Programm Photovoltaik Ausgabe 2008 ... - Bundesamt für Energie BFE
Programm Photovoltaik Ausgabe 2008 ... - Bundesamt für Energie BFE Programm Photovoltaik Ausgabe 2008 ... - Bundesamt für Energie BFE
3/5 Description of the process flow: The demo unit is built to illustrate 3 steps of typical wafer handling in real production environment. 1) The singulation 2) Wafer Quality Control and Sorting 3) The cassetting or carrier loading The overall cost structure of wafering has been estimated. It appears clearly that silicon (raw material) is the dominant cost factor, followed in second position by the slicing consumables. 100% 80% 60% 40% 20% 0% 28% 68% (156, 200um WT, 160um KL) 2% 2% 17% 81% 1% 1% 12% 86% Si @ 50 €/kg Si @ 100 €/kg Si @ 150 €/kg 1% 1% Running Consumable Equipment Si Material Figure 3: Overall cost structure for wafering with three different Silicon raw material market prices 29% 7% 4% 86% Figure 4: Relative importance of raw material usage factors Thickness Wire Grit Pitch Within the slicing consumables, the cost of new slurry (abrasive SiC + coolant) accounts for more than 50%. Because the slurry plays a dominant role in cost of consumables, it becomes important to adapt recycling strategies of used slurry. Best overall cost savings in slurry consumables is obtained by combining external service (out-sourcing), and in-house equipment for slurry recycling. This way, endusers can easily reach 60% or more slurry cost reductions. BiThink, P. Nasch, Applied Materials Switzerland Seite 71 von 288
Seite 72 von 288 Table 5 summarizes the achievements in BITHINK by comparing the situation at start of project and the results obtained. Start of BITHINK End of BITHINK Wafer thickness �m 240 120 W ire diameter �m 160 120 Grit size �m 13 9 Production yield % 95 90 Raw material usage m 2 /kg 0.98 1.53 Cost €/m 2 102 65 g/Wp 7.87 5.02 €/W p 0.79 0.50 Table 5: 36% Cost reduction (€/Wp) achieved in BITHINK by reducing wafer thickness, wire diameter, and grit size. Cost calculations are made assuming 100€/kg of poly-silicon, 13% solar conversion efficiency, and a solar constant of 1 kW/m 2 . When comparing BITHINK achievements in terms of g/Wp obtained with market roadmap and trends (Figure 6), one can see that the present results are anticipating the market situation in 2 years from now. Wafer Thickness (microns) Product Roadmap 250 200 150 100 50 0 240 10.5 160 200 7.3 140 160 6.1 120 120 4.3 2004 2006 2008 2010 Time E500SD-B Start of BITHINK project (end 2004) E500SD-B/5 End of BITHINK project (end 2007) E500SD-B/6 Figure 6: European market trend survey and roadmap BiThink, P. Nasch, Applied Materials Switzerland Wafer thickness Wire diameter g / Wp 100 WP1 Apollo achievements within the BITHINK project: 5g/Wp 10 5 0 Grams per Wp 4/5
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3/5<br />
Description of the process flow:<br />
The demo unit is built to illustrate 3 steps of typical wafer handling in real production environment.<br />
1) The singulation<br />
2) Wafer Quality Control and Sorting<br />
3) The cassetting or carrier loading<br />
The overall cost structure of wafering has been estimated. It appears clearly that silicon (raw material)<br />
is the dominant cost factor, followed in second position by the slicing consumables.<br />
100%<br />
80%<br />
60%<br />
40%<br />
20%<br />
0%<br />
28%<br />
68%<br />
(156, 200um WT, 160um KL)<br />
2%<br />
2%<br />
17%<br />
81%<br />
1%<br />
1%<br />
12%<br />
86%<br />
Si @ 50 €/kg Si @ 100 €/kg Si @ 150 €/kg<br />
1%<br />
1%<br />
Running<br />
Consumable<br />
Equipment<br />
Si Material<br />
Figure 3: Overall cost structure for wafering with three different Silicon raw material market prices<br />
29%<br />
7%<br />
4%<br />
86%<br />
Figure 4: Relative importance of raw material usage factors<br />
Thickness<br />
Wire<br />
Grit<br />
Pitch<br />
Within the slicing consumables, the cost of new slurry (abrasive SiC + coolant) accounts for more than<br />
50%. Because the slurry plays a dominant role in cost of consumables, it becomes important to adapt<br />
recycling strategies of used slurry. Best overall cost savings in slurry consumables is obtained by<br />
combining external service (out-sourcing), and in-house equipment for slurry recycling. This way, endusers<br />
can easily reach 60% or more slurry cost reductions.<br />
BiThink, P. Nasch, Applied Materials Switzerland Seite 71 von 288