SOLARAWARDS2011 WINNERS
Product Challenge: Oerlikon Solars THINFAB addresses the challenge to reduce manufacturing cost by 60%. The first generation of thin film silicon manufacturing lines launched 2007 allowed modules to be produced at approximately 1.2 €/Wp. To reach grid parity level in sunny regions to make solar power economically viable, manufacturing cost have to cut down to no more than 0.5 €/Wp.
Problem Solved: Oerlikon Solars next generation fab THINFAB will enable total module production costs at or below 0.5 €/Wp and 120 MWp output capacity. With the THINFAB with module manufacturing cost at or below 0.5 €/Wp, energy can be produced at 0.10 €/kWh in for example Southern Europe. In many regions of the world this allows energy production at or below grid parity level.
Noteworthy: The key performance drivers to make solar power economically viable are module efficiency, high productivity of the manufacturing line and low module material costs. Recent champion modules on full scale with over 11 % initial efficiency and the world record stable cell efficiency for Micromorph® of over 11.8 % form the foundation for 10 % efficiency in average production. In less than 3 years since the market introduction of Oerlikon Solars Micromorph technology 2007 in Milan the productivity of an Oerlikon Solar fab has been increased by more than 100 % which helps to significantly drive down the CAPEX per Wp. The continuous optimization of core equipment, line concept, module design and qualification of new materials drives down costs and increases the manufacturing robustness by simplifying the production steps.
Innovation: With Oerlikon Solars THINFAB thin film silicon solar power becomes economically viable first time. In less than 3 years since the market introduction of Oerlikon Solars Micromorph® technology 2007 in Milan the productivity of an Oerlikon Solar fab has been increased by more than 100 % which helps to significantly drive down the CAPEX per Wp. The continuous optimization of module design and qualification of new materials drives down costs and increases the manufacturing robustness by simplifying the production steps. Radical innovations in the core equipment of the end-to-end manufacturing line contribute to the reduction in cost per Wp by offering higher efficiency, higher throughput per capital invested as well as lower energy and material consumption. Oerlikon Solars unique line concept includes but is not limited to improved central handling system renewed manufacturing execution system and considers all aspects of material logistics. In a cross-functional development approach every detail is optimized for the THINFAB, Oerlikon Solars most advanced turnkey photovoltaic thin film silicon manufacturing line.
Customer Benefits: With the THINFAB with module manufacturing cost at or below 0.5 €/Wp, energy can be produced at 0.10 €/kWh in for example Southern Europe. In many regions of the world this allows energy production at or
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www.solar-pv-management.com I Issue IX 2011
below grid parity level. Therefore thin film silicon solar power becomes economically viable first time.
Note from the Judges: Thin film solar refers to a number of different types of thin film semiconductors covering a substrate. Thin film has had a roller coaster few years but the momentum remains and despite the hiccups the sector is tipped to continue to develop. The main challenge thin film has is to reduce manufacturing costs by 60% to bring it in line with (or improve) the competition. The first generation of thin film silicon manufacturing lines in 2007 allowed modules to be produced at approximately 1.2 €/Wp. To reach grid parity level in sunny regions to make solar power economically viable, manufacturing cost have to cut down to no more than 0.5 €/Wp.
The winning entry for this sector has developed a manufacturing tool that will enable total module production cost at or below 0.5 €/Wp and a 120 MWp output capacity.
Silicon Innovation Award
REC’s “fluidized bed reactor” (FBR) process
Description: RECs proprietary Fluidized Bed Reactor (FBR) process represents the cutting edge technology in silicon production. After 15 years of R&D, REC has developed a process that produces silicon in a continuous process (vs. a batch process) and results in a ready-to-use output that requires no post-processing. The NextSi Granular Polysilicon, which is produced by the environmentally-conscious FBR process gives REC-produced solar modules an industry-leading payback time of one year, 20% less time than competing products Challenge: A major part of the energy consumption associated with producing solar cells is related to the purification of silicon. The “Fluidized Bed Reactor” (FBR) technology, used by REC for the silicon purification process, consumes significantly less energy for producing high purity silicon used for high performance solar products. Moreover, the FBR process lowers the cost of making solar products, whilst saving large amounts of electricity.
Problem Solved: With the “Fluidized Bed Reactor (FBR) process, REC can produce solar-grade silicon, while using 80- 90% less energy than the traditional Siemens method for converting silane gas to high purity silicon. Firstly, it does not waste energy by placing heated gas and silicon in contact with cold surfaces. Secondly, it produces more silicon per cubic meter of reactor space because the silicon crystals have a larger
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