was intended to further strengthen the motivation of the legislative authorities to restrict the use of lead in the field of silicon photovoltaics, a substance that is harmful to the environment and health. This should lay the foundation for a legal requirement that can give German PV module manufacturers and the material manufacturers supplying them a competitive advantage. International activities for the assessment and certification of sustainably produced PV modules were also supported. The objectives of the project were summarised as follows: Scientific / technical: - Practical demonstration of the feasibility of lead-free modules with comparable performance and service life using industry-standard methods and equipment. - Determination of optimal process parameters for cell metallisation, string production and module construction for the production of lead-free modules. - Determination of the influence of standard production process fluctuations on the performance and service life of lead-free modules. - Illustration of the influence of the elimination of lead on the energy and economic balance of a PV power plant. - Presentation of the influence of the elimination of lead on the ecological balance of PV modules over the entire life cycle. - Evaluation of the emission of pollutants from PV modules when considering different life cycle scenarios. - Creation of utilisation, recycling and damage scenarios based on experimental studies. Economic: - Supporting the German supplier industry for materials by presenting new sales opportunities in the field of ecologically harmless components (e.g. lead-free pastes, fluorine-free backsheets) - Developing unique selling points for German module and system manufacturers (production systems) by demonstrating the feasibility of adapting regulatory requirements with regard to lead content (e.g. linking funding to compliance with RoHS requirements) and creating the basis for visualising the ecological properties of a PV module for users and consumers (eco-certification).