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Large Scale Roll-To-Roll Produced Organic Photovoltaic Devices: Manufacturing, Lifetime and Environmental Impact

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Large Scale Roll-To-Roll Produced Organic Photovoltaic Devices: Manufacturing, Lifetime and Environmental Impact Downloaded from orbit.dtu.dk on: Apr 20, 2018 Large scale roll-to-roll produced organic photovoltaic devices: manufacturing, lifetime and environmental impact Benatto, Gisele Alves dos Reis Publication date: 2017 Document Version Publisher's PDF, also known as Version of record Link back to DTU Orbit Citation (APA): Benatto, G. A. D. R. (2017). Large scale roll-to-roll produced organic photovoltaic devices: manufacturing, lifetime and environmental impact. Department of Energy Conversion and Storage, Technical University of Denmark. General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. • Users may download and print one copy of any publication from the public portal for the purpose of private study or research. • You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately and investigate your claim. TECHNICAL UNIVERSITY OF DENMARK LARGE SCALE ROLL-TO-ROLL PRODUCED ORGANIC PHOTOVOLTAIC DEVICES: MANUFACTURING, LIFETIME AND ENVIRONMENTAL IMPACT PH.D. THESIS GISELE ALVES DOS REIS BENATTO JANUARY 2017 Author: Gisele Alves dos Reis Benatto Title: Large Scale Roll-to-roll Produced Organic Photovoltaics Devices: Manufacturing, Lifetime and Environmental Impact Supervisor: Professor Frederik Christian Krebs Co-supervisor: Dr. Nieves Espinosa Martinez Assessment committee Professor Jens Wenzel Andreasen, Technical University of Denmark Professor David M. Tanenbaum, Pomona College, CA, USA Associate Professor Ergang Wang, Chalmers University of Technology, Sweden Date of defence: 9 March 2017 Sponsorship: Energinet.dk. Grant Number: 12144 Danish Ministry of Science, Innovation and Higher Education. Grant Number: DFF-1335-00037A ISBN: 978-87-92986-60-3. __________________________________________________________________________ DTU Energy Department of Energy Conversion and Storage Technical University of Denmark OEM - Organic Energy Materials Risø Campus Frederiksberg 399 4000 Roskilde, Denmark [email protected] http://www.energy.dtu.dk/ “The first and last thing which is required of genius is the love of truth.” Johann Wolfgang von Goethe i Preface The present Ph.D. Thesis contains the main results obtained during the three years of Ph.D. studies at the Technical University of Denmark (DTU), from 15th January 2014 to 14th January 2017. The vast majority of the work was carried out at the Organic Energy Materials (OEM) section in the Department of Energy Conversion and Storage (DTU Energy), located at Risø Campus, Roskilde, Denmark. During this period, collaborations with the School of Electronic Engineering in Bangor University and University of Applied Sciences and Arts Northwestern Switzerland (FHNW) in Basel, Switzerland where performed. While the former corresponded to 5 months external stay. This work was funded by the Danish Ministry of Science, Innovation and Higher Education grant number: DFF-1335-00037A, and Energinet.dk grant number: 12144. The structure of the thesis This thesis is focused on large scale manufacture, operational lifetime and environmental impact assessment of organic photovoltaics (OPV). This is done by using established methodologies and also developing new setups. A brief introduction to energy demand, resources, solar energy, and photovoltaics generations is given in Chapter 1; along with a general description the OPV technology, research challenges, and contributions to the literature. The following chapter describes printing and coating techniques for large scale OPV production and the statistics of four different OPV devices in the size of postcards. Such OPV modules were based on carbon electrodes, and Chapter 3 presents the life-cycle assessment methodology applied to evaluate such modules environmental performance in comparison to OPV with metal-based electrodes. Environmentally friendly OPV modules can use the strategy of using no metals at all or use lower amounts of it. OPV modules using both these strategies have their operational lifetime tested in Chapter 4, including eight different OPV technologies. To verify if a new technology is truly green, outdoor leaching setups were developed simulating real outdoor use phase and disposal in a landfill. Such experiments and their outcomes are described in Chapter 5. Chapter 6 describes a full product which includes an OPV panel, compared with 2 other similar products already established in the market. Lastly, the overall conclusions and outlook are presented in Chapter 7. The total contribution of this work to the literature comprises so far of 13 peer-reviewed publications. 12 of them are included in the appendix, as they are better connected to this Ph.D. thesis. Acknowledgements I still remember that, seven years ago when I was reading Frederik’s publications, how it would be to work in DTU with him, in such productive group. Today I know that the research that comes from his group goes far beyond anything I could imagine and that the environment is better than I had ever idealized. I thank Frederik Krebs immensely, for giving me the opportunity to be supervised by him. In these three years he was always available when I needed, always good natured, and with the mind full of amazing ideas that inspired me immensely and still does. I thank also Eva for calling me and give the news that I was selected for the PhD position, and for this great time in OEM, for her help and smiles. I thank Mikkel for being permanently helpful among his fascinating and fruitful work. ii In the beginning when you first come to a new place, and later, there are so many things to solve. For this I thank hugely Bente and Birgit for all the careful assistance in all kinds of paper work and documentation. Birgit especially, for the essential help with the abstract translation and frequent willingness for helping. I hugely thank also Nieves, for her close and continuous help, guidance and friendship. Her intelligence and open attitude motivated me every time during these three years. I thank also greatly for the fast and super-efficient help from Kristian, Torben and Martin. Ole and June for the Danish conversation practice. And for the breakfast club members for such nice time every Friday morning. I would like to especially thank Morten and Markus for the proof reading of several chapters of this thesis. I thank Nieves again for her time dedicated in these last writing months. I thank Suren, Roar, Thue, Ilona, and Tiago as well for the help with corrections. From the people I had the pleasure to know in my stay in Basel, Switzerland, I thank Markus Lenz for the valuable and dedicated guidance; Yannick Zimmerman for the real high quality training, teaching, countless help and great time; and finally Éva Ujaczki and Karen Viacava for the kind and sincere friendship. Thank you all my amazing colleagues: Michael, Bérenger, Francesco Livi, Dechan, Francesco Pastorelli, Michail, Lea, Emil, Mariana, Tiago, Jacob and Henrik, Jon and Martin, Markus, Thue, Morten, Suren, and Rafael; for the funniest talks, high level talks, scientific discussions, and the highly motivating conversations. Thank you Ilona for such special and tight friendship! So many stories told, lived, experimental problems being solved and scientific discussions all in between. These whole three years and even more this last year, have been unique for me because of her. I finally thank my husband Herick for his strong confidence in what is possible, for his company and endless laughing times, and his intense belief in me and my capacity that were essential for the development of the PhD studies. Finally, I thank my parents Nelson and Helena, more than anything, for my existence. Risø campus, 14th January 2017. Gisele Benatto. iii Abstract The world energy production has risen intensely during the last decades bringing human development until the point that our current society cannot function without it. Two-thirds of global greenhouse gas emissions, along with other releases which can be highly harmful to humans and the ecosystem come from electricity production. Consequentially, the need for clean, renewable and sustainable ways of energy production rises up, due to pollutants and the finite nature of fossil fuels. Solar energy is by far the most abundant renewable resource available and fulfils the requirements of a truly green energy resource. The most efficient form of harvesting energy from the sun is through photovoltaics (PV) devices, for which the most used technology require high amounts of materials and energy, and brings several drawbacks to overall solar energy production such as high price and long energy payback times (EPBT). The development of new PV technologies brought a new horizon to the PV industry in terms of cost and applications. Organic photovoltaics (OPV) has the shortest EPBT and can avoid the use of high energy demanding processes and hazardous elements, with low environmental impacts over its entire life cycle of the system, i.e., from its manufacturing through its deployment and operation up to its final disposal. As OPV comes about as an emerging technology just about to be commercialised, this thesis demonstrates the reproducible production of vacuum-, indium tin oxide (ITO)-, and silver-free OPV. The fast roll-to-roll (R2R) processing of these devices can bring such low costs to OPV that it balances its lower efficiencies and lifetime compared with other PV technologies. Such silver-free devices use carbon as electrode material instead and represent a potential truly green technology. To evaluate the truly environmental friendliness of OPVs, four electrodes alternatives have been assessed using the life-cycle assessment (LCA) methodology, indicating that metal based electrodes are the major contributors to the environmental burden of the OPV modules.
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