Photovoltaics:%20Solar%20Electricity%20Technology%20Overview

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Photovoltaics Solar Electricity Technology
Overview

• John P. Benner, Manager
• Electronic Materials and Devices Division
• National Center for Photovoltaics

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A Decade of Growth

• Then 1991
• Total Sales 46.5 MW
• Cost Module 6, System 12
• Major Manufacturers
• ARCO/Siemens 7 MW
• Solarex 5.4 MW
• Sanyo 4.9 MW
• Kyocera 4.5 MW
• Use
• Grid-Connected 15
• Off-Grid 60
• Wholesale 1
• Consumer 24

• and Now 2001
• Total Sales 287.7 MW
• Cost Module 4, System 8
• Major Manufacturers
• Sharp 50 MW
• Kyocera 42 MW
• BP Solar 41 MW
• Siemens/Shell 33 MW
• Use
• Grid-Connected 55
• Off-Grid 44
• Wholesale 1
• Consumer --

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World PV Cell/Module Production (1988-2001)(in
Megawatts)
From PV News, Paul Maycock, editor yearly
February editions.
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Photovoltaics (PV) is Cost Competitive in Many
Applications today!-- Further Cost Reductions
will expand markets eventually reaching utility
scale applications in the U.S. Advanced
Technology Required

• Engineering in manufacturing and new designs to
  reduce cost of collector area (/ft2)
• Physics and Chemistry of higher efficiency
  materials, processes and devices (more watt/
  ft2)
• Systems tests and durability to extend service
  life

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PV Portable Power Systems
Remote, off-grid power Telecommunications
Signaling
Disaster mitigation Emergency power
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PV Markets and Applications International

• Rural electrificationSchools and clinics

Zambia
India
South Africa
Brazil
Mexico
Village power
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The U.S. Photovoltaic Industry Roadmap
What Would You Hope a Roadmap Will Do?

• Establish a consistent message within the
  community
• Instill confidence in decision makers and
  investor
• Identify and guide opportunities for shared
  development
• Develop improved interactions with other
  industries that have solved similar problems
  before us
• Clarify barriers and coordinate response within
  the community

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U.S. Terrestrial PV Industry Roadmap Vision

• What does the U.S. industry look like with
  25 annual growth to 2020?
• gt6 GW sales ...Where are you going to put it?
• Big Picture Requirements for this growth
• Good business
• Faster growing domestic markets
• Continuation of 80 experience curve
• Markets and Applications -- 5050
  DomesticExport
• Domestic Markets Segments in 2020
• 1/2 AC Distributed, e.g. BIPV (retail)
• 1/3 DC AC value applications
• 1/6 AC Grid (wholesale)

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Cumulative Worldwide PV Shipments
Utility, Wholesale
High Value, National Residential, Enabling
Microgrids, Village, Commercial
BIPV, Architectural
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Technical, Market Institutional
BarriersExample Creating 200-MW Factories by
2020

• Requirements
• 5-fold cost reduction by 2010, 10-fold by 2020
• 80-Fold increase in module volume
• Near Term Actions (0-3 years)
• Develop partnerships between manufacturers
  suppliers
• Manufacturing Center of Excellence
• high volume equipment demonstrations
• Develop in-line diagnostics and intelligent
  processing
• Longer-Term Actions
• Design lower-cost packaging
• Develop industry standard equipment

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Other Key Barriers

• Infrastructure
• Supplies of Si Feedstock, encapsulation
• Trained manufacturing, installation, and
  inspection labor force
• Distribution and support channels
• Standards and Consistency
• Feedstock, materials production equipment
• Products, packages services
• Utility interconnection, electricalmechanical
  interfaces, and ratings
• Government policy
• Communication, Awareness Education

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What is the NCPV ?

• The NCPV is the organization established (11/96)
  by the U.S./DOE
• to lead their photovoltaics efforts by
• Performing world-class RD dedicated to
  advancing PV
• Promoting partnering growth opportunities
• Serving as a forum and information source and
• Guiding and assisting the U.S. DOE PV
  activities toward
• maintaining enhancing U.S. technological and
  industrial
• leadership.

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Founding Objectives

• Partner with the U.S. PV industry toward
  achieving performance
• and cost goals, making PV competitive on a
  global scale.
• Serve as the single point-of-contact for PV
  information, education,
• and outreach.
• Provide strategic guidance, direction, and
  coordination to ensure
• the best use of our DOE national laboratory
  and university
• capabilities.
• Facilitate strategic partnerships with domestic
  international
• stakeholders, especially to overcome
  market/institutional barriers.
• Implement DOEs national PV Program through
  RD, in partnership
• with the U.S. industry.

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NCPV RD PV Program

• Laboratory
• Electronic Materials Devices
• Measurements Characterization
• Engineering Reliability
• PV Systems
• Applications Outreach
• Basic Sciences

• Contracts
• Thin Film Partnership
• PVMaT
• High Performance
• Beyond the Horizon
• PV Buildings (Bonus)
• Applications

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Crystalline Silicon (Ingot-Based) PV

• 90 of today's market
• Proven products, 20-year warranties
• Large ingots 100 kg CZ, 200 kg casting
• Multiple ingots w/ melt replenishment
• Wire saw lt 300 µm wafers, lt 200 µm kerf
• Well-developed technology base
• new understanding of defects/impurities
• New interest in thin silicon growth

Efficiency Status Cells Modules Czochralski
22.0 1315 Cast poly 19.8 1013
Ribbon 14-15 10-12 Silicon Film 12
8-10 Key Issue PV is now outgrowing the IC
industry! Silicon Feed Stock Supply
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Powerlight Roof Integrated PV System
Combines PV Power with Energy Saving from
Insulation
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Rekindled Interest in Concentrators
1/6 of Domestic Market in Roadmap High
Performance 1/3 of the Sun Coordination with
Concentrated Solar Power Program NREL 1 eV
Material GaInAsN BGaInAs ZnGeAs2 Spectral
Standards Coordination with Module
Development Utility Interest
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High-Efficiency and Concentrator PVProgress and
Status
ENTECH
Spectrolab
Amonix

• Key companies Amonix, Spectrolab, Tecstar,
  Emcore, Sunpower, ENTECH Solar Research Corp.
  (Australia)
• Manufacturability demonstrated
  Low-concentration, line focus
  High-concentration, point focus High
  efficiency cells (Si, GaAs, multijunctions) in
  production
• Limited applications in today's markets

• Efficiencies Si (up to 400X) 27 GaAs (up to
  1000X) 28 GaInP2/GaAs (1X)
  30.3 GaInP2/GaAs (180X) 30.2 GaInP2/GaAs
  /Ge (40600X) 34.0
• Module efficiencies 15-17 (Si) best
  prototypes gt20 (Si), gt24 (GaAs), 28
  (GaInP2/GaAs/Ge,10X)
• Large space markets drive GaInP2/GaAs and
  GaInP2/GaAs/Ge commercial cell production

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NREL
CuInSe2 CdTe Amorphous silicon (stabilized)
NREL
NREL
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Univ. of So. Florida
BP Solar
EuroCIS
Boeing
Boeing
Univ. of So. FL
ARCO
12
Kodak
Photon Energy
Boeing
AMETEK
Efficiency ()
United Solar
Monosolar
Boeing
Kodak
8
Matsushita
Boeing
The Best One-of-a-Kind LaboratoryCell
Efficiencies for Thin Films(Standard Conditions)
Univ. of Maine
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RCA
0
2000
1995
1990
1985
1980
1975
2005

• Record laboratory efficiencies, new materials,
  and innovations
• Commercial product efficiencies and reliability
  increasing
• 20-25 year warranties for crystalline
  silicon, 5-10 years for thin films
• Multiple technology paths Crystalline silicon
  (ingot- and non-ingot-based) Thin films
  (amorphous Si, CdTe, copper indium diselenide,
  silicon) Concentrators and high
  efficiency

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Thin-Film PV
Efficiency status Cells Modules a-SiH
(stabilized) 13.2 78 CIS 18.8 5-11.5 CdTe 16.5
gt10 Concentrators 21.5 --

• 5 and 10 MW plants a-SiH operational
• Tens of MW in polycrystalline nearing production
• Unique products for building integration
  (e.g., roofing, cladding)
• Advanced Transparent Conducting Oxides (TCOs)

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BP Building Integrated PV Systems
Transparent
Power the pumps.and improve sales
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Toano, Va Facility Throughput Yield
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Thin-Film Copper Indium Diselenide (CIS)
PVResearch Issues and Directions
c. Slightly In-rich
a. Cu-rich
SEM images of stages of film growth (a ? d)
b. Stoichiometric
d. In-rich

• Very high-efficiency (25) device research
  Higher bandgaps and multijunctions
• Optimization of solar resource
  high-efficiency
• top cell (2/3 of total efficiency)
• Tunnel (shorting) junction
• Process compatibility of different layers
• Alternate front and back contacts

• Scalability of high-efficiency processes
  Predictive models of materials growth, devices,
  and processes Real-time process controls
  Yield and throughput
• New techniques and materials Non-vacuum
  approaches Low-temperature depositions

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Flexible Thin-Film Products Open New Markets
Uni-Solar Amorphous Silicon Field Applied Roofing
Products in units to 128W (18x16, 17 lbs, 33V
3.88 A _at_mp)

• CIGS on Polyimide and Stainless Steel from Global
  Solar 36.5 W 4.9 module, 8.9 cell _at_28.5 cm2
  area
• Understanding Stainless Steel
• Incorporating Na
• Intelligent Process Controls

Flexible
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Highest Efficiency Large-Area, Thin-Film Modules
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Average Annual Government PV Research,
Development, and Deployment Budgets
- Domestic market 16 of Sales-
Manufacturing locating near major
markets- Research moving to most
favorable locations
Millions US Dollars
Year
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U.S. Photovoltaic Industry Production
Energy Significant
Energy Significant
Business Success
10 of U.S. Electricity Capacity
Prudhoe Bay
Product Development
10 of new electricity capacity
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Terrestrial Photovoltaics in the U.S.

• Growth Entering the Steep Slope of the S Curve
• Hockey Stick?
• New Markets, Larger Installations
• BIPV, Utility tied concentrators
• Large Investments
• 50B in U.S. based Systems, 20B Direct
  Manufacturing,
• 10B Feed stock, Glass, and other vendors
• Time to Production
• Infrastructure and Supply Chain
• Silicon supply will again be limiting within 2
  years and wont go away
• Strong Consumer Support
• Trends in Distributed Power and Global Climate
  Change

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Photovoltaics is Solar Electricity
Good for our economy and energyindependence
DOE PV Program GoalU.S. leadership in
technology, industry, and markets
Good for our environment
Solar can supply all electricity for the
U.S.using this area (100 x 100 mi.) in the SW
OR Distributed applications
throughout the U.S. (vacant land,
building-integrated, etc.)
Clean and abundantenergy for the21st Century
High-technology manufacturing jobs
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