Photovoltaic Module Resin Removal With Controlled Oxygen Combustion
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Solution Overview
Problem
Existing methods for recycling photovoltaic modules face challenges with incomplete thermal decomposition of polyethylene terephthalate (PET) back sheets, leading to soot formation and difficulty in recovering valuable materials due to unstable temperature control and high oxygen concentrations, especially in continuous treatment processes.
Innovation Solution
A method involving continuous heat treatment of photovoltaic modules on a ceramic support placed on a porous material carrying a transition metal oxide, with controlled oxygen concentration between 6-15% by volume, allowing for stable temperature control and gentle combustion of resin components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high oxygen concentration (15% or more) is used in the heating furnace, then resin components can be rapidly combusted and removed, but rapid combustion occurs causing unstable temperature control and difficulty in continuous operation
Solution Approach 1:
The patent changes the oxygen concentration parameter from high (15% or more) to controlled low (6-15% by volume) to suppress rapid combustion while maintaining continuous operation stability. This parameter adjustment resolves the contradiction by enabling steady temperature control during continuous photovoltaic module processing.
Solution Approach 2:
The patent introduces a porous catalyst layer containing metal oxides (such as manganese oxide, cobalt oxide, or nickel oxide) as an intermediary substance. This catalyst layer mediates the combustion process by promoting resin decomposition and combustion at lower oxygen concentrations, enabling stable temperature control while maintaining productivity in continuous operation.
2Loss of substance
If thermal decomposition is performed at around 450°C, then resin components can be decomposed, but explosive combustion occurs causing fire hazards and unsuitability for large-scale operation
Solution Approach 1:
The patent adjusts the temperature parameter from high (450°C causing explosive combustion) to controlled range (300-400°C in the first stage, then 400-550°C in the second stage) combined with controlled oxygen concentration (6-15%). This resolves the contradiction by enabling complete resin decomposition while preventing explosive combustion and fire hazards.
Solution Approach 2:
The patent divides the thermal processing into two stages: first stage (300-400°C) for preliminary decomposition and second stage (400-550°C) for complete combustion. This segmentation prevents explosive combustion by gradually decomposing resin components before complete combustion, eliminating fire hazards while maintaining decomposition effectiveness.
3Object-affected harmful factors
If oxygen concentration is controlled to very low levels (1.0-3.0% by volume) to prevent rapid combustion, then resin decomposition can occur without explosive reaction, but the operation becomes complicated and requires considerable skill
Solution Approach 1:
The patent introduces a porous catalyst layer as an intermediary that enables resin decomposition and combustion control at higher oxygen concentrations (6-15%) compared to conventional methods (1.0-3.0%). This catalyst mediation simplifies operation by eliminating the need for very low oxygen control while preventing rapid combustion through catalytic control of the decomposition process.
Solution Approach 2:
The patent increases the oxygen concentration parameter from very low (1.0-3.0%) to moderate levels (6-15%) while using catalyst support to maintain combustion control. This parameter change improves ease of operation by allowing higher oxygen levels that are easier to control while still preventing rapid combustion through catalytic mediation.
4Productivity
If continuous heat treatment is performed in an oxidizing atmosphere, then large-scale photovoltaic module processing is enabled, but unstable temperature control prevents consistent resin removal
Solution Approach 1:
The patent introduces a porous catalyst layer containing metal oxides as an intermediary that enables continuous heat treatment with stable temperature control. The catalyst promotes consistent resin decomposition and combustion reactions, enabling large-scale photovoltaic module processing while maintaining reliable and consistent temperature control throughout the continuous operation.
Solution Approach 2:
The patent optimizes the oxygen concentration parameter to a specific range (6-15% by volume) that enables stable combustion in continuous operation. This parameter optimization, combined with catalyst support, resolves the contradiction by enabling large-scale continuous processing while maintaining consistent temperature control for reliable resin removal.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables effective removal of resin components without soot formation, facilitating the recovery of valuable materials like glass, cells, and aluminum frames by suppressing rapid combustion reactions.
Implementation Method 1
a porous material (B) carrying a transition metal oxide is used... oxidatively decompose resin components... suppressing rapid combustion reactions
Implementation Method 2
the photovoltaic module is placed on a porous ceramic support (A), and the ceramic support (A) is placed on a porous material (B)... stable temperature control
Implementation Method 3
heating a photovoltaic module... to melt and oxidatively decompose resin components... oxygen concentration in the combustion section is controlled
Implementation Method 4
oxygen concentration in the combustion section is controlled to a range from 6 vol % to less than 15 vol %... suppressing rapid combustion reactions
Data Source
AI summary
This waste photovoltaic module processing method is a method of continuously treating a waste photovoltaic module. The method includes a heating step of heating a photovoltaic module having a resin back sheet, etc. in a thermal decomposition furnace to melt and oxidatively decompose resin components included in the photovoltaic module, in which the heating step is performed by moving the photovoltaic module in the thermal decomposition furnace from an inlet of the thermal decomposition furnace toward an outlet in a state where the photovoltaic module is placed on a porous ceramic support (A), and the ceramic support (A) is placed on a porous material (B) carrying a transition metal oxide, and an inside of the thermal decomposition furnace includes a temperature rising section in a stage where a temperature of the photovoltaic module rises, and a combustion section in a stage where the resin components are oxidatively decomposed, and an oxygen concentration in the combustion section is controlled to a range from 6 vol % to less than 15 vol %.