made in the u.s.a. photovoltaic energy...

Made in the U.S.A. Photovoltaic Energy Solutions

John P. Benner Executive Director

Bay Area Photovoltaic Consortium Stanford, California

Institute for Materials Research Colloquium

Ohio State University March 6, 2012

Bay Area Photovoltaic Consortium

BAPVC

Bay Area Photovoltaic Consortium 2

Electricity from Photovoltaic Solar Energy Conversion

•Reliable •Bankable •Growing •Improving •Subsidized

Solar Electric Energy Today

Silicon Feedstock Ingot Growth Slicing Wafers

Cell Fabrication Module Encapsulation Photovoltaic System

Cash purchase. Includes all Federal, state, and local (utility) incentives, as of Q4 2010. State average retail electricity rates.

Principal Analyst: Sean Ong, NREL SEAC

$5/Watt

Cost Projections

BAPVC

Original Source: Deutsche Bank, January 2011; Systems are global (i.e., blended across geographies) My source: R. Swanson, IEEE PV Specialists Conf., June 2011

Installed System Price per Watt, 2008-2011

5

3Q10 Breakout

$3.17

$2.83

$3.72

$5.92

PV Learning Curve ($2010) Historical to 2002 with projection from Silicon Roadmap

6 R. Swanson, IEEE PV Specialists Conf., June 2012

Comparison to Actual

7

PV Learning Curve ($2010) Projected vs Realized

R. Swanson, IEEE PV Specialists Conf., June 2012

2011 $1.25/W

8 R. Swanson, IEEE PV Specialists Conf., June 2011

Wire saws

Wafer thickness 300

Wafer thickness 200

Wafer thickness 150

First Solar

PV Learning Curve ($2010) Projected vs Realized

BAPVC Photovoltaic Module Shipments (MWp)

0

5000

10000

15000

20000

25000

2002 2003 2004 2005 2006 2007 2008 2009 2010 2011

U.S. Europe Japan ROW China & Taiwan

9 Source data: Paula Mints, Principal Analyst, Navigant

BAPVC U.S. PV Production:

Supply Chain Perspective

PV Supply Chain 2010 Sales ($B)

PV Poly Silicon (exported) 2.5

Encapsulation -- Glass, EVA, Backsheet ~2

PV Equipment 1.4

PV Modules 1.6

U.S. % of Global PV Product Sales ~25%


Source: SEIA/GreenTech Media. U.S. Solar Energy Trade Assessment 2011

BAPVC

• Re-gain U.S. Leadership in PV manufacturing • Establish significant PV generating capacity

The DOE SunShot Initiative


“ The SunShot Initiative accelerates and advances existing DOE research efforts by refocusing its solar energy programs — valued at approximately $200 million per year — to make large-scale solar energy systems cost competitive without subsidies by the end of the decade.”

BAPVC Objective: Dollar-per-Watt Price for Utility Scale Systems

To achieve $1/W installed system, it is critical to get the module cost below $0.50/W.


BAPVC The DOE SunShot Initiative


Inst

alle

d S

yste

m P

rice

($/

Wp)

Cash purchase. Unsubsidized. State average retail electricity rates.

$1/Watt

Principal Analyst: Sean Ong, NREL SEAC

Note: Change to legend from previous slide.

Cost Projections

BAPVC Photovoltaic Manufacturing Initiative (PVMI)

• Industry-led consortium, SEMATECH – PVMC $62.5M Copper indium gallium selenide (CIGS) pilot line, in partnership with CNSE cSi metrology and wafering technologies, in partnership with UCF in Florida

• PV manufacturing development facility – SVTC $30.0M Baseline silicon solar cell tool set Development services Specialized tool bays & characterization

• Bay Area Photovoltaic Consortium – BAPVC $25.0M University Focus – Industry Led Stanford/Berkeley Host Support for University Research Nationwide Full Module Approach

Absorber photon management Contacts Substrate Characterization Module packaging Reliability


Bay Area Photovoltaic Consortium (BAPVC) $25M funded within the DOE SunShot Initiative


Co-Director: Yi Cui Stanford University

Co-Director: Ali Javey UC Berkeley

Executive Director: John Benner Stanford University

Industry Liaison: Stephen Eglash Stanford University

BAPVC Internal Research Partners


Lead Institutions

Partner Institutions

BAPVC Initial Industry Members Reflect Full Supply Chain


BAPVC DOE PVMI: Objectives

- Perform industry-relevant R&D to facilitate high-volume PV manufacturing - Establish scope of research with explicit industry support - Manage open and competitive solicitations - Develop highly trained workforce - Speed up commercialization of cutting-edge PV technologies

BAPVC plans to achieve all these objectives


BAPVC Organization


Executive Board Richard Swanson, Chair

BAPVC Management

Yi Cui, Co-Director Ali Javey, Co-Director

John Benner, Exec Director Steve Eglash, Industry Liaison

U.S DOE Sunshot PVMI

Industry Board • Executive • Members • Participating

Research Participants Internal

Research Participants Nationwide

Separate RFPs

Cost-Share Technology Guidance

Funding $5M Annually Program Guidance

BAPVC Operations Led by Industry Members


InternalWorkshopCall ReleasedProposal Prep.Review January 12-13EvaluationExec. BoardNegotiation

NationwideIndustry BoardCall ReleasedConcept PapersDown SelectRFPProposal Prep.ReviewEvaluationExec. BoardNegotiation & Award

Apr May June JulyNov Dec Jan Feb Mar

Stanford Berkeley Nat'l Labs

BAPVC Our Whole Module Approach to Reach $0.50/W Modules

Transparent electrode

Antireflection

Absorber and junction

Substrate

Transparent electrode

Encapsulation

Bottom contact

Nanoscale photon management

Nanocone substrate

500nm

Substrates

50 µm

Metal nanowire transparent electrode

Novel electrodes

Substrate

H2O, O2, H2other active chemical

species

photochemical reactions

cracking and debonding

UV Exposure

defect evolution in nanomaterial

layers

surface weathering

Substrate

H2O, O2, H2other active chemical

species

photochemical reactions

cracking and debonding

UV Exposure

defect evolution in nanomaterial

layers

surface weathering

Reliability

Advanced materials characterization

Thin film absorber

Encapsulation

BAPVC Downward Trending Costs of PV Electricity Can Be be Sustained

Crystal Solar -- Vapor to Wafer Lift-Off

- single crystal film silicon; high rate epitaxy

Group 4 – much less than 50 µm

25 25

Rolling &

Heating

Solution-based

buffer growth

HW-CVD Si deposition (replacing numerous and

costly Si-processing steps)

Module Fabrication (common techniques for light trapping, top contacts, etc.)

Even thinner Silicon – Ampulse Manufacturing Process crystalline-silicon manufactured with thin-film economies

Ampulse “c-Stack”

BAPVC January 12 Industry Board Meeting $0.50/Wp @ 20% Module Efficiency

Topics particular relevance to industry • Thinner wafers – 50 um

(mechanical stress, breakage) • Low cost ingots compatible

with high efficiency • Direct wafer generation –

kerfless • Kerf loss reduction • Bulk passivation (hydrogen

passivation of multicrystalline wafers)

• Mono cast and other absorbers

Issues/Approach specific to Universities • Cleaning and texturing of 50 um thick

wafers (dry, black silicon etc) • Low cost cleaning (environmentally

friendly cleaning) • Inline emitters (HIT structure) – dry

(plasma doping, ion implant etc) • Simultaneous surface passivation and

light trapping – Light management – Bulk & surface defects – n-type Si

• Metallization - less Ag and new metallization scheme eg Cu etc

• Low cost methods for inline metrology • Better understanding of mono cast

(absorber)

Alta Devices 28.2% efficient thin-film cell

Source: B. Kayes, IEEE PVSC, June 2011

Voc = 1.13 V near perfect photon recycling

BAPVC III-V and CPV Concentrator Optics High Performance and Ultra-low Cost

Substrates and Absorbers

Measuring and Analyzing System Efficiency Novel low-cost substrates (e.g. not Si) Broadband cell ARC – incl low temp on acrylic Low-cost growth Non-fouling High Performance Mirror Designs (e.g. coatings)

Strategies for High Efficiency Cells (e.g. 2.2 eV Top Cell)

Eliminating the secondary 45% efficiency

Optics Reliability Non-incremental technolgies

High Performance and Low Cost Thermal Management

Test and measurement

Ultra-low cost packaging Indoor testing system for the module level

Novel Passive Cooling Measurement of optical efficiencies Reliable packaging Reliable packaging

ZnO, ITO 2500 Å

CdS or ZnS 500 Å

Mo 0.5-1 µm

Glass, Metal Foil,

Plastics

CIGS 1-2.5 µm

CIGS Device Structure

29

Higher Cell Efficiency through Higher Photo Current

30

•Record Jsc << Best Si

•Window materials – TCO and CdS – dominate losses.

•Improve buffer/emitter layers and photon management without sacrifice of Voc and FF values

Potential for efficiency = 20.3% x (40.5/35.4) = 23.2%

31

Coevaporated CIGS (on glass): road map

• Assumes current (2011) In and Ga prices (historic highs)

Goodrich, A.; Woodhouse, M.; Noufi, R. “CIGS Road Map”. NREL Technical Report (In preparation), 2011

BAPVC Transparent Metallic Electrodes

• Line width: Smaller than light wavelength 40 nm • Separation: ~ equal to light wavelength 400 nm


J.Y. Lee, S.T. Connor, Y. Cui, P. Peumans,Nano Lett. 8, 689–692 (2008).

BAPVC Electrospinning of Nanofibers for

Transparent Electrodes


(Pioneer: Y. Xia) http://www.youtube.com/watch?v=87uRQ7KwbB0

20 um

Pathways to increase CIGS Short Circuit Current Density from commercial (30 mA/cm2) to best lab cell (36 mA/cm2)

Slide 34

Action

Potential Current Increase

(mA/cm2)

Technical Risk

Pathways

Reduce CdS window layer thickness

1.5 Medium Develop 20 nm thick continuous CdS layer without shunting.

Larger band gap junction partner

2.5 Medium Replace CdS ( e.g. 2.5 eV) with wide bandgap emitter (i.e., ZnS (3.1 eV))

Improved TCO 1.5 Medium Develop TCO with high conductivity, transparency, environmental stability (i.e., a-InZnO)

Minimize reflection off CIG surface

1.5 Medium Develop a suitable low cost anti-reflection coating

BAPVC

Interconnects cost 12% of active area. - boost Jsc by 3 mA/cm2?

Advanced Scribe and Print

BAPVC Thin-Films 20% Module Efficiency Developing manufacturing process

Understanding the materials doping, defects, microstructure, boundaries, etc.

Controls and diagnostic tools for materials

Enabling next generation of thin-films Achieving high deposition rates/high throughput

TCO issue (coatings)

Uniform deposition of thin film

earth abundant new materials

High Performance Reliability

Photon management

Accelerated life tests for new materials

High deposition rate Identification of failure mechanisms

Improve CdTe champion cell efficiency Standardization of testing

Novel packaging

BAPVC U.S. Manufacturing Drivers

• Market – Competitive Without Subsidies

• Investment – R&D – Expansion Capital

• Time to cash flow positive • Advantage

– Production Cost – Shipping – Reduced Risk

• Supply, Inflation, Exchange Rates, IP Control – Great ideas


BAPVC Summary

- The PV industry delivers significant amounts of high-value electricity, with improving technology replacing declining incentives.

- PV modules prices have been cut 10-fold in the past 20 years; cut in half during the past 18 months; and, are or will soon be competitive in most electricity markets.

- BAPVC provides a forum for industry and universities to jointly and creatively set direction and priorities for research in PV manufacturing technologies.

- We will find and fund the best university teams to deliver solutions in 3 to 5 years to our industry.

- Industry membership from full supply chain expedites technology transfer and we intends to generate abundant IP to exploit this benefit.


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