Survival Path Seen For Amorphous Thin Film

July 23, 2010

Applied Materials pulled the plug this week on its turnkey SunFab line of manufacturing equipment for amorphous thin-film solar cells.

Competitor Oerlikon is making no such concession. The company says it is on target for an aggressive reduction in manufacturing costs – to 70 cents a watt this year – and foresees further reductions next year.

The claims of progress from Oerlikon Head of Market Development Chris O’Brien come as amorphous technology finds itself under assault. With crystalline module prices down 40 percent last year and financing for utility-scale projects under pressure, thin-film is finding the road ahead tough.

Applied’s answer was to pull back from the market and discontinue SunFab sales. The company vows to continue research and development, and to sell production equipment piecemeal.

Oerlikon says its Kai MT production machinery helped improve factory performance - keeping it in front of Applied Materials.

Equipment supplier Oerlikon, on the other hand, is not balking. O’Brien says he expects the global production capacity of amorphous cells to someday rival that of cadmium telluride, presently the most popular thin-film technology. First Solar, the world’s largest solar producer and the only significant maker of cadmium telluride, has about 18 percent of the global solar market.

Amorphous production capacity from manufacturers, such as Sharp and Konica Minolta, will add up, says O’Brien.

Thin-film advocates, such as Oerlikon, argue that a lot of the expected cost reductions have already been wrung from crystalline-cell manufacturing. Price declines will eventually slow.

This will leave an opening for thin film. It is an opening Oerlikon hopes to capitalize on. The company says the cost of thin-film cells made with its equipment will drop to 70 cents a watt by the end of the year, from $1 at the year’s start and a $1.50 in 2008.

This may not enable them to catch those from First Solar, which early this year reached 81 cents. (First Solar is likely to offer a new benchmark when it releases quarterly earnings next week.) But O’Brien sees competition increasing and says more significant cost reductions are expected next year. He declined to offer a target.

He says Oerlikon was able to avoid Applied Materials’ fate by maintaining a technological advantage. First, the company’s micromorph tandem junction technology is generating module efficiencies of 8.5 to 9 percent, up from the 7 to 8 percent of a single junction cell.

Second, the company’s new generation Kai MT production machinery offered a big improvement in factory throughput this year. Added to that, Applied was unable to match the company’s transparent conductive oxide, or TCO, which offered an improvement in efficiency.

O’Brien separately says he sees strong growth in the U.S. market over the next three years. Module sales should almost double this year to 800 megawatts of capacity from 440 megawatts last year. By 2013, analysts project the market should expand to 1,600 megawatts, and that outlook could be too conservative, he says.

How much of that will go to thin film is hard to say.


Innovalight To Double Silicon Ink Efficiency

July 14, 2010

Innovalight boasts that it will be able to double the solar potency of its nanocrystalline silicon ink as soon as next year.

By 2012, additional improvements should push the efficiency of a mainstream crystalline solar cell using the ink to above 20 percent.

Conrad Burke, chief executive of the Sunnyvale, CA, company, said the company’s silicon ink today adds 1 percentage point to the efficiency of a mainstream solar cell. So a cell that is 18 percent efficient jumps to 19 percent.

Next year, the ink will add 2 percentage points to overall efficiency, and in 2012, the target is 3. That should push the 18 percent crystalline cell to 20 percent next year.

The company expects to see this level of efficiency in its labs this year, Burke said at the Intersolar conference in San Francisco.

Such a boost should interest solar cell makers fighting for each tenth of a percentage point gain – and challenge efficiency leader SunPower. SunPower’s cell design is more complex than others and may not easily lend itself to a silicon ink.

Innovalight’s silicon ink is made up of silicon particles 5nm to 10nm in size. It is applied using the screen-printing technology typically used by semiconductor lines during back-end metallization.

When applied to solar cell production, screen-printing becomes a front-end process, and a relatively simple one, says Burke. Pattern alignment is not complicated.

Burke said prices for the printing tool have fallen to about $400,000. For this reason, don’t be surprised to see 20 percent efficient solar cell coming out of China sooner rather than later.

Already, Chinese solar cell maker JA Solar Holdings has latched onto the technology. The company this week announced a three-year contract with Innovalight and said its Secium cells would use the technology.

The cells are in pilot production and have achieved 18.9 percent efficiency.


Is Ivanpah The World’s Most Efficient Solar Plant?

June 21, 2010

BrightSource Energy’s planned Ivanpah plant will be one of the world’s largest solar farms and possibly its most efficient.

When the solar-thermal plant is built on the edge of the Mojave National Preserve (construction is expected to start this year), it will operate at 18 percent efficiency and earn a capacity factor of 30 percent.

BrightSource boasts of 18 percent plant efficiency and a 30 percent capacity factor.

This performance should make the 392-MW facility more efficient than plants with crystalline-silicon panels, thin-film cells or rival thermal technologies using parabolic mirrors, according to analysts.

The plant is to be laid out on three nearby tracts covering 3,500 acres of desert and should run at full capacity 10 to 11 hours a day. The company says a back-up natural gas system will aid performance during its long hours of operation, easing power fluctuations on cloudy days. This consistency of power should put electricity costs on par with natural-gas plants, something photovoltaic plants will take another two years to achieve, some analysts say.

While comparing plants is complex and imperfect, the newly available figures from BrightSource make the exercise a useful chore. Sun intensity, atmospheric moisture levels and power transmission costs of course differ plant location to plant location.

But determining who holds the industry’s bragging rights – as well as who deserves project investment dollars – is a task utilities attempt everyday, despite the difficulties.

In an interview, BrightSource Product Manager Andy Taylor described Ivanpah’s efficiency as a sunlight-to-electricity calculation based on two years of testing the company’s Luz Power Tower 550 in Israel’s Negev Desert. At the top of the towers, boilers absorb sunlight reflected from 7-square-meter ground-mounted mirrors and heat water to more than 1,000 degrees Fahrenheit, the highest temperature in the industry. The super-heated steam drives turbines.

The company says a back-up natural gas system permits the long operating hours and the ability to run most of the day at full capacity. The gas is used to warm boilers in the morning and augment solar power on cloudy days to keep output high.

“We’re pretty much a sun-up-to-sun-down resource,” Taylor says.

BrightSource, which has so far raised more than $300 million in financing, expects the plant’s efficiency to rise as the company moves beyond its first-generation technology. Higher-efficiency turbines are already in the market, and additional mirrors, or heliostats, can be deployed. Water temperatures also will rise to above 1,100 degrees.

In contrast to Ivanpah’s 18 percent efficiency, the efficiency of utility-scale crystalline silicon and thin-film plants is likely less than 12 percent. Solar-thermal plants with parabolic mirrors also have difficulties keeping up. Ivanpah’s higher boiler temperatures give it an advantage, and dual-axis tracking can more accurately follow the sun through the seasons. The average efficiency of other solar thermal plants is 13 to 15 percent, says Cara Libby, project manager at the Electric Power Research Institute.

That doesn’t mean Ivanpah won’t have competition, One crystalline-silicon vendor, SunPower, with industry leading 18 percent efficient solar cells, could give BrightSource a run for its money, says Travis Bradford, president of the public-policy think tank, Prometheus Institute. A SunPower farm with a single axis tracking could have an efficiency of 15 percent, maybe slightly higher depending on the location, he says.

Broader competition will come with falling solar-panels prices, unless a stronger Chinese currency slows the trend. Panel prices tumbled about 40 percent last year and, while they are more stable this year, they continue to decline more rapidly than solar thermal efficiency is improving.

BrightSource responds that plant efficiency is only one measure of performance, and not necessarily the best. Capacity factor, a calculation of a farm’s ability to deliver full power over time, may be more important, the company says.

Ivanpah’s capacity factor (including the use of natural gas) should be 30 percent, Taylor claims. A wind farm in an ideal location (think Tehachapi) can have a factor of 40 percent. Photovoltaic plants generally are lower. A Carnegie Mellon Electricity Industry Center study estimates a PV plant in Arizona should be closer to 20 percent.

Another useful metric is the delivered cost of electricity. BrightSource claims this measure makes Ivanpah “extremely competitive,” but declines to release figures to back up the claim. The calculation looks at plant output versus costs and factors in development and financing charges.

An examination of California Public Utilities Commission documents shows only that expected delivered costs are to be less than 12.5 cents a kWh. It doesn’t state how much less.

Nevertheless, Nathaniel Bullard, a solar analyst at Bloomberg New Energy Finance, calculates that the cost of Ivanpah’s electricity will be lower than photovoltaic power and about the same as natural gas. Of course no one knows for sure until the plant is built. “We’ll see if they can meet the targets they have in place,” Bullard says.


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