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Presentation: REC Granular Polysilicon Technology

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RENEWABLE ENERGY CORPORATION<br />

GRANULAR<br />

POLYSILICON<br />

TECHNOLOGY<br />

Tore Torvund, CEO <strong>REC</strong> Silicon<br />

SNEC 2012 (Shanghai, China)<br />

May 17, 2012


Disclaimer<br />

This <strong>Presentation</strong> includes and is based, inter alia, on forward-looking information and statements that are subject to risks<br />

and uncertainties that could cause actual results to differ. These statements and this <strong>Presentation</strong> are based on current<br />

expectations, estimates and projections about global economic conditions, the economic conditions of the regions and<br />

industries that are major markets for <strong>REC</strong> ASA and <strong>REC</strong> ASA’s (including subsidiaries and affiliates) lines of business. These<br />

expectations, estimates and projections are generally identifiable by statements containing words such as ”expects”,<br />

”believes”, ”estimates” or similar expressions. Important factors that could cause actual results to differ materially from those<br />

expectations include, among others, economic and market conditions in the geographic areas and industries that are or will<br />

be major markets for <strong>REC</strong>’s businesses, energy prices, market acceptance of new products and services, changes in<br />

governmental regulations, interest rates, fluctuations in currency exchange rates and such other factors as may be<br />

discussed from time to time in the <strong>Presentation</strong>. Although <strong>REC</strong> ASA believes that its expectations and the <strong>Presentation</strong> are<br />

based upon reasonable assumptions, it can give no assurance that those expectations will be achieved or that the actual<br />

results will be as set out in the <strong>Presentation</strong>. <strong>REC</strong> ASA is making no representation or warranty, expressed or implied, as to<br />

the accuracy, reliability or completeness of the <strong>Presentation</strong>, and neither <strong>REC</strong> ASA nor any of its directors, officers or<br />

employees will have any liability to you or any other persons resulting from your use.<br />

This presentation was prepared for SNEC 2012 Silicon Materials Session held in Shanghai, China on May 17, 2012.<br />

Information contained within will not be updated. The following slides should be read and considered in connection with the<br />

information given orally during the presentation.<br />

The <strong>REC</strong> shares have not been registered under the U.S. Securities Act of 1933, as amended (the "Act"), and may not be<br />

offered or sold in the United States absent registration or an applicable exemption from the registration requirements of the<br />

Act.<br />

2 2012 Copyright <strong>REC</strong>


<strong>REC</strong> Silicon: Global Reach<br />

Moses Lake WA,<br />

USA<br />

<strong>REC</strong> Silicon headquarters<br />

Manufacturing Facilities<br />

Sales Offices<br />

3 2012 Copyright <strong>REC</strong><br />

Butte MT, USA<br />

Houston TX, USA<br />

Tokyo, Japan<br />

Shanghai, China<br />

Taipei, Taiwan


Overview of Our <strong>Polysilicon</strong> Plant<br />

� Our polysilicon plant consists of two separate plants working seamlessly<br />

together<br />

– Silane gas plant<br />

– <strong>Polysilicon</strong> plant (Siemens and FBR reactor plant)<br />

4 2012 Copyright <strong>REC</strong><br />

SILANE GAS PLANT<br />

POLYSILICON PLANT


Our Operational Flexibility & Redundancy<br />

5 2012 Copyright <strong>REC</strong><br />

Silane Loading<br />

Silicon II<br />

Silane<br />

Silane gas to TFT,<br />

Semi and Solar<br />

Butte Moses Lake<br />

Siemens<br />

<strong>Polysilicon</strong> to Solar<br />

and Semi<br />

Silicon I<br />

Silane<br />

Silicon III<br />

Silane<br />

Silicon IV<br />

Silane<br />

FBR Silane Loading<br />

Solar grade Silane gas to TFT ,<br />

Semi and Solar


FBR: <strong>Technology</strong> for<br />

a Sustainable Future<br />

RIGHT HERE AT <strong>REC</strong><br />

<strong>REC</strong> Silicon production plant, Moses Lake WA, USA


<strong>REC</strong> Fluidized Bed <strong>Technology</strong> (FBR)<br />

� Reactors<br />

– Vertical Reactors: High flow rates that allow<br />

fluidization<br />

– Fluidization: Granules balanced by gas flow<br />

friction, improved heat transfer<br />

– YIELD: High yield with proprietary silane<br />

process<br />

� Significant energy savings<br />

– Continuous vs. Batch Process<br />

– Hot Wall vs. Cold Wall Design<br />

� Demonstrated volume production<br />

– <strong>REC</strong> has invested over 10 years of research<br />

in Silane-based fluid bed deposition<br />

7 2012 Copyright <strong>REC</strong><br />

Silane<br />

+<br />

H2<br />

Effluent<br />

Gas


Consumption KWh/Kg Optimized Siemens vs. FBR<br />

* GT SDR-400 Commercial field data, as of June 2011<br />

** FBR Actual Q1 2012<br />

8 2012 Copyright <strong>REC</strong><br />

CVD ELECTRICITY CONSUMPTION<br />

45 KWh/kg<br />

4.1 KWh/kg<br />

100% 9%<br />

Best in Class TCS Siemens* <strong>REC</strong> FBR**


<strong>REC</strong> Silicon FBR Cost Breakdown<br />

9 2012 Copyright <strong>REC</strong><br />

Other Mfg<br />

Costs<br />

26%<br />

Electricity<br />

Silane<br />

4%<br />

Manufacturing<br />

Labor &<br />

Support<br />

32%<br />

Electricity<br />

FBR<br />

1%<br />

MGS<br />

37%


Cash cost of USD 12.5/kg - Leading cost Position<br />

among <strong>Polysilicon</strong> Companies<br />

� FBR production target of<br />

15,000 MT in 2012, 40 percent<br />

above design capacity<br />

10 2012 Copyright <strong>REC</strong><br />

Silicon – FBR<br />

USD/kg<br />

42<br />

4<br />

16<br />

23<br />

Q3’10<br />

-39%<br />

26<br />

4<br />

8<br />

14<br />

Q4’11<br />

-13%<br />

SG&A and R&D<br />

Depreciation<br />

Cash production cost<br />

23<br />

3<br />

7<br />

12.5<br />

Q1’12<br />

3<br />

7


Significant Growth in <strong>REC</strong>’s FBR Capacity<br />

MT<br />

25 000<br />

20 000<br />

15 000<br />

10 000<br />

5 000<br />

0<br />

11 2012 <strong>REC</strong> - Strictly Confidential<br />

6 000<br />

<strong>REC</strong> Silicon Production Capacity by <strong>Technology</strong><br />

6 300<br />

7 500<br />

13 000<br />

19 000<br />

21 500<br />

FBR<br />

70%<br />

2007 2008 2009 2010 2011 2012<br />

FBR<br />

Siemens


FBR <strong>Granular</strong> Increases Process Efficiency for<br />

Wafer Manufacturers<br />

� Customers<br />

– About 20 different customers are currently<br />

using our <strong>Granular</strong> products<br />

– Users have quickly built a strong preference<br />

for <strong>Granular</strong> material<br />

� Cost savings<br />

– Customers confirm significant cost savings<br />

achieved by using granular material (blended<br />

with chunk)<br />

– Enables recharge (i.e. replenishing the melt<br />

as the ingot is pulled)<br />

– Maximizes initial crucible charge weight<br />

– Enables top-off (i.e. adding polysilicon to the<br />

crucible after the initial melt to raise the<br />

molten silicon level towards the top of the<br />

crucible)<br />

12 2012 Copyright <strong>REC</strong><br />

Use of <strong>Granular</strong> in ingot making process<br />

The <strong>Granular</strong> form factor improves productivity<br />

used together with chunk polysilicon by<br />

increasing crucible charge weight<br />

� Increased packing density<br />

� Enables top-off and recharge<br />

� Easier to handle


FBR <strong>Granular</strong> Significantly Increases Productivity<br />

Blend<br />

100%<br />

Siemens<br />

50%<br />

Siemens<br />

50%<br />

<strong>Granular</strong><br />

13 2012 Copyright <strong>REC</strong><br />

Filling<br />

Time<br />

48.5<br />

mins.<br />

28.5<br />

mins.<br />

Improvement vs.<br />

100% Siemens<br />

Weight<br />

Improvement vs.<br />

100% Siemens<br />

N/A N/A 63.8 kg N/A N/A<br />

20.0<br />

mins.<br />

40% improvement<br />

in filling time<br />

Note: Same 60 kg. crucible used for all tests. Crucible filled to top, level with crucible edge in all tests.<br />

41.2% 82.5 kg 18.7 kg 29.4%<br />

30% increase in<br />

charge weight


Future<br />

Development<br />

RIGHT HERE AT <strong>REC</strong><br />

<strong>REC</strong> Silicon materials


P I L O T S T U D I E S<br />

Fluid Bed Development History – Timeline<br />

1990s 2004 2005 2006 2007 2008 2009 2010 2011 2012<br />

FBR Pilot<br />

Reactors 1, 2 & 3<br />

- Feasibility<br />

Modeling/Validation/Operability<br />

15 2012 <strong>REC</strong> - Strictly Confidential<br />

C O M M E R C I A L<br />

FBR-B Next Generation Reactor<br />

- Started-up 3Q 2009<br />

FBR-A Demonstration Reactor<br />

- Process Control ↔ Key Controls<br />

- Design of Experiments ↔ Process Optimization<br />

- Design Validation ↔ Scale Up<br />

- Customer Qualification<br />

Plant 3.0 Commercial Process<br />

- Design ↔ Engineering ↔ Construction<br />

- Started-up 4Q 2008<br />

FBR-B Next Generation Reactor<br />

- Proof of Enhanced Quality &<br />

Operability at Reduced Cost<br />

Implementation of<br />

FBR-B Developments<br />

Plant 3.0 Commercial Process<br />

Continual Process Improvement<br />

- 15,000 MT/yr<br />

N E X T G E N E R A T I O N


<strong>Polysilicon</strong> Supply, Demand & Spot Prices<br />

MT<br />

500 000<br />

450 000<br />

400 000<br />

350 000<br />

300 000<br />

250 000<br />

200 000<br />

150 000<br />

100 000<br />

50 000<br />

0<br />

16 2012 Copyright <strong>REC</strong><br />

2011 2012 2013 2014 2015 2016<br />

<strong>Polysilicon</strong> Production Capacity (All Companies)<br />

Capacity Top 5 Companies<br />

Semi Demand<br />

Semi + PV Demand<br />

Top 5 Companies: GCL, OCI, HSC, WCH & <strong>REC</strong><br />

Source: iSuppli PV Integrated Market Tracker (Q1 2012)<br />

$/kg<br />

80<br />

70<br />

60<br />

50<br />

40<br />

30<br />

20<br />

Jan<br />

Apr<br />

7/4/2011<br />

7/25/2011<br />

8/15/2011<br />

9/5/2011<br />

9/26/2011<br />

10/17/2011<br />

11/7/2011<br />

11/28/2011<br />

2011 2012<br />

PV Insights Bloomberg<br />

Data as of April 25, 2012.<br />

Source: Bloomberg New Energy Finance & PV Insights.<br />

12/19/2011<br />

1/9/2012<br />

1/30/2012<br />

2/20/2012<br />

3/12/2012<br />

4/2/2012<br />

24,64<br />

24,48<br />

4/23/2012


Only ~20,000 MT FBR <strong>Polysilicon</strong> Available<br />

250000<br />

200000<br />

150000<br />

100000<br />

50000<br />

0<br />

17 2012 Copyright <strong>REC</strong><br />

2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020<br />

Si V<br />

Market opportunity for<br />

flowable polysilicon<br />

Si VI<br />

Si VII<br />

Installed FBR Cpacity Potential Market for FBR Poly (Assuming 50/50 blend ratio)


China is the Main Market for <strong>Polysilicon</strong> to the Solar<br />

Wafer Market<br />

Japan<br />

7 %<br />

Korea<br />

14 %<br />

18 2012 Copyright <strong>REC</strong><br />

<strong>Polysilicon</strong> Production<br />

Source: Solarbuzz<br />

Germany<br />

15 %<br />

USA<br />

24 %<br />

China<br />

40 %<br />

Other<br />

5 %<br />

USA<br />

3 %<br />

Solar Wafer Production<br />

Germany<br />

3 %<br />

Japan<br />

7 %<br />

Taiwan<br />

6 %<br />

China<br />

76 %


FBR - A Disruptive <strong>Polysilicon</strong> <strong>Technology</strong><br />

19 2012 Copyright <strong>REC</strong><br />

PRELIMENARY ESTIMATES<br />

Current FBR cash cost vs China FBR cash cost (USD/kg)*<br />

12,5<br />

Q1 2012<br />

cash cost<br />

MGS<br />

Manufacturing<br />

labor &<br />

support<br />

*) Based on high level preliminary studies<br />

Other<br />

7,9<br />

China FBR<br />

Cash cost*


FBR Capex – Competitive with Siemens<br />

20 2012 Copyright <strong>REC</strong><br />

107,0<br />

Current FBR Optimized<br />

capex/kg plant design<br />

China<br />

location<br />

savings<br />

50,0<br />

China FBR<br />

Capex/kg*<br />

PRELIMENARY ESTIMATES<br />

Current FBR capex/kg vs China FBR capex/kg (USD/kg)*<br />

*) Based on high level preliminary studies


FBR Cost Per Kg* Development<br />

*Blended cost per kg for all quality grade polysilicon<br />

21 2012 Copyright <strong>REC</strong><br />

USD/kg<br />

35<br />

30<br />

25<br />

20<br />

15<br />

10<br />

5<br />

0<br />

32,9<br />

12,9<br />

20,0<br />

Q1 2010<br />

25,9<br />

10,0<br />

15,9<br />

19,1<br />

6,6<br />

12,5<br />

Q1 2011 Q1 2012<br />

11,3<br />

3,3<br />

7,9<br />

FBR China<br />

PRELIMENARY<br />

ESTIMATES<br />

Deprication<br />

Cash cost


The STAR Center<br />

� Silicon Technologies Applications Research Center<br />

– Location: Shangyu, Zhejiang Province<br />

– In partnership with Zhejiang Jingsheng M&E Engineering Co. Ltd.<br />

– Phase 1 scope: Solar Grade CZ puller/s, analytical, FIBC transport, de-dusting<br />

& recharge systems<br />

– Operational by Q4 2012<br />

22 2012 Copyright <strong>REC</strong>


<strong>REC</strong> Silicon to Launch an Applications<br />

Center in China<br />

� Aligns <strong>REC</strong> to market-driven requirements<br />

� Assists in market acceptance of our<br />

products<br />

� We become a resource not just a source<br />

� A localized customer support & application<br />

facility<br />

– Sample Activities:<br />

– Material performance testing<br />

– Customer training & interaction on product<br />

handling, packing, blend, safety, etc.<br />

– Product development<br />

– New account qualification<br />

23 2012 Copyright <strong>REC</strong>


<strong>REC</strong> Position on a possible trade dispute between<br />

China and the US<br />

� <strong>REC</strong> Silicon believes that tariffs are NOT in the best interest of the<br />

global solar industry<br />

– Tariffs stifle innovation/add costs to a development industry that needs to<br />

reduce costs to compete with traditional power and grow<br />

� <strong>REC</strong> Silicon opposes a trade war between the US and China<br />

– Escalation/retaliatory tariffs damaging to all industry participants<br />

� The May 17, US Department of Commerce AD tariff is provisional only<br />

(final decision to be made late 2012)<br />

– <strong>REC</strong> Silicon will continue to work together with other members of the solar<br />

industry in the US and China and with the US government with a view to<br />

convincing the decision makers in the US to “see sense” and ensure that the<br />

final tariff decision imposes no or negligible tariffs only<br />

24 2012 Copyright <strong>REC</strong>


Summary: <strong>Granular</strong> <strong>Polysilicon</strong><br />

� <strong>REC</strong> Silicon is technology and cash<br />

cost leader<br />

– World-class supplier and by far the largest producer<br />

of <strong>Granular</strong> <strong>Polysilicon</strong> – at the lowest cost<br />

� Customers Benefit from using<br />

<strong>Granular</strong><br />

– <strong>Granular</strong> <strong>Polysilicon</strong> helps customers increase<br />

productivity and reduce Total Cost of Processes and<br />

Production<br />

� We are a committed supplier of<br />

<strong>Granular</strong> Products<br />

– Have increased capacity to 15,000MT to deliver to a<br />

growing market<br />

– Developing Silicon research center in Shangyu<br />

– Driving toward electronic grade quality<br />

25 2012 Copyright <strong>REC</strong>


RENEWABLE ENERGY CORPORATION<br />

THANK YOU<br />

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