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SOLAR GENERATION - Greenpeace

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PV Cells and Modules<br />

PV cells are generally made either from crystalline silicon,<br />

sliced from ingots or castings or from grown ribbons, or thin<br />

film, deposited in thin layers on a low cost backing. The<br />

majority of module production (89% in 2003) has so far involved<br />

the former, while future plans will also have a strong focus on<br />

the latter. Thin film technology based on silicon and other<br />

materials is expected to gain a by far larger share of the PV<br />

market in the future. This technology offers several advantages<br />

such as low material consumption, low weight and a smooth<br />

visual appearance.<br />

Crystalline silicon<br />

Crystalline silicon is still the mainstay of most power modules.<br />

Although in some technical parameters not the ideal material<br />

for solar cells, it has the benefit of being widely available, well<br />

understood and uses the same technology developed for the<br />

electronics industry. Efficiencies of more than 20% have been<br />

obtained with silicon cells in the laboratory, but production<br />

cells are currently averaging 13-17% efficiency. The theoretical<br />

limit for crystalline modules approaches 30%.<br />

Thin film<br />

Thin film modules are constructed by depositing extremely<br />

thin layers of photosensitive materials on a low cost backing<br />

such as glass, stainless steel or plastic. This results in lower<br />

production costs compared to the more material intensive<br />

crystalline technology. This price advantage is counter balanced<br />

at the moment, however, by substantially lower efficiency rates<br />

and less experience of the modules’ lifetime performance.<br />

Three types of thin film modules are commercially available at<br />

the moment. These are manufactured from amorphous silicon<br />

(a-Si), copper indium diselenide (CIS, CIGS) and cadmium<br />

telluride (CdTe). All of these have active layers in the thickness<br />

range of less than a few microns. This approach allows higher<br />

automation once a certain production volume is reached, while<br />

they all use an integrated approach to the module architecture.<br />

This is less labour intensive compared to the assembly of<br />

crystalline modules by interconnecting a number of individual<br />

cells. At approximately 6% in 2003, the market share of thin<br />

film technology is still fairly low, but can be expected to<br />

increase in the future.<br />

Figure 1.3: Market shares of different cell technologies<br />

sold in 2003 (installed capacity)<br />

mono c-Si<br />

33,2%<br />

ribbon-/sheet<br />

c-Si 4,3%<br />

CIS 0,7%<br />

a-Si 4,5%<br />

CdTe 1%<br />

poly c-Si 56,3%<br />

Amongst these three commercially available thin film<br />

technologies, a-Si is the most important in terms of production<br />

and installation (4.5% of the total market in 2003).<br />

Multicrystalline thin film on glass (CSG) is a promising thin<br />

film technology under development, but not yet available on a<br />

commercial scale. Microcrystalline technology, in particular<br />

the combination of amorphous silicon and microcrystalline<br />

silicon (a-Si/µ-Si) is another approach with encouraging results.<br />

The efficiency world record for cells with this technology is<br />

currently 14.7%, while modules are already commercially<br />

available with an efficiency of 10% stabilized. The aim is to<br />

increase this level to 12% in 2005.<br />

Other cell types<br />

Concentrator cells focus light from a large area onto a small<br />

area of photovoltaic material using an optical concentrator<br />

(such as a Fresnel lens), thus minimising the quantity of PV<br />

cells required. The two main drawbacks with concentrator<br />

systems are that they cannot make use of diffuse sunlight and<br />

must always be directed towards the sun with a tracking<br />

system.<br />

Spheral solar technology uses minute silicon beads bonded to<br />

an aluminium foil matrix. This offers a big cost advantage<br />

because of the reduced requirement for silicon. Two companies,<br />

from Canada and Japan, are planning to commercialise<br />

modules with spheral solar cells, with one of them already<br />

predicting a module efficiency of 11%. This represents an<br />

excellent example of the rapid technical progress in<br />

photovoltaics. When the first edition of Solar Generation was<br />

published in 2001, the development of spheral cells was not<br />

even at a stage that allowed a detailed prediction of its<br />

commercial availability.<br />

Modules<br />

Modules are clusters of PV cells incorporated into a unit, usually<br />

by soldering them together under a sheet of glass. They can be<br />

adapted in size to the proposed site, and quickly installed. They<br />

11

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