September 2011 - I-Micronews
September 2011 - I-Micronews
September 2011 - I-Micronews
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PV<br />
Manufacturing<br />
SEPTEMBER <strong>2011</strong><br />
ISSUE N°13<br />
From Equipment and Materials to Solar Business<br />
INDUSTRY REVIEW<br />
The HCPV sector<br />
starts to talk<br />
in megawatts<br />
Courtesy of AZUR SPACE - Printed on recycled paper<br />
COMPANY INSIGHT<br />
Trident Solar:<br />
Progress on solar<br />
inkjet<br />
ANALYST CORNER<br />
The future of<br />
photovoltaics is<br />
inescapably about<br />
efficiency<br />
Free subscription on www.i-micronews.com
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
C O N T E N T S<br />
INDUSTRY REVIEW 4<br />
• The HCPV sector starts to talk in megawatts<br />
Makers of concentrating photovoltaic systems are at last installing systems<br />
measured in megawatts, and even getting a few utility power purchase<br />
agreements for future 100+MW systems.<br />
• Maturing HCPV supply chain looks to volume production issues<br />
Once the HCPV industry starts shipping hundreds of megawatts, its supply chain<br />
will have to transition to volume production as well. And a high volume business<br />
can’t be built all on custom components and custom assembly equipment.<br />
COMPANY INSIGHT 12<br />
• Trident Solar: Progress on solar inkjet<br />
Longer lasting print heads and combo processes could make inkjet a viable<br />
alternative for next generation solar cell processing.<br />
• ESI: Progress on laser technology opens new process options<br />
Tailored-pulse laser targets more precise micromachining across PV processes.<br />
ANALYST CORNER 16<br />
• The future of photovoltaics is inescapably about efficiency<br />
As efficiency becomes the key differentiator among solar brands, it means<br />
opportunity for new equipment processes and higher purity materials,<br />
and perhaps even for HCPV.<br />
FROM I-MICRONEWS.COM<br />
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area: current news, market & technological<br />
analysis, key leader interviews, webcasts<br />
section, reverse engineering / costing,<br />
events calendar, latest reports …<br />
> Solopower receives $197 million<br />
loan guarantee from US DOE to<br />
build thin film photovoltaic module<br />
facilities<br />
> GT Advanced Technologies announces<br />
Korea-based polysilicon producer<br />
OCI selects the newest generation<br />
SDR reactors as part of its phase<br />
4 expansion program<br />
> Dow Corning begins monosilane<br />
production<br />
GOLD PARTNERS:<br />
For more information, please contact S. Leroy (leroy@yole.fr) or B. Stinson (stinson@i-micronews.com)<br />
2 P V M a n u f a c t u r i n g
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
E D I T O R I A L<br />
Looking outside the mainstream at emerging<br />
approaches to improve PV efficiency<br />
Ramping low cost gigawatt-scale volume production has grown PV to a 40 GWp<br />
business, according to Yole Développement fi gures, but the focus is now turning<br />
to improving effi ciency to gain distinguishing competitive advantage in the crowded<br />
market. In this issue of PVManufacturing we look at the state of some emerging approaches<br />
to higher effi ciency solar installations, from High Concentration PV (HCPV) to developments<br />
in inkjet and laser components for PV equipment.<br />
…When overall enddemand<br />
slows down,<br />
these innovative<br />
solutions can help<br />
companies again<br />
generate growth…<br />
E V E N T S<br />
HCPV remains a tiny business of small-scale installations to date, but the sector made a big<br />
step up from mostly kilowatt-scale to multiple 1-2 megawatt-scale projects last year. The<br />
leading companies now have 10MW-scale or larger projects in the pipeline. Moving to these<br />
volumes means the HCPV sector will need to add volume automated production capacity and<br />
fi gure out how to work more closely with its supply chain to optimize component design for<br />
manufacturing—and that has potential to signifi cantly bring down costs.<br />
Some components suppliers are also trying to jumpstart co-design to improve performance by<br />
getting together to test, optimize and publish data on how different primary optics, secondary<br />
optics and multijunction cells work together. Concentrator Optics, Isuzu Glass and AZUR<br />
SPACE are testing results in mockup test HCPV modules made from their components, and<br />
next plan to work with equipment suppliers to design production systems for the optimal<br />
components.<br />
The recent growth of HCPV installations in the US is partly because of the favorable economics<br />
for the technology of high DNI desert climate conditions conveniently near big population<br />
centers that particularly need power for air conditioning late on summer afternoons when<br />
HCPV outperforms fl at plate PV, but it has also been spurred by government requirements<br />
for aggressive new renewable energy portfolio standards for utilities, and by local efforts to<br />
create manufacturing jobs. If the technology is going to compete more widely with fl at panel<br />
PV, it will now need “muscle, manufacturing and money” as Amonix CTO and chairman<br />
Vahan Garboushian says, to transition to a volume manufacturing business, and to keep<br />
improving effi ciency and cost as fast as the fl at plate PV sector does, when that much larger<br />
industry can pour vastly more resources into the effort.<br />
• European PVSEC<br />
<strong>September</strong> 5 to 9, <strong>2011</strong> – Hamburg, Germany<br />
• Semicon Europa<br />
October 11 to 13, <strong>2011</strong> – Dresden, Germany<br />
• PV Japan<br />
December 5 to 7, <strong>2011</strong> – Tokyo, Japan<br />
PLATINUM PARTNERS:<br />
The fl at panel PV side’s pursuit of higher effi ciencies of course continues to generate<br />
innovative alternatives to the common processes. And when overall end-demand slows<br />
down, these innovative solutions can help companies again generate growth. So we also take<br />
a look in this issue at recent developments in laser and inkjet technology that have interesting<br />
potential for new equipment processes to improve results. Controlled micromachining by<br />
ESI’s tailored-pulse fi ber laser is showing some interesting results for precise scribing and<br />
via drilling. Trident Solar is using its industrial stainless steel inkjet head that holds up to<br />
aggressive chemicals to develop a process for printing etchant and dopant for selective<br />
emitters by one pass of a single ink.<br />
Arnaud Duteil<br />
Market & Technology analyst<br />
Yole Développement<br />
duteil@yole.fr<br />
P V M a n u f a c t u r i n g 3<br />
For more information, please contact S. Leroy (leroy@yole.fr) or B. Stinson (stinson@i-micronews.com)
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
INDUSTRY REVIEW<br />
SolFocus HCPV module<br />
(Courtesy of SolFocus)<br />
The HCPV sector starts to talk<br />
in megawatts<br />
Makers of concentrating photovoltaic systems are at last installing systems measured<br />
in megawatts, and even getting a few utility power purchase agreements for future<br />
100+MW systems.<br />
“A year ago at<br />
Intersolar people<br />
asked how CPV<br />
worked, this<br />
year they asked<br />
how much they<br />
could get and<br />
when,” says Vahan<br />
Garboushian,<br />
CTO of Amonix.<br />
4<br />
But the real sign that the HCPV niche may<br />
be becoming a significant solar alternative<br />
is the 100MW-scale capacity HCPV module<br />
manufacturing the industry leaders plan this year.<br />
SolFocus plans to double capacity to 100MW by the<br />
end of the year. Amonix executives have said they<br />
plan to ramp to 100MW capacity by the end of the<br />
year. Though Soitec has yet to finalize the specifics<br />
for its planned new San Diego plant, local papers have<br />
reported a target of 200MW capacity, and production<br />
facilities to support the 300MW in power purchase<br />
agreements from San Diego Gas & Electric will need<br />
to be multiple times larger than the current ~30MWcapacity<br />
Soitec production facility in Germany.<br />
These planned volume plants will help move the<br />
niche HCPV sector towards becoming a more mature<br />
manufacturing business, with significant potential<br />
now to reduce costs by automated production, a<br />
supporting supply chain infrastructure, outsourcing<br />
or production partnerships with established volume<br />
assembly companies, and moving away from all<br />
custom components and production equipment.<br />
Local interest in clean tech jobs from HCPV is also<br />
boosting the sector, as this newer technology on the<br />
verge of ramping mass production currently looks like<br />
a better prospect for local development now that the<br />
flat plate solar manufacturing business is increasingly<br />
a big company game dominated by low-cost regions<br />
of the world. Soitec’s planned HCPV plant in the San<br />
Diego area was apparently a key sweetener for the<br />
PPA deals with San Diego Gas & Electric. The US<br />
government supported Amonix’s new $18M plant<br />
in Nevada with almost $6M in subsidies, then also<br />
guaranteed a $90M loan for its 30MW Alamosa,<br />
Colorado, project. The Chinese province of Gansu’s<br />
deal for 20MW of ZenithSolar HCPV projects also<br />
requires local manufacturing. And several of the<br />
installations at educational institutions are related to<br />
solar job training programs.<br />
P V M a n u f a c t u r i n g
I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />
Amonix aims to put 40MW-50MW<br />
of HCPV in the ground this year<br />
“We’ll put 40MW to 50MW in the ground this<br />
year,” says Amonix founder, CTO and Chairman<br />
Vahan Garboushian, who argues that the sector<br />
is finally turning the corner towards becoming<br />
a volume business. Work is underway on<br />
the 30MW installation in Alamosa, Colorado.<br />
Construction is also finishing up at the 5MW<br />
installation in Hatch, New Mexico, where tracker<br />
posts were in and frames on site back in the<br />
last available public photos of the site back<br />
in March. Amonix was hiring field engineers<br />
for commissioning and running both these<br />
sites earlier this summer. The company also<br />
dedicated a 2MW project in Tucson in April.<br />
Garboushian says customers are now looking for<br />
HCPV demonstration projects in the MW range,<br />
as the focus has moved from demonstrating<br />
the technology to demonstrating how the<br />
technology performs at a particular location.<br />
And he notes Amonix’ recently announced joint<br />
venture in India targeting large distributed<br />
generation projects in an area without the<br />
highest DNI, where HCPV still looks competitive<br />
with flat plate PV costs.<br />
“A year ago at Intersolar people asked how<br />
CPV worked, this year they asked how much<br />
they could get and when,” says Garboushian.<br />
“They’re not asking if the technology is viable<br />
anymore.” The maturing of the technology also<br />
means that the key factor for success moves<br />
from innovation to execution. “Now what it will<br />
require is muscle, manufacturing, and money,”<br />
Garboushian argues.<br />
Amonix’s uses solar grade PMMA treated with UV<br />
retardants for its Fresnel lenses, putting multiple<br />
cells on one receiver plate per Fresnel lens<br />
parquet, and using a secondary reflective optic of<br />
highly polished aluminum. “We’ve experimented<br />
with different materials including glass for many<br />
years, but we’ve been using this same material<br />
in the field since 1994 and it still looks robust,”<br />
he says, noting the acrylic’s better transmissivity<br />
and better manufacturing tolerance. Company<br />
data tests showing 0.3%-0.4% degradation per<br />
year suggest the modules would maintain over<br />
90% of their original efficiency for 25 years if<br />
this rate of change remained constant. Amonix<br />
Amonix HCPV systems (Courtesy of Amonix)<br />
originally produced everything except the<br />
lenses in house, but as production increased it<br />
outsourced its designs to others. Though it can<br />
do cell finishing in house, it buys most of its cells<br />
from Spectrolab and Emcore and assembles<br />
them in the receiver package and on the<br />
receiver plate, then assembles and aligns all the<br />
components into its megamodule.<br />
Compared to the more established flat plate<br />
PV technology, HCPV likely has much more<br />
headroom for improving efficiency and cost,<br />
though the smaller sector has much less total<br />
money and manpower than flat plate PV to<br />
Annual manufacturing capacity of some HCPV companies<br />
(Yole Développement, <strong>2011</strong>, HCPV report)<br />
300<br />
250<br />
200<br />
MW/yr<br />
150<br />
100<br />
50<br />
0<br />
Amonix<br />
Renovalia<br />
Energy<br />
Green<br />
Guascor<br />
Emcore and Gold<br />
Isofoton MagPower Soitec Sol3G SolFocus Suntrix<br />
Foton<br />
Energy<br />
As of <strong>2011</strong><br />
Planned<br />
100 11 10 50 15 10 12 30 12 50 10<br />
100 NA NA NA NA NA 50 280 NA 100 NA<br />
P V M a n u f a c t u r i n g<br />
5
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
“Compared to the<br />
more established<br />
flat plate PV<br />
technology, HCPV<br />
likely has much<br />
more headroom<br />
for improving<br />
efficiency<br />
and cost,”<br />
says Milan Rosina,<br />
Yole Développement.<br />
throw at the work. Garboushian ticks off potential<br />
ways to gain a few percentage points improvement<br />
across almost all the various components in the<br />
systems - from better multijunction cell efficiency, to<br />
better pitch angles and more accurate facets in the<br />
Fresnel lenses, up through more accurate alignment<br />
in the balance of systems, which could together<br />
perhaps add up to as much as 50% improvement<br />
overall.<br />
Key to much of this improvement is the growth and<br />
increasing maturity of the supply chain. “While the<br />
solar supply chain continues to mature, there has<br />
been no shortage of innovation,” he says, noting that<br />
the optics and components are constantly improving.<br />
On the cell side, Garboushian notes that the best<br />
cells are already 5% to 10% better than those<br />
from some other suppliers, and spectral tuning for<br />
particular locations can add up to another 5% to 10%<br />
improvement in energy generation. But going beyond<br />
three junction cells won’t be an easy step for the<br />
optics and the rest of the system.<br />
Garboushian and Amonix have been making<br />
concentrating solar for some 20 years, and were<br />
among the pioneers of the big move from silicon to<br />
compound semiconductor triple junction cells for the<br />
boost in efficiency that did much to help create a viable<br />
HCPV market not so very long ago. The company’s<br />
early 7.8 MW-scale HCPV project with Guascor<br />
Foton in Spain in 2006-2008 used silicon cells, and<br />
depended on European government subsidies to be<br />
economic. Working with Emcore and Spectrolab to<br />
stabilize the process, prove the cell reliability, and<br />
redesign the rest of the system took a year, but it cut<br />
costs roughly in half and enabled output to jump from<br />
25kW to 37kW.<br />
SolFocus permitting 30MW project, plans<br />
to double production capacity to 100MW<br />
SolFocus is stepping up to tens-of-megawatt projects<br />
as well, with a 30MW power supply agreement<br />
from San Diego Gas & Electric now in the permitting<br />
process, which may be ready to start installation later<br />
this year. Nancy Hartsoch, VP of marketing, says the<br />
company also plans to increase its production capacity<br />
from the current 50MW to 100MW this year, by adding<br />
a second $10 million robotic assembly cell at its<br />
assembly facilities in China.<br />
The San Jose, California, company has installed<br />
projects in a dozen countries, most so far relatively<br />
small, essentially to test the HCPV performance<br />
under various conditions at different sites around the<br />
world. Recent larger US installations include the 1MW<br />
Victor Valley College project, the 1MW Nichols Farm<br />
pistachio processing plant, and the ~0.5MW Coachilla<br />
water reclamation plant, the latter two particularly<br />
significant because they were put together by heavy<br />
weight project managers Bechtel and Johnson<br />
Controls, suggesting these big companies think it<br />
worthwhile to learn the HCPV business on these<br />
relatively small installations for its future potential.<br />
Another big step: the first performance warranty<br />
insurance for HCPV from Munich Re.<br />
Though the utility market will be the bigger one,<br />
Hartsoch also sees a strong market for HCPV in this<br />
type of distributed generation, for the educational,<br />
agricultural processing, and water treatment markets,<br />
all users that tend to have big electrical bills, extra<br />
land already, and renewable energy goals.<br />
Like most of the other companies in this young<br />
technology, SolFocus designed and originally made<br />
not only its own components, but even much of its<br />
custom production equipment, but as volume has<br />
increased, it has outsourced all production. The<br />
company’s founders decided from the beginning to<br />
focus on proven glass, aluminum and steel materials,<br />
and on designing for manufacturability as the best<br />
way to create a low cost product. Major parabolic<br />
dish glass supplier Flabeg makes the mirrors, using<br />
SolFocus-designed equipment to slump a square<br />
mirror. One of the big electronics assembly houses<br />
assembles the receiver units and optical cones, and<br />
an assembly company in China puts together the final<br />
systems, using a monster press to stamp out the<br />
backpan in one piece, and a three-robot cell designed<br />
to SolFocus specifications by a company from the<br />
automotive assembly industry.<br />
Hartsoch argues that the company’s unique optics<br />
design may add complexity, with its third non-imaging<br />
optic that focuses the light down through a prism to<br />
more evenly illuminate the cell, the unusually wide<br />
1.6° acceptance angle allows more margin for some<br />
misalignment in assembly, installation and tracking.<br />
“You can lose a lot of energy for every 0.25° smaller<br />
acceptance angle,” she argues.<br />
The new generation systems just introduced swap out<br />
the cells for the next generation of more efficient ones,<br />
to boost panel efficiency to 29%, and redesign the<br />
modules for easier field assembly to reportedly reduce<br />
installation costs by cutting field installation time by<br />
half. The new modules add more panels per tracker,<br />
for fewer total trackers, and pre-assemble more panels<br />
into units, for fewer units per tracker to install, and no<br />
need for alignment in the field. The electronics are also<br />
now premounted on the tracker head, so no electronics<br />
assembly is required in the field. Hartsoch says that cut<br />
field assembly time in half. “And that’s with engineers,”<br />
she quips. “In the field with construction people it<br />
should be more than a 50% reduction in assembly<br />
time.” The relatively light dish units can be installed<br />
with cranes or scaffold forklifts, and can go on spread<br />
foundations or steel piers instead of concrete and in<br />
problematic soils like sand or landfills.<br />
6<br />
P V M a n u f a c t u r i n g
I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />
ZenithSolar expects to ship 1MW this<br />
year, two 10MW projects in pipeline<br />
Also now starting to ship systems for multiple new<br />
projects is Israel’s ZenithSolar, whose unique watercooled<br />
HCPV systems also supply significant amounts<br />
of hot water at 75°-80°C or more, hot enough for<br />
industrial as well as household uses. Now that the<br />
three-year-old company’s 250kW demonstration<br />
system at Kibbutz Yavne in Israel has been up and<br />
running for about 18 months, a half dozen other<br />
customers are stepping up to try the systems—<br />
perhaps a sign of the growing maturity of the HCPV<br />
sector. Zenith started shipping its first products to<br />
projects outside of Israel in March. It now has projects<br />
in the pipeline in Australia, Gulf states, Asia and Italy,<br />
for various applications that need a lot of hot water,<br />
ranging from hospitals to utility central heating plants<br />
to water desalinization projects. CEO Roy Segev says<br />
the company expects to ship a total of 1.2MW by the<br />
end of the year. These wattage figures totals include<br />
roughly one third direct production of electricity,<br />
roughly two-thirds the thermal energy of the hot water.<br />
The ZenithSolar system was designed for cogeneration,<br />
giving up some electrical efficiency in<br />
the interests of operating at higher temperature to<br />
create the extremely hot water needed for industrial<br />
applications. The dish mirror optics focus 850x-900x<br />
suns on a dense array of cells developed with Azur<br />
Space. The cell array is attached to a microchannel<br />
heat exchanger, similar to those used in the<br />
automotive industry, which heats the pressurized<br />
cooling water to close to 100°C so it can be piped<br />
away for other uses. That means the cell itself has<br />
to operate at a dauntingly high ~120°C, but Segev<br />
argues that the cells are rated to survive under these<br />
high temperatures, albeit with some loss of efficiency.<br />
Company materials also note that the cell array can<br />
be swapped out to upgrade the system later.<br />
Key to the technology, says Segev, is the company’s<br />
high temperature transparent encapsulation paste,<br />
which seals the glass directly to the cells to protect<br />
them from degradation from air or humidity. The<br />
trackers can be placed close together because they<br />
can tolerate some shading, as the optics consist of<br />
multiple rectangular facets, each about the size of<br />
the receiver array, and each independently continues<br />
to focus its light on the array, so any shading only<br />
reduces the concentration by that of the shaded<br />
facets. Like other companies in this young sector, as<br />
volumes have increased ZenithSolar has outsourced<br />
production of more of its initially internally designed<br />
and produced components.<br />
“A lot of customers were waiting to see the Yanev<br />
data base,” says Segev, referring to the demonstration<br />
project at the Israeli town of ~1000 that gets almost<br />
all its household hot water from the HCPV system,<br />
as well as all the hot water needed for its agricultural<br />
ZenithSolar parabolic dish system<br />
(Courtesy of ZenithSolar)<br />
P V M a n u f a c t u r i n g<br />
7
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
processing businesses. The kibbutz uses high volumes of 75°-80°C<br />
water for sterilization in its canning plant and in its dairy, as well as for<br />
the heat for incubating eggs. A 5000 gallon storage tank often provides<br />
enough hot water for residents’ nighttime use, though of course there is<br />
also a backup system. The kibbutz also harvests the wine grapes from<br />
the vineyard under the trackers. Electricity is sold into the grid to earn<br />
Israel’s high feed- in tariff.<br />
ZenithSolar also has an agreement with the government of China’s Gansu<br />
province for two 10MW demonstration installations, one for centralized<br />
water heating for a residential neighborhood, one for a metal processing<br />
plant, even though purely on cost there is no way the HCPV system can<br />
compete with the very low rates for the cheap, low grade coal now used<br />
there. But the very cold and dry climate at 2000M elevation at the edge<br />
of the Gobi desert has very high DNI that should be ideal for HCPV, the<br />
systems would reduce the heavy pollution from burning the low grade<br />
coal, and ZenithSolar has agreed to move manufacturing there for clean<br />
tech local jobs and, presumably, technology development. Details will<br />
take a while longer to work out before production starts.<br />
“Things are changing very fast in China,” says Segev. “China, India and<br />
Africa will be most of the solar market in the future just because most<br />
of the energy need will be there.”<br />
Paula Doe for Yole Développement<br />
Vahan Garboushian, Founder, Chief Technology Officer, and<br />
Chairman of the Board of Directors, Amonix<br />
Mr. Garboushian has pioneered the development of concentrated<br />
photovoltaic (CPV) technology since launching Amonix in 1989;<br />
his passion, vision, and leadership over the past 20 years have made<br />
Amonix the most efficient, reliable CPV technology on the market today.<br />
Nancy Hartsoch, Vice President of Marketing and Business<br />
Development, SolFocus<br />
She is responsibe for the company’s global marketing activities and<br />
ROW business development activities. Nancy is also currently the<br />
Chairman of the CPV Consortium, a global industry organization in the<br />
CPV market segment. Prior to joining SolFocus she was CEO of Pacific<br />
Technology Group which she co-founded in partnership with Taiwan-based Acer<br />
Labs Inc. (ALi) to provide marketing, sales and applications engineering to launch<br />
an existing product line into the global market. Her 25 years of technology<br />
experience include five years as COO and VP of Marketing and Sales for Ali.<br />
Roy Segev, Founder & CEO, ZenithSolar<br />
Roy has close to 20 years of experience in Israeli and global<br />
high-tech businesses. In 2006, Roy founded ZenithSolar in order to<br />
provide comprehensive energy via a distributed network. Prior to<br />
founding ZenithSolar, Roy was a partner at Sadot, a venture capital<br />
fund that invests in early stage technology companies. Previously<br />
Roy was responsible for the finance and business development of “Magink_,<br />
a leading company in the digital ink technology for signs and billboards.<br />
Roy holds a B.Sc. in Physics and Mathematics from Hebrew University and a<br />
M.Sc. from Boston University.<br />
8<br />
P V M a n u f a c t u r i n g
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• Sept. 28:<br />
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Future devices<br />
and materials<br />
for power electronics<br />
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S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
INDUSTRY REVIEW<br />
Maturing HCPV supply chain looks<br />
to volume production issues<br />
Once the HCPV industry starts shipping hundreds of megawatts, its supply chain will<br />
have to transition to volume production as well. And a high volume business can’t be<br />
built all on custom components and custom assembly equipment.<br />
step is to work with assembly companies to design<br />
efficient production processes for these components.<br />
Then HCPV makers won’t have to do the iterations of<br />
the optics design themselves, but they can choose<br />
the appropriate balance of performance vs cost, and<br />
the tooling will already be there. “Customers can<br />
then buy components off the shelf, like in a mature<br />
industry,” says Leutz, noting that some users might<br />
for example prefer the lighter weight of PMMA, while<br />
others installing in areas with frequent sandstorms<br />
may prefer more scratch-resistant glass.<br />
Concentrator Optics<br />
Fresnel Lens Parquet<br />
(Courtesy of Concentrator Optics)<br />
“Performance<br />
data that we can<br />
talk about<br />
will help the<br />
bankability of the<br />
whole sector,”<br />
explains Ralf Leutz,<br />
Concentrator Optics.<br />
10<br />
Some helpful steps would be openly available<br />
data on the performance of some HCPV optics<br />
components, coordinated optimization of<br />
the design of the primary and secondary optics to<br />
work together, and coordinated optimization with<br />
manufacturing technologists to design efficient volume<br />
production. So Concentrator Optics founder and GM<br />
Ralf Leutz cooked up a plan to work with secondary<br />
optics supplier Isuzu Glass and cell and receiver maker<br />
AZUR SPACE to make test mockup HCPV modules<br />
to compare various combinations of three different<br />
Fresnel lenses, two different secondary optics and two<br />
different multijunction cells, to get module performance<br />
data that could be released publicly. “With tighter<br />
tolerance budgets, the design of the primary and<br />
secondary optics have to be optimized together with<br />
multiple iterations, but when we make these products<br />
for customers we can’t share how results compare to<br />
other designs or materials,” says Leutz. “Performance<br />
data that we can talk about will help the bankability of<br />
the whole sector.” Aiming for quick results, the three<br />
companies each simply supplied their components for<br />
the mockup modules for testing.<br />
Early results are showing relatively small differences<br />
between PMMA and silicone-on-glass (SOG) Fresnel<br />
lenses, and are quantifying the difference between the<br />
relatively higher performance kaleidoscope secondary<br />
optics and the lower cost half-egg alternatives. With<br />
the data on the optimized optical designs, next<br />
“We’ve played with the process long enough,” asserts<br />
Leutz. “There will have to be some standardization.”<br />
He argues that though leading companies will<br />
continue to distinguish themselves with their<br />
particular technologies, much of the industry will<br />
go to a mainstream volume production option using<br />
Fresnel lenses, secondary optics and triple junction<br />
cells. “Once the HCPV industry gets to a few hundred<br />
megawatts, it will start to look a lot more like the<br />
flat panel PV market,” suggests Leutz. “The key issues<br />
will move beyond technology, to the financing, the<br />
marketing, and the big companies. We have to be<br />
prepared for that.”<br />
While a second tier of upstart HCPV players might<br />
economically ramp production of these more standard<br />
systems, currently all the leading HCPV systems<br />
makers choose quite different options to optimize<br />
their systems. Soitec uses SOG Fresnel lenses but<br />
skips the secondary optic for easier and cheaper<br />
manufacturing, and instead compensates with extra<br />
accuracy in its trackers. Amonix uses lighter acrylic<br />
Fresnel lenses for its large units, but with a low cost,<br />
reflective aluminum secondary optic. SolFocus uses<br />
mirrors for both the primary and secondary optics,<br />
but does use a rod-shaped refractive third optic to<br />
gain a particularly large acceptance angle to allow<br />
more tolerance for imprecision in assembly and<br />
installation.<br />
Isuzu Glass: Design for manufacturing,<br />
optimization with primary, may reduce<br />
secondary optics cost<br />
Systems makers have had to design their solutions<br />
without fully knowing manufacturing costs for their<br />
custom designed components. Molded glass optics<br />
specialist Isuzu Glass reports that many HCPV<br />
companies have come to it with their designs for
I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />
secondary optics to convert the Fresnel spot to more<br />
homogenous light, to avoid hotspots that can damage<br />
the cell, and to allow a wider acceptance angle for<br />
better performance with less strict requirements<br />
for accuracy on the part of the tracker. However,<br />
typically, says Isuzu sales manager Mehmet Sinan<br />
Ata, the module makers provide the glass maker with<br />
the drawings for the glass parts, and then discover<br />
afterwards that their design is not possible to actually<br />
manufacture for anything close to the $1 or so per<br />
unit target price they expected, so few have yet to<br />
move the systems to volume production.<br />
“Then to eliminate<br />
shipping costs, the<br />
optics production<br />
lines will have to<br />
be located close to<br />
the final assembly<br />
of the modules,”<br />
added Leutz.<br />
The high cost of the precision molds and tooling make<br />
high performance molded optics expensive unless<br />
those costs are spread over high volumes, so initial<br />
requests for quotes for relatively small orders are<br />
expensive, and not particularly profitable nor of much<br />
interest to the optics companies that churn out lenses<br />
for projectors and cell phone cameras in serious high<br />
volumes. Costs can however be reduced by making<br />
the lenses as small as possible, and keeping the<br />
shapes simple and rounded for easier molding.<br />
“We’ve gotten many inquiries from different companies<br />
with totally different module designs, and we are<br />
currently supplying several module manufacturers’<br />
pilot plants around the world, but so far none have<br />
moved into high volume production,” says Ata. “We<br />
decided to work with other components suppliers<br />
to help push development ahead faster, instead of<br />
waiting for the market, to help the business move<br />
ahead more quickly.”<br />
Supply chain matures towards<br />
automated production, 20-year<br />
warranty for solar acrylic<br />
Leutz argues that the challenge of high volume, low<br />
cost production of precision optics can effectively be<br />
met only with full automation, and with a parallel<br />
production system to replicate all units from one initial<br />
master, at high speed and high optical quality. “This<br />
automated high volume production system does not<br />
fall out of the sky,” he notes. “Even companies that<br />
wanted to do it in house are needing partners.” Then<br />
to eliminate shipping costs, the optics production lines<br />
will have to be located close to the final assembly<br />
of the modules, which currently realistically means<br />
plants in the southwestern US.<br />
Concentrator Optics makes Fresnel lenses in both<br />
acrylic and silicone on glass, and Leutz argues that<br />
the differences are actually relatively minor. “Concerns<br />
over PMMA yellowing or cracking are issues of the<br />
past,” he asserts. Only PMMA has been under the<br />
sun for 20 years, but accelerated test results on both<br />
materials look good. Major PMMA supplier Evonik and<br />
Concentrator Optics now offer a 20-year performance<br />
warranty for lenses made of their UV-enhanced<br />
material, developed specifically for solar to let in more<br />
P V M a n u f a c t u r i n g<br />
Rod lens (Courtesy of Isuzu Glass)<br />
light and be more stable under extreme temperatures.<br />
Processing that heats the material thoroughly before<br />
embossing to avoid introducing stress also helps to<br />
avoid cracking or corrosion later in the field. SOG<br />
meanwhile remains slightly more expensive because<br />
of the material costs.<br />
AZUR SPACE: Clear roadmap to 45%<br />
cell efficiency<br />
AZUR SPACE also joined the project with Concentrator<br />
Optics and Isuzu Glass to try to help push the HCPV<br />
market along to more serious volumes, designing<br />
the receivers for the systems. “The most important<br />
thing is that HCPV needs to start deploying tens of<br />
megawatt projects,” says Gerhard Strobl, director of<br />
business development, AZUR SPACE Solar Power. “It<br />
needs volume to decrease costs—though it also needs<br />
to decrease costs to get to volume.”<br />
Efficiency of the multivolume cells is key to the<br />
efficiency—and ultimately the cost—of the HCPV<br />
systems, and luckily also perhaps the part of the<br />
system with the clearest roadmap for significant<br />
improvement. AZUR says it is currently shipping 40%<br />
efficient cells, aims at 42% in two years by moving<br />
from lattice matched to metamorphic cells, and then<br />
to four junctions for 45% efficiency in 4-5 years. In<br />
the long run 50% cells will be possible, says Strobl.<br />
AZUR has sufficient capacity to make the terrestrial<br />
cells on its existing lines for space applications, and<br />
steady demand for additional volumes that allowed<br />
the lines to run steadily at higher output would be<br />
key to maintaining tight process control and reducing<br />
costs. Based on optics from Concentrator Optics and<br />
Isuzu Glass, AZUR is able to deliver essentially offthe-shelf<br />
receivers for Fresnel systems and dense<br />
array receivers for mirror systems.<br />
“One gigawatt of HCPV means four square kilometers<br />
of lenses and 160 million secondaries and cells,”<br />
notes Leutz. “This is a challenge the supply chain is<br />
prepared for.”<br />
Paula Doe for Yole Développement<br />
Dr. Ralf Leutz,<br />
co-founder, CTO and<br />
CEO, Concentrator<br />
Optics<br />
He is also author of the<br />
book Nonimaging Fresnel<br />
Lenses: Design and Performance of Solar<br />
Concentrators (Springer, 2001). He<br />
earned his PhD from Tokyo University of<br />
Agriculture and Technology.<br />
Mehmet Sinan Ata,<br />
Sales Manager, Isuzu<br />
Glass Deutschland<br />
Dedicated to the company’s<br />
optical glass, lenses and<br />
color filters across the<br />
optoelectric, medical and photovoltaic<br />
industries. Previously he did overseas<br />
procurement for DMW Corp. in Japan. He<br />
has a masters degree from Rheinische<br />
Friedrich-Wilhelms-University in Bonn,<br />
Germany.<br />
Dr. Gerhard Strobl,<br />
Director Business<br />
Development, AZUR<br />
SPACE Solar Power<br />
GmbH<br />
Dr. Gerhard Strobl is now<br />
with AZUR SPACE (or its predecessor<br />
companies) since 25 years. For many<br />
years he was responsible for the space<br />
silicon solar cell development and later<br />
for the GaAs triple junction development<br />
within AZUR. Under his responsability<br />
AZUR introduced in 2003 the first fully<br />
European space triple cell with 25%<br />
efficiency (AM0, 25°C), in the last years<br />
he and his team improved the technology<br />
and the cells to 30% for space (AM0,<br />
25°C) and 40% for CPV (500x AM1.5d,<br />
25°C).<br />
Since 2007 as director business<br />
development, he is not only responsible<br />
for all R&D topics, but also for bringing<br />
new products such as CPV cells and<br />
receivers to customers and to the<br />
market.<br />
11
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
COMPANY INSIGHT<br />
Trident Solar: Progress on solar inkjet<br />
Longer lasting print heads and combo processes could make inkjet a viable alternative<br />
for next generation solar cell processing<br />
Steve Liker,<br />
Director of Sales &<br />
Marketing, Trident Solar -<br />
Trident Industrial Ink Jet<br />
Inkjet printing has been a hard sell to the solar<br />
industry to date, but it’s one possible option<br />
for solving some of the process issues as the<br />
industry moves to thinner wafers, better contacts,<br />
and selective emitter and back contact patterning.<br />
Trident Solar says new inkjet technology may now<br />
be ready to do etching and doping in one step, at<br />
2000-3000 wph, with improved reliability.<br />
There’s likely a limit to how much more the<br />
industry can improve the efficiency of contacts<br />
screen printed with porous paste, pushing the<br />
sector towards electroplating, while efforts to<br />
reduce costs continue to push towards thinner<br />
wafers that require non-contact printing of fineline<br />
seed layers. “We’ll need a non-contact process<br />
and narrower lines,” argues Steve Liker, Trident<br />
director of sales and marketing. “All the arrows are<br />
pointing away from screen and laser.” Trident Solar<br />
is a division of graphics print head and ink supplier<br />
Trident Industrial Inkjet in Brookfield, Connecticut.<br />
The company is introducing a single-step etching<br />
and doping ink for printing selective emitters<br />
in concert with screen printing metallization<br />
fingers. One of the components in the etching<br />
solution is a phosphoric acid, which first etches<br />
through the SiNx layer when heated, then as the<br />
temperature increases further begins to work as a<br />
phosphor n-dopant. Trident worked to develop the<br />
material for a year and half with partner Cookson<br />
Electronics, who will produce the solution. Trident<br />
is working with Roth & Rau’s OTB Solar and other<br />
integrators to provide the wafer handling and<br />
transfer, and to market and service the tools. That<br />
same Roth & Rau unit already markets competing<br />
screen printing and laser systems for these same<br />
applications.<br />
The next step in development is to also add the<br />
chemistry to print a seed layer for electroplating<br />
the contacts with the same etchant/dopant ink,<br />
so all three steps for forming the selective emitter<br />
and seed layer could be printed in the same pass.<br />
It would, however, also be possible to minimize<br />
process steps by a separate print head or a<br />
separate printing pass on the same tool.<br />
The technology is still in the R&D stage at<br />
customers, with most interest currently focused on<br />
selective emitters and emitter wrap through, says<br />
Liker, though some customers are also looking<br />
at patterning back contacts. There’s also some<br />
interest from thin film solar makers for etching and<br />
Trident 256 Jet Solar printhead (Courtesy of Trident)<br />
12<br />
P V M a n u f a c t u r i n g
I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />
metalizing vias. Here too Trident is working on development of an<br />
ink that can do both the etching and the metallization in one pass.<br />
Liker argues that non-contact inkjet processing for etch, doping and<br />
metallization will result in higher yields than either screen printing<br />
or laser processes, especially for high efficiency processes on<br />
thinner wafers. Better lasers do ablation or vias with less damage<br />
than the older lasers, but reportedly still do some damage to the<br />
morphology of the textured silicon top surface for selective emitter<br />
processes, and around the via holes for back contact processes,<br />
while the sector now expects ever less wafer loss. “It used to be<br />
acceptable to have 0.5% to 1% scrap,” notes Liker. “But now the<br />
goal is 0.1% scrap.”<br />
Liker reports the company has solved some of the nagging<br />
reliability issues with inkjet in production by designing a print head<br />
specifically for solar applications, made of stainless steel so it can<br />
hold up to aggressive liquids, from 2-14 pH, for jetting things like<br />
phosphoric acid and KOH etchants. The company claims its head<br />
lasts at least 5x longer in production with acids than earlier print<br />
heads adapted from the graphics industry. Trident’s piezoelectric<br />
piston design draws fluid into the chamber when the piston pulls<br />
back, then pushes forward to eject the fluid out the nozzle. This<br />
high pressure produces droplets as small as 7pl, and enables thicker<br />
fluids to be jetted.<br />
Focus so far has been on single pass, single step process applications,<br />
where one or two of the four-inch heads can cover the entire wafer.<br />
That simplifies handling to merely passing the wafer under the head,<br />
allowing target speeds of typical solar rates of 2000-3000wph.<br />
Patterning can be done on the fly by digitally selecting when to open<br />
which of the 256 holes across the head.<br />
Inkjet printing is of course already a well established high speed<br />
industrial process. Trident Industrial Inkjet has been making ink<br />
jet heads and inks for the graphics printing industry, used in high<br />
speed, low cost printing of thing like packaging and bar codes, for<br />
more than 30 years. The industrial inkjet business is one of the<br />
many businesses of Illinois Tool Works (ITW), a $16B diversified<br />
manufacturer of fasteners, components and materials for everything<br />
from the auto industry to industrial packaging, commercial food<br />
equipment to chemicals.<br />
www.trident-itw.com<br />
Steve Liker, Director of Sales & Marketing, Trident Solar<br />
Trident Industrial Ink Jet<br />
He has 31 years of experience in the engineering and marketing of Piezoelectric<br />
Ink Jet printheads for industrial applications. His experience prior to joining<br />
Trident-ITW was as an Engineer in the field of ink jet development with<br />
Dataproducts and Exxon Office Systems. Mr. Liker holds five patents in ink<br />
jet technology. He has a B.S. degree in Physics from Upsala College in New<br />
Jersey, U S A.<br />
P V M a n u f a c t u r i n g 11
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
COMPANY INSIGHT<br />
ESI: Progress on laser technology<br />
opens new process options<br />
Tailored-pulse laser targets more precise micromachining across PV processes<br />
Richard Murison,<br />
CTO and Director<br />
of Product Marketing,<br />
PyroPhotonics Lasers<br />
One interesting option for faster, cleaner<br />
material removal process steps could be<br />
tailoring the temporal shape of the laser<br />
pulse to precisely control the micromachining.<br />
Already in mass production use for DRAM repair,<br />
such tailored pulse lasers are slated to be<br />
integrated into solar scribing production systems<br />
for all three scribes for CIGS thin film solar cells by<br />
the first half of next year.<br />
Supplier ESI says the ability to customize the shape,<br />
height, and width of the laser pulse nanosecond by<br />
nanosecond, independent of the repetition rate,<br />
enables higher quality P2 and P3 scribes on CIGS<br />
at lower cost than the current mechanical scribing.<br />
The company reports encouraging research results<br />
as well for scribing ZnO and CdTe on glass with less<br />
damage, and for drilling holes at high speeds for<br />
emitter wrap through applications.<br />
where it offers higher throughput than the current<br />
needle scribing process, avoids the need to stop<br />
to change the scribing needle as it dulls, and may<br />
potentially allow the scribes to be spaced closer<br />
together as space no longer has to be left to<br />
allow for chipping. Though the system is not yet<br />
in production, PyroPhotonics co-founder and CTO<br />
Richard Murison says the company is talking to<br />
most of the major CIGS makers and almost all of<br />
the thin film solar scribing equipment integrators.<br />
“First we have to convince the CIGS maker that the<br />
process works, and then they hand it off to their<br />
preferred integrator, so the process takes a while,”<br />
notes Murison. His co-founder Tullio Panarello,<br />
now GM, says that some customers trying the<br />
more expensive competing pico-second lasers<br />
are finding issues with heat damage on one of the<br />
scribes so are coming back to consider the tailored<br />
pulse option.<br />
Tullio Panarello, General<br />
Manager of the Laser<br />
Business Unit, ESI<br />
ESI (Portland, Oregon) acquired the technology<br />
by purchasing startup PyroPhotonics Lasers<br />
(Montreal, Canada) to assure its supply of the<br />
lasers for its memory business, but the company<br />
is now targeting the potentially far larger solar<br />
market for laser processes. First market driver<br />
is for P2 and P3 scribing passes for CIGS cells,<br />
Murison also reports some success scribing ZnO<br />
on glass, where the alternative process for the<br />
P1 scribe has been difficult to control precisely<br />
enough to avoid either leaving cracks in the glass<br />
on the one hand, or else not cleanly scribing away<br />
the oxide. But tailoring the laser pulse to start with<br />
a large spike and then reducing to a lower intensity<br />
CIGS scribing by time domain tailored-pulse laser (Courtesy of ESI)<br />
14<br />
P V M a n u f a c t u r i n g
I S S U E 1 3 S E P T E M B E R 2 0 1 1<br />
is said to cleanly remove the oxide without<br />
damaging the glass. Work on the P1 scribe for CdTe<br />
thin film shows potential to reduce process steps<br />
by leaving intact a barrier layer which prevents<br />
sodium from the soda-line glass diffusing into<br />
the scribe and poisoning the CdTe. Typically the<br />
CdTe P1 scribe removes the barrier layer and must<br />
therefore be backfilled with a planarizing filler to<br />
avoid sodium diffusion. The tailored pulse laser,<br />
however, can etch precisely through only the TCO<br />
on the architectural glass substrate, leaving the<br />
underlying SiO 2<br />
barrier layer intact.<br />
Other work with the Fraunhofer Institute in<br />
Michigan found that the shaped beam laser was<br />
much faster than conventional lasers for drilling<br />
the thousands of hole per second across the<br />
wafer needed for emitter wrap through solutions.<br />
Practical mass production of EWT will likely need<br />
drilling some 10,000 holes across the wafer at<br />
one wafer per second without too much damage,<br />
while a conventional 100W laser can only do about<br />
4,300 holes per second. ESI’s 25W tailored-pulse<br />
laser drilled 6,800 holes per second in the tests<br />
in the Fraunhofer lab. Murison says ESI has since<br />
made considerably more improvement in its own<br />
lab as it has learned more about how light actually<br />
interacts with silicon. The solution turns out to be<br />
tailoring the pulse to first heat up the silicon before<br />
hitting it hard, which enables the material to use<br />
the available energy more efficiently. Typically<br />
a laser drills quickly down through the first part<br />
of the hole as the silicon melts, but then about<br />
halfway through the process slows down as the<br />
silicon starts to boil and vaporize, filling the hole<br />
with silicon plasma that absorbs the laser light.<br />
The relatively low 25W power of the ESI pulseshaped<br />
laser currently limits the throughput of<br />
removal processes, and so limits use for a number<br />
of c-Si solar laser applications. The company<br />
is currently working on the tricky business of<br />
developing a higher power version, as pulsetailoring<br />
is typically only possible at relatively<br />
low power. Unlike a standard Q-switching laser,<br />
where the energy is stored up then all released<br />
in one flash that can’t be precisely controlled, the<br />
fiber laser’s low power continuous beam can be<br />
shaped by an optical modulator. The PyroPhotonics<br />
technology controls the modulator by changes in<br />
voltage, for faster response rate than changing<br />
the current. The beam must then be amplified to<br />
be most useful. The founders say their approach<br />
allows very precise control of the shape at low<br />
power, so the beam remains tailored even through<br />
the distortions created by amplification.<br />
www.esi.com<br />
Richard Murison, CTO and Director<br />
of Product Marketing,<br />
PyroPhotonics Lasers<br />
Richard Murison received his BSc in<br />
Physics from Loughborough University of<br />
Technology, UK and is Chief Technology<br />
Officer and Director of Product Marketing<br />
at PyroPhotonics Lasers, a subsidiary of<br />
ESI, Inc.<br />
Tullio Panarello, General Manager<br />
of the Laser Business Unit, ESI<br />
Tullio Panarello serves as the General<br />
Manager of the ESI’s Laser Business Unit.<br />
Mr. Panarello joined ESI in <strong>September</strong><br />
2010 following the acquisition of<br />
PyroPhotonics Lasers, Inc. He co-founded<br />
PyroPhotonics in 2003 and served as the<br />
company’s CEO.<br />
Register<br />
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15
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
A N A L Y S T C O R N E R<br />
The future of photovoltaics is<br />
inescapably about efficiency<br />
As efficiency becomes the key differentiator among solar brands, it means<br />
opportunity for new equipment processes and higher purity materials, and perhaps<br />
even for HCPV.<br />
Milan Rosina,<br />
Market and Technology<br />
Analyst,<br />
Yole Développement<br />
As gigawatt-scale production in low cost<br />
regions has pushed the cost of solar modules<br />
down sharply, the balance of systems and<br />
installation costs have come to account for a larger<br />
percentage of total system costs, making higher<br />
efficiency for each module an increasingly important<br />
way to reduce all these area-related costs. But with<br />
the current oversupply of commodity modules,<br />
efficiency is also becoming the key differentiator<br />
for solar brands, providing visibility and indicating<br />
quality and reliability.<br />
That means increasing user interest in new process<br />
equipment technologies to improve efficiency,<br />
and in higher purity materials. It also means the<br />
competitive advantage will increasingly accrue<br />
to high volume producers with stable control of<br />
their process, making it harder for small players<br />
to successfully bring alternative technologies to<br />
market. And as all technologies continue to improve<br />
in cost and performance, those with more limited<br />
potential for improving efficiency - like amorphous<br />
silicon - will get left behind, while those with<br />
greater potential efficiency may have the ultimate<br />
advantage.<br />
Demand for higher efficiency opens<br />
opportunity for equipment makers<br />
to supply new processes<br />
The drive for efficiency means increasing customer<br />
interest in low cost solutions for improving<br />
performance, particularly in those areas with big<br />
potential impact from relatively modest changes<br />
to the total cell design or process flow, such as<br />
decreasing the width and increasing the conductivity<br />
of metallization lines, adding selective emitters, and<br />
going to some back-contact designs. Screen printing<br />
will likely hit a wall in 2-3 years, to be replaced by<br />
some sort of plating. The industry is also going to<br />
move to thinner wafers, not just to reduce costs, but<br />
also to improve efficiency by reducing the impact of<br />
defects: by reducing thickness of the material with<br />
defects through which the photons and electrons<br />
must travel. That will open opportunities for gentler,<br />
non-contact processes like inkjet printing and laser<br />
ablation.<br />
Development status for different PV technologies showing an increasing potential<br />
for high efficiency PV technologies<br />
(Yole Développement, <strong>2011</strong>, HCPV report)<br />
Efficiency at module level<br />
30%<br />
22%<br />
14%<br />
12%<br />
11%<br />
10%<br />
9%<br />
8%<br />
6%<br />
Very high efficiency - Low<br />
volume production<br />
High efficiency - Mass<br />
production<br />
Medium to low efficiency -<br />
Mass production<br />
Very low efficiency - Very low<br />
production (R&D stage)<br />
DSSC<br />
-V<br />
HCPV<br />
CIGS<br />
C-Si<br />
CdTe<br />
a-Si/μc-SI<br />
a-Si<br />
“Moving<br />
target”<br />
5%<br />
Organic<br />
Fundamental<br />
research<br />
Industrial<br />
research<br />
Pilot Medium volumes<br />
Development status<br />
Mass production<br />
>1GW<br />
16 P V M a n u f a c t u r i n g
I S S U E N ° 1 3 S E P T E M B E R 2 0 1 1<br />
Inkjet has high potential for non-contact deposition<br />
of etchants, dopants and metals, though the process<br />
can be slow, and the fast-drying materials can easily<br />
clog the tiny nozzles to limit performance, presenting<br />
needs for new inks, new head designs and cleaning<br />
processes, and perhaps new solutions to recognize<br />
and correct print areas where blocked nozzles<br />
have impacted deposition quality. Lasers also have<br />
considerable potential for innovative improvements<br />
to solar manufacturing, as their highly-localized<br />
heating allows precise control of micromachining<br />
with little thermal stress or mechanical damage for<br />
fine geometry features on delicate thin wafers. Both<br />
inkjet and laser production processes are already<br />
well established in other high volume industries,<br />
which could accelerate the development of solar<br />
applications.<br />
Higher quality cells require purer,<br />
higher-performance materials, more<br />
controlled processes<br />
Improving solar efficiency will also require purer<br />
materials and more careful control of processes<br />
for contamination. As cell efficiency starts to get<br />
closer to theoretical limits, after 18% or so, eking<br />
out the next round of gains will mean paying<br />
more careful attention to the small stuff. The PV<br />
industry will need to evolve beyond its focus on<br />
high speed automation modeled on that of the<br />
automotive industry, to start to look more like the<br />
semiconductor industry - with its obsession with<br />
contamination control and process monitoring, and<br />
its practices of filter use, cleaning technologies, and<br />
keeping humans away from the processing. Gases,<br />
de-ionized water and other standard materials<br />
for PV production will all move to higher levels of<br />
purity and quality. On the cost reduction front,<br />
replacing silver metallization with copper could gain<br />
a significant advantage, but some reliability issues<br />
with corrosion and Cu migration into the silicon<br />
remain, necessitating additional buffer and capping<br />
steps that add back costs.<br />
Demand will move to higher purity<br />
polysilicon as well<br />
PV makers are increasingly demanding higher<br />
quality polysilicon as well, for higher efficiency cells.<br />
Yole Développement projects that demand will<br />
move to semiconductor grade material—9 nines to<br />
11 nines purity—essentially displacing solar-grade<br />
poly almost entirely in the market. With a backlog<br />
of solar module supply built up in inventory, and<br />
slowing demand from the cutbacks in government<br />
incentives, demand for poly this year looks likely<br />
to come in considerably below last year’s 160,000<br />
MT, leaving an oversupply in the sector. The four<br />
leading suppliers Wacker Chemie (Germany),<br />
Hemlock Semiconductor (Michigan, US), OCI<br />
(Korea) and GCL Poly (China), who are all providing<br />
semiconductor-grade material, together have enough<br />
P V M a n u f a c t u r i n g<br />
capacity among them to supply the entire PV<br />
industry demand this year. With no constraints<br />
on availability, it will be the higher purity material<br />
from these leading suppliers that sells, and enough<br />
demand for it to maintain poly prices stable at<br />
around $50/kg this year. Many of the new entrants<br />
who more recently added poly capacity have found<br />
it harder than expected to optimize this complex<br />
chemical process to match the leading pure-play<br />
players in quality and cost, and many will likely<br />
quietly get out of the business.<br />
HCPV efficiency could provide an edge,<br />
if sector and supply chain can scale to<br />
volume<br />
Long term trends towards efficiency could bode<br />
well for the future of HCPV, and this still barely<br />
commercial technology has wide margin to bring<br />
down costs if it moves to volume production. HCPV<br />
now reaches 29% efficiency at the module level at<br />
leading suppliers, compared to 17%-20% for the<br />
top flat panels, and it has even more of an edge in<br />
hot climates, as its performance degrades less at<br />
temperature.<br />
Plenty of hurdles remain, however, for this<br />
complicated new technology. Appropriately sunny<br />
locations remain limited, long term reliability remains<br />
unproven and actual commercial production so far<br />
remains insignificant. Though HCPV suppliers claim<br />
that the technology can deliver the lowest levelized<br />
cost of energy with the least use of land on some<br />
sites, the actual results can vary significantly for<br />
particular location, climate and topography, so even<br />
big users first want to try small test installations on<br />
their sites, and this small installation stage could<br />
continue for some time. Meanwhile, the large flat<br />
panel PV sector is continually investing its far bigger<br />
resources into improving its efficiency and bringing<br />
down its costs. While HCPV may have big potential<br />
with enough investment, with the market still so<br />
small, the sector has limited resources to put into<br />
development.<br />
The supply chain of key components on which<br />
HCPVsystems depend has even less to invest, as the<br />
total markets for each of the various components,<br />
from epi wafers to lenses to trackers, remain even<br />
smaller still. Progress will depend on getting to big<br />
projects to get volumes up to bring down costs,<br />
by spreading the fixed costs of the 25MW-50MW<br />
capacity HCPV plants over megawatt and not just<br />
kilowatt-scale projects, and fully automating both<br />
component production and system assembly - and<br />
finding the significant capital to invest to do so.<br />
Perhaps even more important will be finding the<br />
solutions for the most effective business models or<br />
working partnerships among the parts of the supply<br />
chain. As volumes grow, HCPV systems makers<br />
17<br />
“Lasers also have<br />
considerable<br />
potential for<br />
innovative<br />
improvements<br />
to solar<br />
manufacturing,<br />
as their highlylocalized<br />
heating<br />
allows precise<br />
control of<br />
micromachining<br />
with little<br />
thermal stress<br />
or mechanical<br />
damage,”<br />
says Milan Rosina,<br />
Yole Développement
S E P T E M B E R 2 0 1 1 I S S U E N ° 1 3<br />
HCPV supply chain - Positioning of the HCPV players: three scenarios<br />
(Yole Développement, <strong>2011</strong>, HCPV report)<br />
“HCPV systems<br />
makers are largely<br />
outsourcing<br />
production of their<br />
custom component<br />
designs to<br />
optics makers,<br />
tracker makers<br />
and electronics<br />
contract<br />
assemblers,”<br />
says Milan Rosina,<br />
Yole Développement<br />
are largely outsourcing production of their custom<br />
component designs to optics makers, tracker makers<br />
and electronics contract assemblers. But it is difficult<br />
for the system makers to best optimize the system<br />
cost and performance without knowing exactly how<br />
design choices will impact manufacturing costs at<br />
the supplier, or how one component can best be<br />
optimized to work with another component made<br />
by someone else. Optimizing the system requires<br />
careful balancing of all the parts, trading off more<br />
complicated and expensive optical systems for less<br />
accurate trackers or vice versa, or adjusting the<br />
characteristics of the primary optic to those of the<br />
secondary optic, and that’s hard to do by separate<br />
players.<br />
The fragmented sector is equally a problem from the<br />
supplier side. Suppliers argue that the components<br />
could be better designed for efficient low cost<br />
manufacture if the designer knew something about<br />
the manufacturing process, and that components<br />
could be better optimized to work together if they<br />
were designed together. Tracker makers complain<br />
that they have no visibility into if the market is big<br />
enough to support development of custom trackers<br />
for modules of entirely different size, weight, and need<br />
for accuracy. Designing custom components for each<br />
separate system maker’s kilowatt-scale projects is a<br />
very low volume business, with volumes sometimes<br />
only in the hundreds of units, often too small a<br />
business to be of much interest for the supplier, and<br />
too small for efficient volume production.<br />
Much depends on the successful performance of the<br />
early megawatt-scale HCPV projects now coming<br />
on line to build credibility for the technology. But<br />
building the first larger 10s and 100s of megawattscale<br />
installations will also require business<br />
models that enable optimized system design and<br />
foster a viable supply chain to support volume<br />
manufacturing.<br />
www.yole.fr<br />
Milan Rosina is analyst at Yole Développement for<br />
photovoltaic market & technologies. He received<br />
his Ph. D. in 2002 from the INPG in France. He<br />
gained experience as a research scientist in several<br />
renowned R&D institutions & industrial companies<br />
where he worked in the field of microelectronics, PV,<br />
LED & nanotechnology.<br />
18 P V M a n u f a c t u r i n g
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