Recycling Old Car Batteries to Make Solar Cells

Recycling Car Batteries

Researchers at MIT are proposing a system that recycles materials from old car batteries, a potential source of lead pollution, into new, long-lasting solar panels that provide emissions-free power.

 

The system is described in a paper published in the journal Energy and Environmental Science, co-authored by professors Angela M. Belcher and Paula T. Hammond, graduate student Po-Yen Chen, and three others.

 

It is based on a recent development in solar cells that makes use of a compound called perovskite, specifically, organolead halide perovskite, a technology that has rapidly progressed from initial experiments to a point where its efficiency is nearly competitive with that of other types of solar cells.

 

“It went from initial demonstrations to good efficiency in less than two years,” says Belcher, the W.M. Keck Professor of Energy at MIT. Already, perovskite-based photovoltaic cells have achieved power-conversion efficiency of more than 19 percent, which is close to that of many commercial silicon-based solar cells.

 

The perovskite technology uses lead, whose production from raw ores can produce toxic resides, as a drawback. But by using recycled lead from old car batteries, the manufacturing process can instead be used to divert toxic material from landfills and reuse it in photovoltaic panels that could go on producing power for decades.

 

Another benefit to using this technology is, since the perovskite photovoltaic material takes the form of a thin film, just half a micrometer thick, the team’s analysis shows that the lead from a single car battery could produce enough solar panels to provide power for 30 households.

 

As an added advantage, the production of perovskite solar cells is a relatively simple and benign process. “It has the advantage of being a low-temperature process, and the number of steps is reduced” compared with the manufacture of conventional solar cells, Belcher says.

 

Those factors will help to make it “easy to get to large scale cheaply,” Chen adds.

 

One motivating reason for using the lead in old car batteries is that battery technology is undergoing rapid change, with new, more efficient types, such as lithium-ion batteries, swiftly taking over the market. “Once the battery technology evolves, over 200 million lead-acid batteries will potentially be retired in the United States, and that could cause a lot of environmental issues,” Belcher says.

 

Today, she says, 90 percent of the lead recovered from the recycling of old batteries is used to produce new batteries, but over time the market for new lead-acid batteries is likely to decline, potentially leaving a large stockpile of lead with no obvious application.

 

In today’s solar panels, the lead containing layer is fully encapsulated by other materials. This limits the risk of lead contamination of the environment. When the panels are eventually retired, the lead can simply be recycled into new solar panels.

 

“The process to encapsulate them will be the same as for polymer cells today,” Chen says. “That technology can be easily translated.”


“It is important that we consider the life cycles of the materials in large-scale energy systems,” Hammond says. “And here we believe the sheer simplicity of the approach bodes well for its commercial implementation.”

 

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