Dr Shahaboddin Resalati

The exponential growth of electric and hybrid vehicles, now numbering close to 6 million on the roads, has highlighted the urgent need to address the environmental impact of their lithium-ion batteries as they approach their end-of-life stages. Repurposing these batteries as second-life batteries (SLBs) for less demanding non-automotive applications is a promising avenue for extending their usefulness and reducing environmental harm. However, the shorter lifespan of SLBs brings them perilously close to their ageing knee, a critical point where further use risks thermal runaway and safety hazards. To mitigate these risks, effective battery management systems must accurately predict the state of health of these batteries. In response to this challenge, this study employs time-series artificial intelligence (AI) models to forecast battery degradation parameters using historical data from their first life cycle. Through rigorous analysis of a lithium-ion NMC cylindrical cell, the study tracks the trends in capacity and internal resistance fade across both the initial and second life stages. Leveraging the insights gained from first-life data, predictive models such as the Holt–Winters method and the nonlinear autoregressive (NAR) neural network are trained to anticipate capacity and internal resistance values during the second life period. These models demonstrate high levels of accuracy, with a maximum error rate of only 2%. Notably, the NAR neural network-based algorithm stands out for its exceptional ability to predict local noise within internal resistance values. These findings hold significant implications for the development of specifically designed battery management systems tailored for second-life batteries.

The increasing number of electric vehicles (EVs) on the roads has led to a rise in the number of batteries reaching the end of their first life. Such batteries, however, still have a capacity of 75–80% remaining, creating an opportunity for a second life in less power-intensive applications. Utilising these second-life batteries (SLBs) requires specific preparation, including grading the batteries based on their State of Health (SoH); repackaging, considering the end-use requirements; and the development of an accurate battery-management system (BMS) based on validated theoretical models. In this paper, we conduct a technical review of mathematical modelling and experimental analyses of SLBs to address existing challenges in BMS development. Our review reveals that most of the recent research focuses on environmental and economic aspects rather than technical challenges. The review suggests the use of equivalent-circuit models with 2RCs and 3RCs, which exhibit good accuracy for estimating the performance of lithium-ion batteries during their second life. Furthermore, electrochemical impedance spectroscopy (EIS) tests provide valuable information about the SLBs’ degradation history and conditions. For addressing calendar-ageing mechanisms, electrochemical models are suggested over empirical models due to their effectiveness and efficiency. Additionally, generating cycle-ageing test profiles based on real application scenarios using synthetic load data is recommended for reliable predictions. Artificial intelligence algorithms show promise in predicting SLB cycle-ageing fading parameters, offering significant time-saving benefits for lab testing. Our study emphasises the importance of focusing on technical challenges to facilitate the effective utilisation of SLBs in stationary applications, such as building energy-storage systems and EV charging stations.

Thin film solar cells offer several benefits over conventional first-generation technologies including lighter
weight, flexibility, and a wider range of optoelectronic tunability. Their environmental impact however needs to be investigated comprehensively to provide a clear comparison point with the first generation photovoltaics currently dominating the market. The main objective of this review is to evaluate current Life Cycle Assessment (LCA) studies conducted on thin film solar cells, highlighting the key parameters considered including life cycle stages, impact categories, and geographical locations. This included both commercially available thin film solar cells (a-Si, CIGS, CIS, CdTe, GaAs and GaAs tandem) as well as emerging (PSC, PSC tandem, DSSC, OPV, CZTS, QD) ones. A critical assessment of the results of 58 LCA studies was conducted and compared with traditional silicon based solar cells. Results indicate that emerging thin film solar cells hold great promise, as they tend to perform better than commercially available ones in the specified indicators, especially for CZTS and OPV. The assessment demonstrated that overall thin film solar cells had less energy requirement and better environmental performance than conventional crystalline silicon solar cell systems. However, due to their lower efficiencies, their energy payback time was higher. This review provides a benchmark for the environmental LCA of different thin film solar cell technologies in order to highlight the relevance of these devices for sustainable energy generation and to give manufacturers and LCA experts information and a basis for future evaluation of solar cells.

Nano-structured fumed silica (FS) is the most used vacuum insulation panel (VIP) core material for building applications. However, the FS VIP core has the majority of the environmental burden associated with conventional VIP manufacture and FS-based VIPs are very expensive. This paper explores aluminium anodizing sludge (ALW), a residue from the aluminium industry, as a new substitute for FS in VIP cores. Al-rich sludge waste is thoroughly characterised, and 100%-based ALW and its hybrid core mixtures with FS are formulated to produce VIPs cores, which are then evaluated. ALW was observed as aggregated clusters of nanosized individual particles in round and smooth-shaped forms typical of hydrated gel-like pure amorphous materials. The microstructure system of the sole ALW VIP core is found to be dissimilar to that of an FS VIP core, with the pore size range of 0.1–0.8 μm for the former and 0.01–0.04 μm for the latter, but the overall volume of large pores being much higher for the FS than ALW cores. The hybridization of ALW and FS resulted in a restructure of the initial ALW core systems. While the thermal conductivity of the ALW VIP core is less proficient than that of the single FS core, the effective thermal conductivity of both ALW50FS50 and ALW25FS75 core compositions at 1 Pa even suppressed that of the sole FS core, presenting 5.8 mW m−1·K−1 against 6.3 mW m−1·K−1 respectively. A life cycle assessment (LCA) study of these hybrid core solutions was also conducted to illustrate the positive environmental benefit of ALW-based VIP compared to FS-based VIP production. The study highlights the potential of using industrial residue ALW in VIP production, contributing to developing more sustainable superinsulation materials.

Kesterite-based structures are being extensively studied for solar module productions due to their earth abundant and nontoxic nature, high absorption coefficient, and a wide variety of scalable deposition methods. Kesterites are mostly manufactured using thin-film technology. However, in the last decade, the monograin approach has gained further attention, providing a third alternative to mono-crystalline wafer and thin film methods. This is due to its high throughput, low-cost deposition techniques, flexibility, and light weight. Despite the technical advancements in the monograin technology, their environmental impacts have not been studied in the literature. This paper, for the first time, presents a cradle to gate environmental life cycle assessment of CZTS monograin module production. The analysis is designed to identify the environmental hotspots associated with materials, energy usage, and manufacturing processes. The results were compared to CZTS thin-film and the commercially available CIGS technologies. The analyses suggested that the front contact accounted for the majority of impact in all categories due to the use of silver. The normalisation results showed that the marine aquatic ecotoxicity impact category dominated the overall impact results. A comparison of CZTS monograin and thin film production demonstrated that monograin outperformed the thin film technology when silver was substituted with alternative materials and was proximate to CIGS even considering their higher achieved efficiency. The analysis presents considerable environmental benefits associated with the monograin technology. Further savings in emissions could be achieved with improved conversion efficiency and usage of renewable energy sources in the manufacturing stages.

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The service life of Lithium-ion batteries disposed from electric vehicles, with an approximate remaining capacity of 75–80%, can be prolonged with their adoption in less demanding second life applications such as buildings. A photovoltaic energy generation system integrated with a second life battery energy storage device is modelled mathematically to assess the design’s technical characteristics. The reviewed studies in the literature assume, during the modelling process, that the second life battery packs are homogeneous in terms of their initial state of health and do not consider the module-to-module variations associated with the state of health differences. This study, therefore, conducts mathematical modelling of second life battery packs with homogenous and heterogeneous state of health in module level using second-order equivalent circuit model (ECM). The developed second-order ECM is validated against experimental data performed in the lab on 3Ah NCM batteries. The degradation parameters are also investigated using the battery cell’s first life degradation data and exponential triple smoothing (ETS) algorithm. The second-order ECM is integrated with the energy generation system to evaluate and compare the performance of the homogenous and heterogeneous battery packs during the year. Results of this study revealed that in heterogeneous packs, a lower electrical current and higher SOC is observed in modules with lower state of health due to their higher ohmic resistance and lower capacity, compared to the other modules for the specific battery pack configuration used in this study. The methodology presented in this study can be used for mathematical modelling of second life battery packs with heterogenous state of health of cells and modules, the simulation results of which can be employed for obtaining the optimum energy management strategy in battery management systems.

The design and performance optimization of fully electric trucks constitute an integral goal of the transport sector to meet climate emergency measures and local air quality requirements. Most studies in the literature have determined the optimum pack size based on economic factors, without accounting for the details of pack behavior when varying the size. In this paper, the effect of battery pack sizing and cargo capacity of a class 8, 41-ton truck on its overall energy performance and technical parameters of its powertrain is investigated. For this purpose, the proposed electric truck is designed and mathematically modelled using AVL CRUISE M software. The second-order equivalent circuit model is developed to predict the battery packs’ parameters. The proposed battery pack model is extracted from experimental analysis on SONY VTC6 lithium-ion batteries performed in the lab. The weight changes due to adding the battery packs to the truck are also estimated and have been taken into account. The mathematical model of the powertrain is simulated in the long-haul driving cycle considering different cargo capacities and battery pack sizes. The results of this study revealed that the battery pack voltage reached its minimum value when the maximum cargo capacity was applied for the 399 kWh battery pack. In addition, increasing the occupied cargo capacity from 10% to 100% resulted in an increase in the regenerative brake energy of up to 9.87 kWh, while changing the battery size imposed minimal impacts on regenerative brake energy recovery as well as energy consumption.

Perovskite solar cells (PSCs) have moved to the forefront of emerging thin-film solar cell research in just a
decade, demonstrating the most promising efficiency records. These technological advancements however, were primarily tested at laboratory scale and there remains significant issues in relation to the scalability of the deposition methods utilised. Inkjet printing, initially used for printed electronics, has recently been applied to solar cell production and demonstrated promising potential for scaling up. Despite various studies that have assessed the technical feasibility of utilising inkjet printing, their environmental performance has not been investigated. This paper, for the first time, presents a comprehensive Life Cycle Assessment (LCA) study of inkjet printing-based PSCs, on a cradle-to-gate basis using GaBi LCA software. The results were compared with those of spin-coating, as the most widely studied deposition method, and demonstrated significant improvement in all impact categories. Global warming potential (GWP) and cumulative energy demand (CED) were used as proxies to compare results obtained in this paper with available studies in the literature. The comparison demonstrated that inkjet printing of PSCs had a GWP and CED of 7.54 kg CO2eq/m2 and 200.18 MJ/m2 while spin-coating had a reported median value of 74.5 kg CO2eq/m2 and 1204 MJ/m2 respectively. This suggests considerable environmental advantage for the inkjet method. The paper also assesses a novel green solvent-based precursor ink investigating the environmental benefits of eliminating the toxic and hazardous solvent materials commonly used in wet chemical deposition of perovskite layers. The green solvent-based precursor ink results demonstrated
significant improvement over conventional solutions with up to six orders of magnitude lower impacts. The LCA results obtained in this paper contributes to forming a full assessment of the development of scalable deposition methods such as inkjet printing by highlighting their environmental hotspots and advantages. The paper also identifies potential opportunities for perovskite precursor ink material composition improvements for sustainable development of PSCs. This will assist in addressing their associated environmental concerns in relation to the use of high-impact toxic solvents.

Thin-film photovoltaics (PV) cells offer several benefits over conventional first-generation PV technologies, including lighter weight, flexibility, and lower power generation cost. Among the competing thin-film technologies, chalcogenide solar cells offer promising performance on efficiency and technological maturity level. However, in order to appraise the performance of the technology thoroughly, issues such as raw materials scarcity, toxicity, and environmental impacts need to be investigated in detail. This paper therefore, for the first time, presents a cradle to gate life cycle assessment for four different emerging chalcogenide PV cells, and compares their results with copper zinc tin sulfide (CZTS) and the commercially available CIGS to examine their effectiveness in reducing the environmental impacts associated with PV technologies. To allow for a full range of indicators, life cycle assessment methods CML 2001, IMPACT 2002+, and ILCD 2011 were used to analyse the results. The results identify environmental hotspots associated with different materials and components and demonstrate that using current efficiencies, the environmental impact of copper indium gallium selenide (CIGS) for generating 1kWh electricity was lower than that of the other studied cells. However, at comparable efficiencies the antimony-based cells offered the lowest environmental impacts in all impact categories. The effect of materials used was also found to be lower than the impact of electricity consumed throughout the manufacturing process, with the absorber layer contributing the most to the majority of the impact categories examined. In terms of chemicals consumed, cadmium acetate contributed significantly to the majority of the environmental impacts. Stainless steel in the substrate/insulating layer and molybdenum in the back contact both contributed considerably to the toxicity and ozone depletion impact categories. This paper demonstrates considerable environmental benefits associated with non-toxic chalcogenide PV cells suggesting that the current environmental concerns can be addressed effectively using alternative materials and manufacturing techniques if current efficiencies are improved.

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This research proposes the application of a holistic methodology for the accurate assessment of financial and environmental feasibility of applying thermal insulation materials, including advanced materials such as vacuum insulation panels (VIPs), for energy efficient building retrofit. The methodology is applied to a case study in which different insulation materials, both traditional (Mineral wool; XPS) and advanced insulation (VIPs), are applied as internal insulation to a typical office building requiring retrofit. The building is simulated through dynamic performance simulation under different climate conditions to evaluate its annual energy needs. Financial and energy analysis including embodied carbon are performed using a proposed holistic approach. The financial feasibility highlighted traditional “heating only” approach might be lacking in correctly identifying energy savings, leading to overestimating for traditional materials with payback time as low as 6.4 years for mineral wool. The “holistic approach”, accounting for the heating and cooling loads and value of space saved, favours advanced materials such as VIPs as soon as the space reaches high enough value, with payback time between 1.3 and 4.2 years for locations investigated. However, the environmental assessment shows that mineral wool has significantly lower carbon payback time compared to VIPs. For VIPs to be competitive environmentally, lower impact core materials or alternatively higher percentage of recycled/reused fumed silica need to be considered in their production. The holistic methodology presented for the first time allows to consider the implications of embodied carbon of insulation materials used in building retrofitting along with the financial and operational energy considerations.

This study investigates the design and sizing of the second life battery energy storage system applied to a residential building with an EV charging station. Lithium-ion batteries have an approximate remaining capacity of 75–80% when disposed from Electric Vehicles (EV). Given the increasing demand of EVs, aligned with global net zero targets, and their associated environmental impacts, the service life of these batteries, could be prolonged with their adoption in less demanding second life applications. In this study, a technical assessment of an electric storage system based on second life batteries from electric vehicles (EVs) is conducted for a residential building in the UK, including an EV charging station. The technical and energy performance of the system is evaluated, considering different scenarios and assuming that the EV charging load demand is added to the off-grid photovoltaic (PV) system equipped with energy storage. Furthermore, the Nissan Leaf second life batteries are used as the energy storage system in this study. The proposed off-grid solar driven energy system is modelled and simulated using MATLAB Simulink. The system is simulated on a mid-winter day with minimum solar irradiance and maximum energy demand, as the worst case scenario. A switch for the PV system has been introduced to control the overcharging of the second life battery pack. The results demonstrate that adding the EV charging load to the off-grid system increased the instability of the system. This, however, could be rectified by connecting additional battery packs (with a capacity of 5.850 kWh for each pack) to the system, assuming that increasing the PV installation area is not possible due to physical limitations on site.

Accurate anionic control during the formation of chalcogenide solid solutions is fundamental for tuning the physicochemical properties of this class of materials. Compositional grading is the key aspect of band gap engineering and is especially valuable at the device interfaces for an optimum band alignment, for controlling interface defects and recombination and for optimizing the formation of carrier-selective contacts. However, a simple and reliable technique that allows standardizing anionic compositional profiles is currently missing for kesterites and the feasibility of achieving a compositional gradient remains a challenging task. This work aims at addressing these issues by a simple and innovative technique. It basically consists of first preparing a pure sulfide absorber with a specific thickness followed by the synthesis of a pure selenide part of complementary thickness on top of it. Specifically, the technique is applied to the synthesis of Cu2ZnSn(S,Se)4 and Cu2ZnGe(S,Se)4 kesterite absorbers, and a series of characterizations are performed to understand the anionic redistribution within the absorbers. For identical processing conditions, different Se incorporation dynamics is identified for Sn- and Ge-based kesterites, leading to a homogeneous or graded composition in depth. It is first demonstrated that for Sn-based kesterite the anionic composition can be perfectly controlled through the thicknesses ratio of the sulfide and selenide absorber parts. Then, it is demonstrated that for Ge-based kesterite an anionic (Se–S) gradient is obtained and that by adjusting the processing conditions the composition at the back side can be finely tuned. This technique represents an innovative approach that will help to improve the compositional reproducibility and determine a band gap grading strategy pathway for kesterites. Furthermore, due to its simplicity and reliability, the proposed methodology could be extended to other chalcogenide materials.

The potential of tandem solar cells combining two chalcopyrite absorbers is evaluated using numerical modeling based on an exhaustive set of experimental parameters, offering a high degree of confidence in the numerical values reported herein. The simple yet reliable approach used here combines a transfer matrix-based optical model of the wide bandgap CIGSe top subcell used as input for the 1D electrical modeling of a reference narrow bandgap CIGSe bottom cell. Various optical optimizations to the top subcell are investigated, with the aim to increase the bottom subcell current and reduce the efficiency threshold needed at the top subcell for the tandem device to beat the current single junction efficiency record. The results here suggest that significant progress compared with the state of the art can be made using a pure CuGaSe2 absorber combined with an optimized back contact with an ultrathin transition metal oxide interlayer. With a bottom subcell current more than doubled in the optimum top subcell configuration, a challenging yet clear pathway for the future realization of tandem solar cells based on chalcopyrite absorbers is offered.

A key factor for achieving nearly-zero energy buildings is to reduce their energy demand using highly efficient thermal insulation materials, such as vacuum insulation panels (VIPs). Currently, the high investment cost of VIPs is hindering the technology penetrating the building market. However, their high thermal performance coupled with reduced thicknesses can lead to economic benefits associated with space savings, significantly changing the economic standing of VIPs. This study presents a comprehensive life cycle cost (LCC) analysis of the application of VIPs in external thermal insulation composite systems (ETICS) in office building façades performed from the landlord perspective. The proposed LCC methodology, based on the EU cost-optimal regulation, allows for comparing the cost-effectiveness of VIPs with conventional insulation materials, taking full account of the additional rental income due to space savings. Energy calculations are performed based on transient heat transfer. The study takes into account varying parameters, such as location, cost of materials, insulation thickness, and rental prices, among others. The results demonstrate that VIPs can be economically viable, in particular in cities where office full-leasing rental prices are high. The range of VIP and rental prices that make their use in buildings cost-effective are identified. For example, it is shown that for rental costs higher than 350 €/(m2.y) VIP can be cost-effective for a current market price of 3000 €/m3, when local climate demands for thermal transmittance bellow 0.19 W/(m2.K). This analysis is useful for VIP manufacturers, project owners and landlords that may be looking for competitive insulation products.

The global market trend for Vacuum Insulation Panels (VIPs) is projecting a significant increase in their uptake in the construction sector. This is mainly due to the uniquely high-performance properties of the ultra-thin insulation materials. This uptake, however, can potentially be hindered by the VIPs’ higher cost and environmental impacts when compared with conventional insulation materials. This paper, for the first time, presents a detailed evaluation of the environmental impact of the most common type of VIPs currently used in different applications with a focus on alternating the core material as the main contributing component to their footprint. Pyrogenic silica, glass fibre, expanded polystyrene, aerogel and a silica/sawdust hybrid core were analysed from cradle to gate. The study, on a comparative basis, demonstrates the sensitivity of the various environmental impact categories to the internal vacuum pressure and the subsequent thermal conductivity values. The results show a lower environmental impact for glass fibre and low density expanded polystyrene compared to the other alternatives. Pyrogenic silica, the most common core material, had the highest environmental impact out of the core materials considered. The higher environmental impacts of pyrogenic silica suggest that measures such as the recycling of the core material alongside the deployment of eco-friendlier manufacturing techniques should be considered if the material is to compete environmentally with the other alternative materials.

Highly insulated building envelopes have become more commonplace as environmental imperatives require reduction of building carbon footprints. Whilst increased insulation levels reduce operational energy demand, the additional embodied energy investment can increase the buildings’ overall environmental impact. The embodied energy consideration can determine whether, and to what extent, additional insulation is justified. The following paper investigates the impact of uncertainties of embodied energy data on the cumulative operational and embodied energy analyses and holistically appraises its implications for different stakeholders involved with the construction sector. Limitations in current life cycle assessment (LCA) calculation methods and high uncertainty of available data are recognized and reflected in the analyses through studying available environmental product declarations of various types of insulation materials and by modelling a typical semi-detached residential building in the UK as the case study. The results of such approach illustrate ‘optimum insulation thicknesses’ beyond which the embodied energy penalty outweighs operational energy savings. These essentially represent idealized levels of building envelope insulation that can inform the development of future standards for low energy/carbon buildings and support the adoption of LCAs as decision-making tools in informing the urgent debate of optimal insulation requirements of buildings.