A method for reducing consumption of pure water in a wet process of a Topcon photovoltaic cell

Abstract

This invention relates to the field of photovoltaic crystalline silicon cell manufacturing technology, specifically a method for reducing pure water consumption in the wet process of Topcon photovoltaic cells. This invention flexibly selects which tanks need to be bypassed based on actual process requirements, making the tank operation logic more intelligent and offering more diverse choices. This improves tank utilization, reduces water consumption in empty tanks, and maintains the compatibility of the tanks with multiple process routes. This invention successfully establishes a linear relationship between pure water consumption, production capacity, and process requirements, transforming the water overflow mode from "passive discharge" to "active control." This effectively solves the problem of excessive pure water supply to workshop equipment under low production capacity conditions, while not adversely affecting the pressure of power waste disposal, achieving efficient resource utilization and optimized management of the production process.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic crystalline silicon cell manufacturing technology, specifically a method for reducing water consumption in the wet process of Topcon photovoltaic cells. Background Technology

[0002] The production of high-purity water currently faces severe challenges. On the one hand, energy consumption in high-purity water production accounts for over 40% of the total cost of related processes, resulting in high costs. On the other hand, traditional production processes have low water resource recovery rates. The energy consumption of the pure water production process accounts for 5%-12% of the industry's total energy consumption, becoming a key bottleneck for the green transformation of the photovoltaic industry chain. Against this backdrop, the issue of reducing pure water consumption in the wet process of photovoltaic cells is no longer limited to simple cost control, but has risen to a strategic level of ensuring the industry's compliant development and enhancing the core competitiveness of enterprises.

[0003] Traditional pure water usage suffers from low utilization rates and inefficient operation. Large quantities of pure water are discharged directly without being fully utilized, resulting in significant resource waste. Currently, the widely used wet-process tank cleaning system, while possessing powerful cleaning capabilities and gaining some recognition, still has significant shortcomings in practical applications. The overflow design of the tank cleaning tank is intended to continuously refresh the water body, but in non-production states or when the equipment is idle, pure water continues to overflow and be discharged. Furthermore, there is no correlation between the overflow rate and production output, making it difficult for companies to achieve intuitive and precise control over pure water usage for cost management.

[0004] In light of the above, implementing refined management of pure water consumption has become an inevitable trend in the industry. Achieving reduced pure water consumption through refined management is of paramount importance for enhancing a company's competitiveness in the market. Summary of the Invention

[0005] The purpose of this invention is to provide a method for reducing pure water consumption in the wet process of Topcon photovoltaic cells, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A method for reducing pure water consumption in the wet process of Topcon photovoltaic cells includes the following steps: S1: Operation Procedure 1: Replace with a large-range flow meter and match an overflow pipe of the same diameter according to the actual flow demand. Operators can establish a dynamic adjustment mechanism to match the daily pure water consumption with the production line by adjusting the pure water mode and flow rate. S2: Operation Procedure 2: Selectively shield the corresponding tank. Through the operation interface of the tank machine and the actual process flow, select the corresponding tank for shielding and skipping settings. After the settings are completed, the system will automatically record the shielding information and execute the settings in the subsequent production process. S3: Production Operation: During the production process, the tanks that are shielded and skipped do not participate in the material flow and do not consume pure water. Other normally operating tanks are cleaned according to the preset process parameters. S4: Pure water overflow control: Matching the production line process by optimizing the overflow of each pure water tank; S5: Effect Evaluation: Evaluate the water-saving effect of pure water by monitoring and analyzing production data.

[0007] Preferably, the flow rate of the large-range flow meter in step S1 is 1500L / H to 1700L / H.

[0008] Preferably, the diameter of the overflow pipe in step S1 is 23 to 27 mm.

[0009] Preferably, step S4, which involves dynamically adjusting the overflow based on production capacity, includes: The process parameters are precisely controlled, with the overflow time adjustable from 10s to 150s and the overflow rate adjustable from 0 to 1700L / H.

[0010] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention allows for flexible selection of tanks that need to be shielded and skipped based on actual process requirements, making the tank operation logic more intelligent and the selection more diversified. This not only improves the utilization rate of the tank and reduces the water consumption of empty tanks, but also retains the compatibility of the tank with multiple process routes. 2. This invention successfully establishes a linear relationship between pure water consumption and production capacity and process requirements, transforming the water overflow mode from "passive discharge" to "active control". This effectively solves the problem of excessive pure water supply to workshop machines under low production capacity conditions, while not adversely affecting the pressure of power waste treatment, thus achieving efficient resource utilization and optimized management of the production process. Attached Figure Description

[0011] Figure 1 This is an overall flow chart of a method for reducing pure water consumption in the wet process of Topcon photovoltaic cells according to an embodiment of the present invention; Figure 2 This is a schematic diagram of the shielding tank in a method for reducing pure water consumption in the wet process of Topcon photovoltaic cells according to an embodiment of the present invention; Figure 3 This is a schematic diagram of the overflow control modification in a pure water consumption reduction method for the wet process of Topcon photovoltaic cells in an embodiment of the present invention. Detailed Implementation

[0012] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0013] like Figure 1 As shown, an embodiment of the present invention provides a method for reducing pure water consumption in the wet process of Topcon photovoltaic cells, comprising the following steps: S1: Operation Procedure 1: Replace with a large-range flow meter and match an overflow pipe of the same diameter according to the actual flow demand. Operators can establish a dynamic adjustment mechanism to match the daily pure water consumption with the production line by adjusting the pure water mode and flow rate. S2: Operation Procedure 2: Selectively shield the corresponding tank. Through the operation interface of the tank machine and the actual process flow, select the corresponding tank for shielding and skipping settings. After the settings are completed, the system will automatically record the shielding information and execute the settings in the subsequent production process. S3: Production Operation: During the production process, the tanks that are shielded and skipped do not participate in the material flow and do not consume pure water. Other normally operating tanks are cleaned according to the preset process parameters. S4: Pure water overflow control: Matching the production line process by optimizing the overflow of each pure water tank; S5: Effect Evaluation: Evaluate the water-saving effect of pure water by monitoring and analyzing production data.

[0014] This invention addresses the technical challenges of "ineffective water consumption due to empty tanks participating in circulation" and "mismatch between overflow mode and production capacity" in the pure water cleaning process of existing tank-type cleaning machines. It provides a pure water consumption reduction method based on tank operation logic optimization and dynamic overflow control. This method comprises two core ideas: 1. Optimization of the selection and shielding of the tank entry sequence for the trough-type machine; 2. Capacity linkage transformation of the pure water overflow mode of the cleaning tank.

[0015] Approach 1: Optimization of the optional shielding mechanism for the inlet sequence of the slot-type machine: Root cause analysis of the problem: In the operation of the trough-type washing machine, the pure water washing tank plays a crucial role in connecting upstream and downstream processes. To meet the production needs of multiple process routes, the machine is equipped with multiple tanks, all of which require water during operation. However, in actual production, some tanks can be eliminated or left idle depending on specific process requirements. If these empty tanks participate in material flow, pure water will be consumed without any practical production significance, resulting in serious resource waste.

[0016] Optimization measures: This invention comprehensively upgrades and optimizes the operating program of the trough-type machine, developing a "shielded trough" function. Operators can independently choose whether to enable a specific trough based on actual production needs through a simple and intuitive operating interface. This function has high flexibility and stability, and will not interfere with other normally operating troughs, ensuring the continuity and stability of the production process.

[0017] Figure 2 This is a schematic diagram of the shielding tank in a pure water consumption reduction method for the wet process of Topcon photovoltaic cells, as described in an embodiment of the present invention. Operators flexibly select tanks that need to be skipped for shielding based on actual process requirements. In practical applications, through detailed analysis and simulation testing of different process routes, the optimal tank shielding combination is determined to achieve the best energy-saving and consumption-reducing effect. For example, as... Figure 2 As shown, if a post-cleaning step is not required, the corresponding tank can be shielded to save pure water consumption.

[0018] Actual testing showed that after optimizing the shielding of the two tanks of the trough-type equipment, the pure water consumption can be reduced by 1.1 tons per 10,000 pieces, and the comprehensive annual revenue can reach 227,600 yuan, as detailed in Table 1 below: Table 1. Water-saving effect and annual benefits of tank shielding optimization This invention boasts excellent versatility and can be widely applied to empty tank scenarios on all trough-type machines, such as in texturing and alkali polishing processes. In practical applications, the intelligent shielding of the tank reduces the ineffective consumption of resources such as pure water and energy at the source. Simultaneously, this invention retains the compatibility of the tank with multiple process routes, achieving a balance between cost reduction and production maintenance, providing a typical example of "lean process optimization + cost reduction" in industrial production.

[0019] Idea 2: Capacity linkage transformation of the pure water overflow mode of the cleaning tank: Root cause analysis of the problem: Traditional trough-type cleaning machines typically use a continuous overflow method to constantly replenish the water in the tank, ensuring effective cleaning. However, this method has a significant drawback: there's no correlation between pure water consumption and output. Pure water is continuously discharged directly through the overflow pipe, resulting in substantial waste. To address this issue, the industry has experimented with a "basket-based overflow" method, where overflow only occurs during production. While this method reduces waste to some extent, it still suffers from the following shortcomings: Shortened overflow time leads to a slower water turnover rate, which can result in poor cleaning performance for tanks with high cleanliness requirements. The overflow demand is too large, exceeding the flow metering range, making it impossible to accurately control water consumption. Detailed explanation of optimization measures: Based on the "basket overflow" mode, this invention makes targeted modifications to the overflow pipeline: First, a large-range flow meter is replaced to ensure accurate measurement of the overflow flow, providing data support for precise water control; second, an overflow pipeline of the same diameter is matched according to the actual flow requirements to improve the water flow capacity and reduce the impact of factors such as water pressure and frictional resistance; finally, by monitoring the overflow flow in real time, the overflow flow is dynamically adjusted according to the production capacity to achieve precise linkage control between production capacity and water consumption. Basis and range for key parameter selection: The selection of the overflow pipe diameter needs to comprehensively consider factors such as actual flow demand and pipe pressure loss to ensure smooth water flow; the selection of the flow meter range should be reasonably determined according to the overflow range to ensure measurement accuracy. In the embodiment of this invention, a flow meter with a range of 1500L / H to 1700L / H is selected, matched with a pipe diameter of 23 to 27mm; the process parameters are precisely controlled, the overflow time can be controlled from 10s to 150s, and the overflow flow rate can be controlled within the range of 0-1600L / H.

[0020] In the alkaline polishing process, the chemicals used in the process tanks are highly corrosive and contain various additives. These additives contain polar groups (such as -OH, -NH2, -Si-O-) that readily form hydrogen bonds or chemical bonds with the hydroxyl groups (Si-OH) on the silicon surface, preferentially adsorbing at the microstructure and forming a dense film. Furthermore, surfactants reduce surface tension, forming micelles that accumulate at the solid-liquid interface, making them difficult for ordinary water to remove. Therefore, contaminants easily accumulate in the water tanks following the process tanks. If the water turnover rate is slow, it can corrode the silicon wafers, severely affecting their appearance and process quality. Therefore, while reducing water consumption in the tanks, it is essential to ensure a sufficient water turnover rate. Based on this, the present invention adopts the following modification and implementation steps: Flow meter replacement: Remove the original small-range flow meter and install a large-range, high-precision flow meter. Calibrate and adjust the flow meter to ensure the accuracy of the measurement data. This invention uses a flow meter with a maximum range of 1600L / H. Overflow pipe modification: Based on actual flow requirements and pipe pressure loss calculations, the overflow pipe is thickened. Suitable pipe materials are selected to ensure corrosion resistance and sealing; this invention uses 25mm diameter PP pipes. Parameter matching optimization: The overflow mode is changed from continuous overflow to basket overflow. By monitoring the overflow rate in real time, the overflow rate is dynamically adjusted according to the production capacity, and the process parameters are precisely controlled. Specifically, the overflow time can be controlled from 10s to 150s, and the overflow rate can be controlled from 0 to 1600L / H. Actual testing showed that the single-tank pure water consumption before and after the modification was basically the same during normal production (both were 0.52 m³ / wpcs). The overflow time was set to 100s and the overflow rate to 1600L / H in this actual test. The specific data are shown in Table 2 below: Table 2 Comparison of pure water consumption before and after overflow modification As can be seen from Table 2, the actual test basically achieved the linkage control of production capacity and water consumption, and the cleaning effect was not affected while reducing consumption, thus achieving a balance between water conservation and cleanliness. The benefits of water conservation are calculated as follows: 1. Production capacity control scenario: When the production capacity of the workshop is reduced by 5wpcs, 10m³ of pure water can be saved; 2. Maintenance / Abnormal Scenarios: The water-saving effect is significant during the production capacity control period of the wet process. For example, the monthly maintenance capacity loss of a certain production line is about 660,000, and the estimated water saving of wet process is 130 m³. Combined with the cost of pure water and treatment costs, the monthly revenue can be about 2,500 yuan.

[0021] This invention successfully establishes a linear relationship between pure water consumption and production capacity and process requirements, transforming the water overflow mode from "passive discharge" to "active control." This effectively solves the problem of excessive pure water supply to workshop machines under low production capacity conditions, while not adversely affecting the pressure of power waste treatment, thus achieving efficient resource utilization and optimized management of the production process.

[0022] In summary, the successful implementation of the two core ideas outlined above has achieved the practical goals of water consumption optimization and cost control. Through the coordinated management of production capacity and water consumption, this invention achieves a dual improvement in water conservation and economic benefits while ensuring production efficiency. It provides a feasible and scalable technical reference for the low-carbon and high-efficiency development of photovoltaic cell manufacturing. The technical solution of this invention is innovative, practical, and operable, and is expected to be widely applied in the photovoltaic cell manufacturing industry, promoting the industry's green and sustainable development.

[0023] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for reducing pure water consumption in the wet process of Topcon photovoltaic cells, characterized in that, Includes the following steps: S1: Operation Procedure 1: Replace with a large-range flow meter and match an overflow pipe of the same diameter according to the actual flow demand. Operators can establish a dynamic adjustment mechanism to match the daily pure water consumption with the production line by adjusting the pure water mode and flow rate. S2: Operation Procedure 2: Selectively shield the corresponding tank. Through the operation interface of the tank machine and the actual process flow, select the corresponding tank for shielding and skipping settings. After the settings are completed, the system will automatically record the shielding information and execute the settings in the subsequent production process. S3: Production Operation: During the production process, the tanks that are shielded and skipped do not participate in the material flow and do not consume pure water. Other normally operating tanks are cleaned according to the preset process parameters. S4: Pure water overflow control: Matching the production line process by optimizing the overflow of each pure water tank; S5: Effect Evaluation: Evaluate the water-saving effect of pure water by monitoring and analyzing production data.

2. The method for reducing pure water consumption in the wet process of Topcon photovoltaic cells according to claim 1, characterized in that, The flow meter described in step S1 has a flow range of 1500 L / H to 1700 L / H.

3. The method for reducing pure water consumption in the wet process of Topcon photovoltaic cells according to claim 2, characterized in that, The diameter of the overflow pipe in step S1 is 23 to 27 mm.

4. A method for reducing pure water consumption in the wet process of Topcon photovoltaic cells according to claims 1 and 2, characterized in that, Step S1 describes establishing a dynamic adjustment mechanism to match the daily pure water consumption with the production line by adjusting the pure water mode and flow rate; and precisely controlling the process parameters, with the overflow time adjustable in the range of 10s-150s and the overflow flow rate adjustable in the range of 0-1700L / H.

Images