SOLARAWARDS2011 WINNERS
total surface area than the rods used in the Siemens process. Thirdly, it is a continuous process rather than a batch process so there is less wasted downtime or setup effort required. And finally, unlike other processes which require the breaking of polysilicon rods, FBR granular is harvested in a ready to use form.
Noteworthy: RECs Fluidized Bed Reactor (FBR) process uses less energy to produce silicon than competing technologies, making it a more environmentally-sound choice. It also gives a payback time of one year, 20% less time than competing products. The company is also committed to reducing waste, using closed processes wherever possible and capturing 95- 99% of the remaining production by-products and repurposing them. REC also uses only hydroelectric and wind power to power the production process.
Innovation: RECs Fluidized Bed Reactor (FBR) process requires less energy to produce than other silicon production processes, giving REC silicon modules an industry-leading payback time of one year. The process produces silicon in a continuous process (vs. a batch process) and results in a ready-to-use output that requires no post-processing. RECs Fluidized Bed Reactor (FBR) process produces Next Sigranular polysilicon, which is easier to handle. The FBR process is an efficient, continuous production cycle and has a ready-to-use output product, as opposed to existing solutions which are inefficient batch production and require additional post-production processing. Improved logistics automation reduces the potential for external contamination resulting in poorer product quality and performance. Granular polysilicon is packaged in bulk containers and because they round and can flow freely, it enables automated material transport and crucible loading.
These factors combined amount to a significant reduction in the cost of solar ingot manufacturing compared to the traditional method further reducing the cost of solar energy. Moreover, there are a number of technological advantages to the RECs Fluidized Bed Reactor (FBR) process.
Customer Benefits: Overall, the RECs Fluidized Bed Reactor (FBR) process is an economically-sound choice because it maximizes productivity. Advantages of FBR-produced silicon include: Increased Process Efficiency maximizes crucible load, ability to top-off and/or recharge crucible, highly repeatable, controlled process, mitigates process problems, increases productivity Optimized logistics reduces amount of shipping and handling, increases operational efficiency, High Automation Potential reduces handling, increases operational efficiency, increases productivity.
Note from the Judges: Silicon based solar and PV have surprised the industry again and again over the last few years. It was only a few years ago when silicon based products were tipped to be hit by materials shortages, efficiency problems and ballooning
costs. For those that bet on this direction at that time, they have discovered that the exact opposite has occurred. To achieve some of the startling results of the last few years has taken a concerted effort at every part of the manufacturing chain to reduce costs through the production process.
A major part of the energy consumption associated with producing solar cells is related to the purification of silicon to achieve the raw material for manufacturing. The winning entry is a process that consumes significantly less energy for producing high purity silicon used for high performance solar products as well as producing silicon in a continuous process and results in a ready-to-use output that requires no post-processing reducing manufacturing time and costs.
Industry Development Award
Wagner Academy Solar Training School
Wagner Solar UK Ltd has set up a training school for UK based solar installers. This training school is specifically aimed at solar installers who are already MCS accredited. The training school is run at different venues depending on the content and number of people expected to attend. As a company, we have invested considerably in resources / material, for example we have built 2 indoor training roofs to provide practical hands-on training. All our courses are offered free of charge on a first come first served basis.
Challenge: Currently, the majority of solar training schools in the UK are specifically focused on MCS accreditation training. As commercially run training schools, these establishments must operate to make a profit, so have commercial partnerships in place for supply of training technology etc. With commercial partnerships in place, unsurprisingly the schools are failing to provide an unbiased view of the industry. Once the installer is accredited, they have a narrow view of the industry. This is one challenge. Another is the pace of advance currently being experienced by the solar industry, which leaves these freshly accredited installers behind, as they struggle to build up experience. Our training school is specifically focused on already accredited installers to provide them with ongoing training.
Problem Solved: As a distributor, we are in a unique position with direct relationships with global manufacturers. Our intention is to invite manufacturers to our training, for them to give
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