Browsing by Subject "ferrosilicon"

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Access status: Open Access ,
Investigation of Ferrosilicon produced with Si recovered from end-of-life photovoltaic panels
(2025) Kuśmierczyk, Filip; Kopyściański, Mateusz; Rai, Adarsh; Kozieł, Tomasz; Goły, Marcin; Kopia, Agnieszka; Migas, Piotr; Karbowniczek, Mirosław; Padhamnath, Pradeep
Wydział Inżynierii Metali i Informatyki Przemysłowej
Recycling end-of-life (EOL) silicon (Si) PV modules have gathered recent attention from researchers. PV modules can be recycled using a closed loop cycle where the materials recovered are reinjected into the supply chain for producing new modules. However, such solutions are extremely complex, expensive and could lead to further generation of harmful chemicals or emissions. Another way to recycle c-Si PV modules is by using them to produce other commercially important materials, for example ferrosilicon, using an easy and inexpensive route. Ferrosilicon is produced by reduction of silica using carbonaceous sources, which generates planet warming greenhouse gases. In this work, we present a simple method to use recycled Si (reSi) obtained from EOL PV modules to produce FeSi using induction furnace and no carbonaceous source. Along with reSi, metallurgical grade Si and commercial FeSi75 were also used to produce FeSi samples for comparison. FeSi samples with different silicon content were prepared. We also investigate the effect of the oxygen in the processing atmosphere, by preparing samples in arc furnace under argon atmosphere. The samples were characterized using scanning electron microscope coupled with Energy dispersive X-ray spectroscopy, to analyse the microstructure. X-ray diffraction was also used to identify and compare the phases formed in different samples. Hardness of the samples was also determined to understand the ease in the mechanical processing of the samples for potential commercial applications. Through the experimental results we have shown that silicon recovered from EOL PV panels could be used in the fabrication of FeSi.
Access status: Open Access ,
Realization of a Novel FeSiAlCuSn Multicomponent Alloy and Characterization of Intermetallic Phases Formed at Different Temperatures During Cooling
(2025) Kuśmierczyk, Filip; Padhamnath, Pradeep; Kopyściański, Mateusz; Gondek, Łukasz; Migas, Piotr; Karbowniczek, Mirosław
Wydział Inżynierii Metali i Informatyki Przemysłowej
Ferrosilicon (FeSi) is a commercially important material with multiple uses in metallurgical processes. Recently, in an attempt to reduce the carbon impact of the FeSi production process, researchers have proposed using recycled Si recovered from electronic waste in the production of FeSi. However, Si recovered from electronic waste usually contains Al, Cu, and Sn as impurities. Hence, FeSi alloys produced with recycled Si from electronic waste may contain all these elements in varying proportions. Al, Cu, and Sn have been explored as alloying elements to produce alloys with Fe. FeSiAl alloys have also been studied recently for their superior properties. In this work, a multicomponent FeSiAlCuSn alloy is produced, and the phases formed at different temperatures are analyzed using different phase identification techniques. We also analyze the hardness of the multicomponent alloy to find any deviation from the standard FeSi alloy without the additional alloying elements. Understanding the phases and the composition of such alloys may help design future multi-component or high-entropy alloys involving Fe, Si, Al, Cu, and Sn for specific applications.
Access status: Open Access ,
Simulation of the effect of impurities in recycled silicon used for the for the production of ferrosilicon
(2025) Padhamnath, Pradeep; Migas, Piotr; Karbowniczek, Mirosław
Wydział Inżynierii Metali i Informatyki Przemysłowej
Decarbonization of steel making and allied processes have been receiving immense attention of researchers. Similarly, recycling of waste resources and conversion or recovery of useful materials from waste destined for landfills to mitigate environmental impact, is also an important area of research. Ferrosilicon (FeSi) is currently produced using carbothermic reduction and an energy intensive process. However, silicon (Si) from electronic wastes could be combined with scrap steel to produce FeSi. The Si from electronic waste will, however, contain some impurities such as Aluminium (Al), copper (Cu) and Tin (Sn), which could be incorporated into the FeSi produced from such Si. Hence, in this work the impact of the impurities on the properties of FeSi was investigated theoretically and systematically with the help of FactSage simulations. The impact of three major impurities associated with recycled Si (Al, Cu and Sn) were analysed when present individually and then all together. The analysis was done with the help of phase diagrams for solidification process occurring under equilibrium conditions. It was found that the impurities impact the proportion of the final phases and the melting and phase-transition temperatures. Further, the presence of different intermetallic phases could impact the mechanical properties of the alloy as well. The presence of three impurities together with Fe and Si leads to a complex multicomponent system. While further experiments are needed to identify the actual phases formed during such process, this work provides as framework for carrying out such experiments in the future.
Access status: Open Access ,
Technologies for resource-efficient recycling of end-of-life crystalline silicon photovoltaic panels
(2025) Nalluri, Srinath; Kuśmierczyk, Filip; Padhamnath, Pradeep; Kopyściański, Mateusz; Karbowniczek, Mirosław
Wydział Inżynierii Metali i Informatyki Przemysłowej
Global PV installations recently crossed the terawatt scale. The growth of photovoltaic (PV) installations is an important and desirable element in generating clean electricity and combating climate change. However, with increased use of PV panels for energy production enormous volumes of PV waste would be generated that would need to be dealt with in an environmentally responsible manner. In this work we present early-stage research results based on experiments conducted with recycling end-of-life (EOL) crystalline silicon (c-Si) PV panels promoting resource efficiency and circularity. We explore experimental pathways for both close-loop and open-loop recycling of EOL PV panels. For closed-loop recycling we present experimental results using the recently developed electrohydraulic shock wave-based fragmentation (EHF) of PV panels. The EHF process allows for the recovery of almost all valuable materials used in the manufacturing of PV panels. We further provide a succinct literature review for further downstream treatment of the end products obtained after EHF processing of EOL PV panels to recover precious metals such as Silver. For open-loop recycling, we propose using the panels in the production of ferrosilicon compounds, thereby reducing the emissions of greenhouse gases accompanied with their production. Through experiments it was onbserved that the size of the recycled Si does not impact the microstructure of the FeSi produced, which means that the technology could be easily used to handle different sizes of Si source. Through careful experiments and analysis we provide recycling methods to improve the circularity and resource efficiency in the management of end-of-life c-Si PV panels. Both experimental recycling pathways discussed in this work could potentially provide sustainable technical pathways to recycle EOL PV modules, which does not involve producing harmful greenhouse gases.
Access status: Open Access ,
Theoretical investigation of the impact of impurities in recycled silicon used for the production of ferrosilicon
(2024) Padhamnath, Pradeep; Migas, Piotr; Karbowniczek, Mirosław
Wydział Inżynierii Metali i Informatyki Przemysłowej