The Energy Blog

DuPont To Enter Thin Film Amorphous Silicon Market

Per DuPont press release:

DuPont (NYSE: DD) announced that it will soon begin construction on a research center in Hong Kong and a manufacturing facility in Shenzhen to support the rapidly growing photovoltaic (PV) solar energy industry.  . . .

DuPont expects growth in the photovoltaic market to exceed 30 percent in each of the next several years. The company has made significant investments in product development and capacity expansions to help keep pace with the demand.

Accelerating its capability to meet emerging materials requirements is critical for DuPont, which has long been a leading supplier of materials primarily serving the crystalline silicon (c-Si) cell and module markets. The expansions in Hong Kong and Shenzhen will provide new offerings to serve the amorphous silicon (a-Si) thin film market.

Thin film technology is well-suited for large-scale utility applications such as "solar farms" and industrial installations. The growth rate for thin film is projected to be approximately twice as high as demand for c-Si, and DuPont expects this increase to drive specifications for both new and existing products that serve the thin film industry.

This announcement is important because it shows that Dupont recognizes that the PV market is significant and growing. It can bring its manufacturing expertise to produce low cost products for the fastest growing segment of the solar PV market. Locating the manufacturing facility in Shenzhen takes on the Chinese manufacturers on their home turf.

Optisolar to Build Largest Solar Farm in North America

OptiSolar, Hayward, California, is developing a 550 megawatt photovoltaic (PV) solar farm, the largest in North America, covering over 6,000 acres, in San Luis Obispo County, California.

OptiSolar intends to submit an application to San Luis Obispo County for a Conditional Use Permit (CUP) in May. Construction is targeted to begin in 2010, after completing the local approval process. Installation of panels will occur over a period of up to three years.

OptiSolar is a vertically intigrated company manufacturing its own solar cells and panels and claims its amorphous silicon thin-film solar PV panels combine proprietary manufacturing processes and innovative design to yield affordable, durable panels that significantly reduce the cost of clean solar power. Their thin-film design requires only about 1% of the silicon used in crystalline systems, thus not being affected by the availability of crystalline silicon. The companies technology enables low-profile solar panels to be placed on simple concrete and steel ballasts with minimal grading.

Although photovoltaic solar panels are currently less efficient than solar thermal systems, OptiSolar claims that its solar cells are significantly more cost effective as they require less expensive silicon during manufacture, consume little water, and require far less maintenance than turbine based systems. In addition they avoid the need for large structures that turbine-based systems require, and do not result in the noise associated with such systems.

OptiSolar Farms Canada has 21 solar project  in Canada under various phases of development including the 60-megawatt "Sarnia Solar" park, which will be broken into six construction phases with the first 10-megawatt phase expected to be completed by year's end and the balance competed in 2009.

Thanks to Tyler Hamilton in the Toronto Star for the tip

Trina Solar Cancels $1 Billion Polysilicon Plant

China-based Trina Solar (NYSE: TSL) announced that it has canceled plans to build a $1 billion polysilicon plant that was revealed in December of 2007, with a target completion date by the end of 2012. Favorable changes in the polysilicon market has led Trina to believe that it can now obtain sufficient polysilicon on the open market to meet its production requirements. 21 new firms started manufacturing polysilicon during 2007.

Trina also announced on 4/2/08 that it has entered an eight-year polysilicon supply agreement with GCL Silicon Technology Holdings Ltd.for enough polysilicon to produce about 2.6 gigawatts worth of solar modules. Trina has now secured about 95 percent of its estimated polysilicon requirements for 2008.

Trina previously had said that it was targeting solar module production capacity of 350 megawatts of annual capacity by the end of this year. Trina announced in late October 2007, that it had launched production on its new multicrystalline module line, complimenting its monosilicon module line.

In a somewhat related announcement Fluor Corporation said that it has been awarded the contract for engineering, procurement and construction management (EPCM) services by LDK Solar for its $1 billion, 15,000MT polysilicon plant in Xinyu City, Jiangxi, China.

High purity silicon ("Polysilicon") is the key feedstock for almost all solar cells and modules produced today. The solar PV industry and semiconductor manufacturers are the two main consumers of polysilicon. In 2000 the solar industry consumed only 10% of the world's silicon supply. In 2006 the PV industry consumed more than half of the world's available supply of polysilicon for the first time ever.

So Trina sees that it can obtain enough silicon from the open market, such that its own production facility is not needed.  Its recent agreement with GCL will supply nearly all of its silicon needs for the next eight years.  Meanwhile silicon suppliers such as LDK Solar continue to expand production. Does this mean that the silicon supply shortage is over?  My opinion is that, at this moment, there is not enough silicon production to allow the much needed expansion of the PV solar cell industry, but that facilities under construction will probably allow for some expansion.  The trend to use more thin film silicon PV and non-silicon PV will reduce requirements for silicon. How much is enough? This will depend on whether solar PV modules can reach the price target of under $1.00 per Wp that have been promised by some. In the meantime there is a market demand for more modules than can currently be produced at relatively high prices (Solarbuzz currently lists $3.74/Wp (€2.36/Wp) as the lowest price for thin film solar modules).

MIT Spin-off Developing Solar Cells That are 27% More Efficient, No more Expensive to Make

1366 Technologies claims that its small multicrystalline solar cells are 27% more efficient than conventional cells while keeping costs about the same.  It also announced its first round of funding of $12.4 million from Venture capitalists co-led by North Bridge Venture Partners and Polaris Venture Partners.

The company's efficiency and cost claims are based on results from small solar cells (about two centimeters across) made in the lab of professor of mechanical engineering Emanuel Sachs, who is one of the company's founders.

1366 Technologies is building a pilot-scale manufacturing plant that will make full-sized solar cells (about 15 centimeters across) that should yield results in about a year.

Sachs says that current solar cells cost about $2.10 per watt generated. When manufactured at a commercial scale, the first cells incorporating his new technology will cost $1.65 per watt while planned improvements will reduce the cost to about $1.30 a watt.

The company's solar cells include three key innovations to improve efficiency:

1. A method for adding texture to the surface of the cells that allows the silicon to absorb more light.
2. A method for making the current collecting wires as small as one-fifth the width of the wires that are typically used, while improving their conductivity.
3. A new Light-Capturing Ribbon that increases the efficiency of a solar module by reflecting light back onto the surface of the cell. This grooved ribbon replaces the traditional wires used to interconnect solar cells.

Professor Sachs previously invented the String ribbon™ wafer technology being commercialized at Evergreen Solar, a leading developer of solar energy products. Sachs is joined by 1366 Technologies co-founder and investor, Frank van Mierlo, who serves as the company’s president. Harvard Business School professor Joseph Lassiter rounds out the board of directors, all of whom hold degrees from MIT.

Sources: Technology Review and 1366 Technologies website.

Sodium Sulfur Batteries to be Used for Energy Storage at MN Windfarm

Xcel Energy, (NYSE: XEL)in partnership with the University of Minnesota, the National Renewable Energy Laboratory and the Great Plains Institute, will soon begin testing a one-megawatt sodium-sulfur battery storage system to demonstrate its ability to store wind energy and dispatch it to the electricity grid when needed.

Fully charged, the batteries could power 500 homes for six and one-half hours. Xcel Energy will purchase the batteries from NGK Insulators, Ltd. that will be an integral part of the project. The sodium-sulfur battery is commercially available and versions of this technology are already being used in Japan and in a few US applications, but this is the first U.S. application of the battery as a direct wind energy storage device.

The 50-kilowatt battery modules, 20 in total, will be roughly the size of two semi trailers and weigh approximately 60 tons. They will be able to store about 6.5 megawatt-hours of electricity, with a charge/discharge capacity of one megawatt. When the wind blows, the batteries are charged. When the wind calms down, the batteries can be used to supply energy to the grid as needed.

"Energy storage is key to expanding the use of renewable energy. This technology has the potential to reduce the impact caused by the variability and limited predictability of wind energy generation."

-- Dick Kelly, Xcel Energy chairman, president and CEO.

The project will take place in Luverne, Minn., with the battery installation beginning this spring adjacent to a nearby 11-megawatt wind farm owned by Minwind Energy, LLC. Testing will begin in October and is expected to last up to two years.

Commercial projects are now underway that use flow batteries, compressed air energy storage, thermal energy storage, pumped hydro, and sodium sulfur batteries for energy storage in connection with renewable energy projects.  American Electric Power (AEP) is also using NaS batteries in a couple of their systems, but not in connection with wind power. While not enough experience has been gained with any of these technologies to make any decision as to which technology is best under what conditions, pumped hydro and sodium sulfur batteries are the most well proven and thus seem to be the first choice of electric utilities. Thermal storage is gaining acceptance for use with thermal solar systems, the only energy technology that it is suitable for use with. As Mr. Kelly stated, energy storage is essential to widespread use of renewable energy technologies. 

REC to Build World's Largest Solar Manufacturing Complex in Singapore

REC Group announced that it will build a new worldscale solar manufacturing complex in Singapore with total investments possibly exceeding US$4.3 billion (EUR 3 billion) within the next 5 years. It has simultaneously signed an agreement with the Singaporean government agency Economic Development Board (EDB) that defines the terms and conditions related to the development of a new production site, the process of establishing a manufacturing complex, as well as operational and commercial conditions.

In addition to wafer, cell and module production, the manufacturing complex will incorporate infrastructure and support facilities, as well as an on-site supplier park. Sufficient space has also been reserved for future R&D activities and possible manufacturing facilities based on potential new technologies.

The green field site can hold a capacity of up to 1.5 GW within each product area, although it is not likely that the production capacity for wafer, cells and modules will be fully balanced. Depending on the final capacity and site development, total investments in the Singapore site may exceed EUR 3 billion within the next 5 years and the total number of employees could be around 3 000 people.

The development of this site will enable us to continue expanding in a cost efficient manner and will support REC's ambitious cost target. Our future cost position will determine our ability to deliver solar products that can compete with traditional energy sources in the sunny areas of the world without government incentives", said Erik Thosen, the President & CEO of REC.

REC is positioned in the solar energy industry as the only company with a presence across the entire value chain. REC Silicon and REC Wafer are the world's largest producers of polysilicon and wafers for solar applications. REC Solar produces solar cells and solar modules. REC Group had revenues in 2006 of US$810 million (NOK 4 334 million) and an operating profit of US$294 million (NOK 1 574 million).

Solar Power to Reach Parity with Fossil Fuels in Sunny Countries in Five Years, Most Countries by 2020

Solar power could be the world's number one electricity source by the end of the century . . . production of solar panels will double both next year and in 2009, according to U.S. investment bank Jefferies Group Inc, driven by government support especially in Germany and Japan. . . . costs are dropping by around 5 percent a year and "grid parity", without subsidies, is already a reality in parts of California. Very sunny countries could reach that breakeven in five years or so, and even cloudy Britain by 2020. . . .  General Electric Co's Chief Engineer Jim Lyons told the Jefferies conference in London; "The solar industry will eventually be bigger than wind." . . . But all the growth is from a tiny base. The sun supplies just 0.3 percent of electricity even in market leader Germany, says Jefferies. "It doesn't even register statistically outside Germany," said Jefferies analyst Michael McNamara.

This article totally agrees with the consensus of what I have been reading over the past year, actually a little more pessimistic than the claims of some companies.  The technology is so close to being there now, the only thing holding it back is the scaling up of production facilities of the right technology to the gigawatt scale - in a single location.  Some form of thin-film PV solar will be the dominant technology, if not more than one.  Even though a lot of the technology is being developed by U.S. and German companies, don't be suprised if a Japanese company with manufacturing in China is the first one to take the big leap.

See complete Reuters article here.

Macy's to Install 8.9 MW of Solar Power in California Stores, Combined with Energy Efficiency Program Utility-Provided Energy to be Reduced 40%

Per a SunPower press release:

Macy's is launching a program to install solar electric power systems at 28 California stores, including 15 in Southern California. SunPower Corporation (Nasdaq:SPWR), a Silicon Valley-based manufacturer of high-efficiency, solar cells, solar panels and solar systems, is partnering with Macy's to design and install the systems. . . .

Through its 28-store partnership with SunPower, Macy's has committed to installing a total of 8.9-megawatts of solar power systems on its California stores. In addition, SunPower is assisting Macy's to improve the energy efficiency at the stores. Combining solar power with energy efficiency will allow Macy's to achieve an estimated 40 percent reduction in utility-provided energy, almost doubling the impact of the solar power alone. . . .

For 17 of the 28 stores, Macy's will purchase solar-generated electricity under the SunPower Access(tm) program, a solar services agreement that allows the retailer to purchase just the electricity generated at its stores -- not the solar power systems. At the end of a 10-year term, Macy's will have the option to renew the agreement, transfer the equipment to a new site, or buy the system. Macy's will buy solar power systems for the remaining 11 stores through an outright system purchase.

SunPower commercial 300 series solar panels deliver panel efficiencies of up to 19.3% and are backed by a 25 year warranty.

The company is headquartered in San Jose, California and is a subsidiary of Cypress Semiconductor Corporation.

This is a very large commitment by Macy's and with a potential energy savings of 40%, with energy efficiency improvements, demonstrates that solar power combined with energy savings has a great potential, even at the present time, in areas where there is high solar radiation. There are large incentives in California, as well as high solar radiation, which enable such installations now and help develop a solar industry that can be incentive free when production costs are reduced as they most certainly will be in the next 3 to 5 years.

Evergreen Solar Breaks Ground on Manufacturing Plant in Massachusetts

Evergreen Solar, Inc. (Nasdaq: ESLR), the Marlborro, MA manufacturer of String Ribbon(TM) solar power products announced on September 13 that it had broken ground for its new $165 million, 70 Megawatt (MW), facility in Devens, MA where it will expand production its solar products. This will bring their worldwide production capacity to 170 MW with plans to increase it to 300 MW by 2010.

Its press release states:

The new manufacturing plant will increase Evergreen Solar's production capacity in Massachusetts to 75 MW including 5 MW at it headquarters. In addition it has 90 MW of production capacity at EverQ in Germany, an equal partnership of Evergreen, Q-Cells AG (XETRA: QCE.DE) ( the worlds second largest producer of solar cells in 2005) and Renewable Energy Corporation ASA (OSEAX: REC.OL) (REC) (Q-cells has a long term silicon supply agreement with REC). The Devens facility keeps Evergreen on schedule to increase its production to 300 MW by 2010

Richard M. Feldt, Chairman, President and Chief Executive Officer, noted that the new factory will use the Company's revolutionary Quad furnace technology with its state of the art automated ribbon cutting feature. This innovative wafer production process provides substantial opportunity to further increase yield, cell efficiency and labor productivity as well as to reduce the Company's already industry-leading silicon consumption.

Applied Materials Aquires HCT and Introduces Integrated Thin Film Production Line

Applied Materials, Inc. (Nasdaq: AMAT) is making its mark on the solar PV industry with recent acquisition of HCT Shaping Systems and the announcement of the introduction of its Applied SunFab^™ Thin Film production line. By applying their four decades of thin film on silicon experience to the manufacturing of solar modules, the company claims that the total volume of solar panels manufactured each year can be vastly increased. At the same time, their products are aimed at reducing the cost per watt of energy produced, to become more competitive with current electricity generation.

HCT Shaping Systems SA (HCT) is the world’s leading supplier of precision wafering systems for manufacturing crystalline silicon (c-Si) substrates for the solar industry. The acquisition of HCT expands Applied’s portfolio of solutions for helping solar customers reduce the costs of manufacturing photovoltaic (PV) cells to make solar energy more competitive with grid electricity.

“This acquisition, combined with our strong production technology and global support infrastructure, will enable us to bring crystalline silicon solar manufacturing to a new level of efficiency and help drive down the cost-per-watt of solar power,” said Mike Splinter, president and CEO of Applied Materials. “HCT’s technology is critical to our roadmap since it complements our high-throughput deposition systems and will enable customers to scale up production and reduce costs.”

Applied SunFab^™ is the world’s first and only integrated production line for manufacturing thin film silicon solar modules using 5.7 square meter (m²) glass panels. These ultra-large substrates, sized at 2.2m x 2.6m, are four times bigger than today’s largest thin film solar production panels. This line defines a new standard for the industry that can be replicated by customers around the globe to rapidly establish solar panel manufacturing capacity and achieve the lowest production cost per watt to drive down the cost of solar electricity.