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Particle Characterisation Supports Cost Control in Solar Cell Manufacture
Worldwide demand for photovoltaic (PV) solar cells is fuelling the emergence of a strong manufacturing sector across Europe and Asia. In support, the Sysmex FPIA-3000 Flow Particle Image Analyser from Malvern Instruments is being used to aid cost control and waste reduction by providing the particle size and shape data necessary for effective recycling of the high value slurries used in cutting silicon wafers. Silicon carbide slurry represents a significant cost in wafer manufacture with one estimate placing the operating cost of running 10 wire saws at as high as $16million per year, making slurry recycling a highly desirable process Multi-wire saw cutting processes that rely on abrasive silicon carbide slurries are used to cut silicon wafers for PV solar cells. These allow the slicing of thousands of wafers in a single run. However, over time, the slurry carried by the wire becomes contaminated, creating a build- up of waste silicon and worn abrasive particles and reducing the effectiveness of the wire-saw process.
By monitoring the size and shape of particles present, the Sysmex FPIA-3000 allows optimum control in slurry recycling. In addition, by characterising the slurry itself, the particle size and particle shape distribution of the silicon carbide can be tuned to enable thinner cuts between each wafer, thereby wasting less raw material. Capable of measuring tens of thousands of particles in just a few minutes, the Sysmex FPIA-3000 uses imaging flow cytometry to measure suspended particles passing through a sheath flow cell, providing robust data that can be used to optimise manufacturing processes.
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PLAS LABS: Clearly Your Best Choice! Circle no. 138
Mixed were solid with solid substances, solid with liquid substances and liquids with solids. As solid phases mostly fine powders are used, which during the mixing process should not be further reduced. The liquid phases include mercury to saline solutions up to resins.
Probably one of the most difficult tasks was the fine distribution of pure liquid mercury in a mixture of fine solid metal powders. Already during the manual mixing with a spatula, with careless work methods without a problem up to 3mm large amalgam grains were produced. The solution was added to the mortar mill PULVERISETTE 2, with an agate grinding set and special adjustments for the minimising of the application of energy found.
From the area of mixtures liquid – solid is the production of filled pastes to be mentioned. Especially challenging here is to add as much as possible solids in the high viscosity organic phase.
An additional example for this is, when one has to add to organic binder (for example synthetic resin or varnish or in the simplest case oil) fine metallic, ceramic or inorganic powders. High viscosity pastes evolve which can be compared which shoe polish in a tube. Experts often talk about filled composite materials. Often the increase of the degree of the solid content is the goal of all activities.
In this concrete case, was a metallic powder to be added to a synthetic resin of high viscosity. Chosen was the Fritsch mortar mill PULVERISETTE 2, equipped with a grinding set of hardened steel. With processing times of up to 30 minutes, the successive addition of the powder and supported by the slight warming from the applied comminution energy, up to 80% of the mass percentage of the solid was homogenously mixed in.
From the areas of mixtures solid – liquid the contamination of ceramic powders with very little amounts of solved in liquid substances are to be mentioned. For the test the mortar mill PULVERISETTE 2 with an agate grinding set was chosen.
The iron nitrate solution was used as the model-solution coloured and therefore the homogeneity of the mixture was very easily visually evaluated. While the mill was grinding, approximately 1ml liquid in 50g powder were instilled. Afterwards it was further homogenised. After 5 minutes a visual consistent system was created.
Circle no. 140 Search: Circle no. 139 labmate-online
LABORATORY PRODUCTS
Production of Mixtures on a Laboratory Scale
INTERNATIONAL LABMATE - AUGUST/SEPTEMBER 2011 - LABORATORY PRODUCTS
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