Quality control issues delay commissioning at REC Moses Lake plant, production pushed out

Facebook
Twitter
LinkedIn
Reddit
Email

REC has updated the status of its polysilicon expansion at Plant III, saying it has formally accepted and taken control over the entire fluidized bed reactor (FBR) area and all related equipment at the new factory under construction in Moses Lake, WA.

While the first reactor test runs have been successfully completed, the company cautions that during final stages of the commissioning in the silane gas production area, quality issues were encountered with certain standard prefabricated carbon steel pipes. Control measures and repairs were begun immediately.

This article requires Premium SubscriptionBasic (FREE) Subscription

Unlock unlimited access for 12 whole months of distinctive global analysis

Photovoltaics International is now included.

  • Regular insight and analysis of the industry’s biggest developments
  • In-depth interviews with the industry’s leading figures
  • Unlimited digital access to the PV Tech Power journal catalogue
  • Unlimited digital access to the Photovoltaics International journal catalogue
  • Access to more than 1,000 technical papers
  • Discounts on Solar Media’s portfolio of events, in-person and virtual

Or continue reading this article for free

Based on the final conclusions of the analysis undertaken during the last few days, start-up of the silane production will be delayed until late January 2009, the company says. This will negatively affect production of polysilicon and, to some extent, wafers and solar cells in 2008 and early 2009.
 
In discussing the quality concerns related to the prefabricated carbon steel pipe welds in the silane gas section, the company says that its inspections revealed that the level of weld defects is above industry standard, and the quality falls outside the guaranteed standard delivery specifications for such “off-the-shelf” pipes.

All defective pipes have been supplied by one particular fabricator with a “seal of approval.” The supplier has taken full responsibility and has agreed to cover costs related to necessary weld repairs to ensure a safe start-up.
 
REC says that it has, together with Fluor and a third-party engineering firm, spent the last few days finalizing the analysis of the issue. Based on the current weld repair rate and the conclusion of the analysis, the start-up of commercial production has been moved to the end of January 2009. Aside from the weld repairs, the construction of the plant is complete.
 
“As a responsible producer we have a rigorous mechanical integrity program which allowed us to discover the defective workmanship,” explained Erik Thorsen, REC’s president/CEO. “The delay is obviously very unfortunate given our tight polysilicon situation, and we are working hard to mitigate and limit consequences as much as possible.” 

Simultaneously, start-up activities continue in the FBR section of the plant. Last week, the first two reactors were started on inert gas. This confirms that control systems and reactor characteristics are working in line with expectations. Next week, REC says it intends to start running full tests of the FBR reactors on silane gas from existing plants.
 
“As we have taken over the FBR-section of the plant, we will continue to prepare for start-up of commercial production and the coming ramp-up period in parallel with the ongoing weld repairs,” Thorsen says. “We remain comfortable with FBR from a technology perspective and its low-cost and high-quality capabilities. However, there is always risks related to starting up new technology.”
 
Plant III was previously scheduled to produce up to 400 metric tons of polysilicon by the end of 2008. Given an expected start-up of commercial production toward the end of January 2009, this year’s production will be reduced to only minor test volumes, according to REC.

For 2009, the production is expected to be about 5000 metric tons; the plant is designed to handle a 6500-metric ton annual production capacity of 6,500 MT.

Read Next

Premium
May 5, 2025
Tom Kenning investigates the scale of local opposition to solar projects and the measures developers are employing to win back support.
May 2, 2025
Sunraycer Renewables has signed two Environmental Attribute Purchase Agreements (EAPAs) with Meta for 310MW of solar PV in Texas, US.
May 2, 2025
A study from researchers at the King Abdullah University of Science and Technology (KAUST) in Saudi Arabia has shown that a synthetic molecule in the design of a perovskite solar cell can boost its energy efficiency and longevity.
May 2, 2025
The European Commission (EC) has allocated €52 million to nine renewable energy projects as part of its cross-border auction process.
May 2, 2025
The Q2 2025 edition (Volume 42) of our downstream solar PV journal, PV Tech Power, is now available to download.
May 2, 2025
Maxeon shipped just 211MW in the fourth quarter of 2024, driving a year-end revenue of less than half of what was reported in 2023.

Subscribe to Newsletter

Upcoming Events

Media Partners, Solar Media Events
May 7, 2025
Munich, Germany
Solar Media Events
May 21, 2025
London, UK
Solar Media Events
June 17, 2025
Napa, USA
Solar Media Events
July 1, 2025
London, UK
Solar Media Events
July 1, 2025
London, UK