Abstract :
[en] The limited theoretical capacity of graphite restricts the energy density of next-generation lithium-ion batteries (LIBs) required for high-demand applications. Silicon (Si), with nearly tenfold higher theoretical capacity, is a promising alternative. However, its practical deployment remains limited by extreme volume expansion, unstable solid electrolyte interphase (SEI), and loss of electrical connectivity during electrochemical cycling.
While several Si-based anode active material (AAM) technologies have been scaled, most rely on gas-phase synthesis or commercial Si nanoparticles, which are energy-intensive and costly due to high-purity precursor requirements. In contrast, solar-grade Si recovered from end-of-life (EoL) photovoltaic (PV) modules offers a sustainable and cost-effective alternative.
In this work, we demonstrate a scalable process to upcycle PV-derived Si into high-performance Si/C composite anodes (GREEnSiBat-Si). Using pilot-scale spray drying, we achieved controlled morphology and consistent quality, reaching technology readiness level (TRL) 6-7. A dual carbon scaffold, combining polymer-derived carbon and carbon nanotubes (CNTs), enhances electronic conductivity and mitigates structural degradation. The resulting anodes deliver high capacity and robust cycling stability, demonstrated at the 2.2 Ah multilayer pouch cell level.
Further integration of graphene oxide coatings and Si/C:SnS2 hybrid structures demonstrates the versatility of this platform for advanced AAM design [1,2]. This work establishes a practical and sustainable pathway for large-scale valorization of PV waste into high-energy LIB technologies.
References:
[1] 1. N. Eshraghi, H. Oubaha, A. Schrijnemakers, L. Fkhar, J. Bodart, V. Delaval, R. Cloots, F. Boschini, A. Mahmoud. J. Power Sources 661, 238585 (2026).
[2] 2. L. Fkhar, H. Oubaha, A. Schrijnemakers, A. Bekzhanov, D. Cupid, F. Boschini, R. Cloots, A. Mahmoud. J. Energy Storage 162, 122007 (2026).
