Owing to the huge demand for photovoltaic products, the market is still very attractive for investments in production facilities. Nevertheless, the increasing number of competing photovoltaic manufacturers and the decrease in governmental subsidies require substantial and continuous cost reductions. Whilst existing facilities can save costs by enhancing cell efficiency, optimizing production processes or reducing material costs and other resources, for new manufacturing sites there is a great potential in making efficient use of economies of scale. This also holds true - to some extent – for expanding existing fabs. This paper presents the logistics behind and the benefits of implementing economy of scale in a PV manufacturing facility.
Materials innovation in solar photovoltaic manufacturing has long played a key role in efforts to raise cell and module conversion efficiencies, improve overall device performance and reliability, and lower the overall cost per manufactured watt. Research and development in areas such as ultrathin-silicon wafering and replacement films for thin-film PV transparent conductive oxides often garner much of the industry’s attention. But a wide range of emerging technologies could provide crystalline-silicon and thin-film cell and module manufacturers the kinds of materials solutions that will accelerate their attempts to reach competitive levelized cost of energy metrics and ultimately attain their goal of achieving grid parity with conventional energy sources – as well as open up lucrative market opportunities for the materials suppliers.
Laser-based tools have become increasingly visible within R&D labs, pilot production lines, and as the preferred technology used by many turnkey suppliers. As equipment types however, relatively little is known about the differences in the laser-based tools used for solar applications within each of the c-Si and thin-film segments. This paper explains the key components of a laser-based tool, and how they are adapting to meet the demands from next-generation production line equipment required by the solar industry.
Transparent conducting oxides (TCOs) are a special class of materials that can simultaneously be both optically transparent and electrically conducting and, as such, are a critical component in most thin-film photovoltaics. TCOs are generally based on a limited class of metal oxide semiconductors such In2O3, ZnO and SnO2, which are transparent due to their large band gap energy and can also tolerate very high electronic doping concentrations to yield conductivities of 1000S/cm or higher. However, these thee basic TCOs alone do not meet the TCO performance needs of emerging PV and other applications.
The rapid expansion of high volume manufacturing to meet growing demand in recent years has highlighted the development of increasingly higher throughput machines, especially in the critical bottleneck process of module assembly, specifically characterised by tabbing and stringing steps. Significant productivity improvements have come about with the development of integrated, highly-automated tabber and stringers from a range of equipment vendors. However, module assembly remains the most expensive step in conventional c-Si cell production. Equipment suppliers are also challenged to meet the evolving demands of processing thinner wafers and to address overall production cost reduction strategies while meeting yield/throughput goals that are seen as a significant enabler of reducing the cost per watt.
Three buzzwords dominate the discussion about the future of the photovoltaic market in the U.S. right now: ITC (investment tax credit), credit crunch, and Obama. All three have the potential to shape how the solar industry will look in the next decades. Primary data results from EuPD Research show that after a year that featured much wailing and gnashing of teeth, market participants are now “realistically optimistic” on the prospects for the industry, despite the influence of the international credit crisis.
The continued tight supply and high cost of polysilicon, coinciding with the growth in demand for solar energy, has been a key catalyst for the rapid adoption of thin-film technologies in just the last two years. Although the technology has in development for over 15 years, it is only now that thin film has emerged as a viable low cost-per-watt alternative to conventional crystalline silicon cells. Taiwan, a powerhouse in the electronics and microelectronics industries, is also turning its attention to photovoltaics. Playing catch-up is something at which the Taiwanese have proven to be very effective, with a growing emphasis on thin film as a means to become another major centre and net exporter.
In the perpetual struggle to reduce the costs associated with PV energy generation, one aspect of the manufacturing process has potential to shine. To date, the PV sector is dominated by crystalline silicon wafers (90%), which largely use silver as the conducting medium for the front side grid, and to a lesser extent the backside contact. The conducting media are crucial to the overall efficiency of the cell by providing the means for current to flow when sunlight strikes the doped silicon wafer. This paper presents silver as a vital factor in the PV process, and discusses the future industry requirements as well as a projection for the overall silver market for the next eight years.
The second edition of Photovoltaics International was published in November 2008. It includes the cost benefits of conversion of used 200mm semiconductor fabs for the PV industry by CH2M Hill in Fab & Facilities, in-line plasma-chemical etching from Fraunhofer IWS in Cell Processing and NREL presents design criteria for back- and front-sheet materials in PV Modules.
This paper presents a detailed assessment of the value of photovoltaic energy within the German energy supply structure, taking into account the correlation between actual consumption and local power generation. Contrary to previous statistical approaches, this paper takes a new dynamic approach, modelling the dynamic behaviour of the PV power generation as a one-year time series. A comparison with the time series of the power demand allows assessment of the value of PV energy. The value of PV energy mainly results from its ability to substitute conventional power generation and the benefit of this kind of decentralized power generation for network stability and quality. An evaluation of these aspects is carried out for the year 2005 and a likely scenario in 2015.
