Thin Film Photovoltaic Solar Pilot Line Thin Film Photovoltaic Solar Pilot Line Thin Film Photovoltaic Solar Pilot Line Thin Film Photovoltaic Solar Pilot Line D. L. Morel, C. S. Ferekides, E. K. Stefanakos D. L. Morel, C. S. Ferekides, E. K. Stefanakos Students: R. Anders, K. Jayadevan, B. Satya Kanth Students: Department of Electrical Engineering Department of Electrical Engineering Department of Electrical Engineering Department of Electrical Engineering Clean Energy Research Center Clean Energy Research Center University of South Florida University of South Florida Collaborators: UF and UCF Collaborators: UF and UCF Presented at the FESC Review Meeting, Tampa, September, 2009 Department of Electrical Engineering, Clean Energy Research Center, University of South Florida
Project Overview Project Overview Objectives Objectives: : Establish a world Establish a world class thin film PV module Establish a world Establish a world-class thin film PV module class thin film PV module class thin film PV module capability capability Attract PV manufacturing operations to the Attract PV manufacturing operations to the Attract PV manufacturing operations to the Attract PV manufacturing operations to the state state Project Project Plan Plan: : Design, build and operate a state Design, build and operate a state-of of-the the- art generic thin film module facility art generic thin film module facility 2 TASK 3 DFT Modeling
Why Thin Film? Why Thin Film? Crystalline Silicon Thin Films • Expensive single crystal • Deposited in large area layers by or multi-crystalline growth y g numerous inexpensive methods p • Wafering kerf loss • 300 – 400 μ m thick • 1 – 5 μ m thick • Individual cells must be • Individual cells must be • Monolithic • Monolithic patterning patterning and and handled and connected interconnection together
Why Thin Film? Why Thin Film? Crystalline Silicon Thin Films • Expensive single crystal • Deposited in large area layers by or multi-crystalline growth y g numerous inexpensive methods p • Wafering kerf loss • 300 – 400 μ m thick • 1 – 5 μ m thick • Individual cells must be • Individual cells must be • Monolithic • Monolithic patterning patterning and and handled and connected interconnection together Thin Films have a significant cost advantage, but commercial thin film modules are 10% efficient vs. 15% for Silicon modules .
Why Thin Film? Why Thin Film? Crystalline Silicon Thin Films • Expensive single crystal • Deposited in large area layers by or multi-crystalline growth y g numerous inexpensive methods p • Wafering kerf loss • 300 – 400 μ m thick • 1 – 5 μ m thick • Individual cells must be • Individual cells must be • Monolithic • Monolithic patterning patterning and and handled and connected interconnection together Thin Films have a significant cost advantage, but commercial thin film modules are 10% efficient vs. 15% for Silicon modules . ☼ Gigawatts of Thin Film production capacity are being installed…
Which Thin Film? Which Thin Film? Organic Organic •Lowest Lowest potential potential manufacturing manufacturing cost cost • High High potential potential materials materials sustainability sustainability • Most Most complex complex of of all all PV PV materials/devices materials/devices • Long Long term term stability stability needs needs to to be be demonstrated demonstrated • Lab Lab cell cell efficiency efficiency 5 – 10 y 10% % • No No significant significant commercialization commercialization 6
Which Thin Film? Which Thin Film? Amorphous Silicon Amorphous Silicon •Easily Easily manufactured manufactured using using plasma plasma enhanced enhanced CVD CVD with with silane silane and and other other gaseous gaseous fuels fuels • Has Has been been in in commercial commercial production production since since the the 1980 1980’s ’s • Major Major instability j j instability problem y p problem has has slowed slowed progress p p progress g g • Tandem Tandem structures structures help help mitigate mitigate stability stability • Commercial Commercial tandem tandem modules modules are are nearing nearing 10 10% % • Low Low lab Low Low lab lab cell lab cell cell efficiency( cell efficiency( efficiency(13 efficiency(13 13-14 13 14 14%) limits 14%) limits limits upside limits upside upside potential upside potential potential for potential for for modules for modules modules modules 7
Which Thin Film? Which Thin Film? Cadmium Telluride Cadmium Telluride • Easily Easily manufactured manufactured using using close close space space sublimation sublimation • Has Has been been in in commercial commercial production production for for five five years years • Psychology Psychology of of Cd Cd has has somewhat somewhat affected affected marketability marketability • Commercial Commercial modules modules are are nearing nearing 10 10 - - 11 11% % • Lab Lab cell cell efficiency( efficiency(16 16% %) ) provides provides some some upside upside potential potential for for modules modules 8
Which Thin Film? Which Thin Film? Copper Indium Gallium Copper Indium Gallium Diselenide Diselenide • Most Most complex complex material material of of the the major major thin thin films films makes makes manufacture manufacture more more challenging challenging • Has Has been been in in (unsteady) (unsteady) commercial commercial production production for for ten ten years years • Commercial Commercial modules C C i l i l modules are d l d l are nearing nearing 11 i i 11 11 11 - 12 12% 12% 12 • Lab Lab cell cell efficiency( efficiency(20 20% %) ) provides provides good good upside upside potential potential for for modules modules 9
Which Thin Film? Which Thin Film? Copper Indium Gallium Copper Indium Gallium Diselenide Diselenide (T St (T St (To Start) (To Start) t) t) Additional Advantage: Additional Advantage: Most expertise among State University System Faculty: USF, UF, UCF 10
Project Overview Project Overview Project Overview Project Overview Milestones/ Timeline : Milestones/ Timeline : Milestones/ Timeline : Milestones/ Timeline : Year 1 Year 1 - - Facility operational, sub Facility operational, sub- -module module experiments underway experiments underway i i t t d d Year 2 Year 2 – – Processing equipment operational, Processing equipment operational, module level processing underway module level processing underway Year 3 Year 3 – Demonstration of effective module Demonstration of effective module fabrication and performance, industry fabrication and performance, industry participation participation p p p p 11 11
Project Overview Project Overview Project Overview Project Overview Milestones/ Timeline : Milestones/ Timeline : Milestones/ Timeline : Milestones/ Timeline : Year 1 Year 1 - - Facility operational, sub Facility operational, sub- -module module experiments underway experiments underway i i t t d d Facility � Design completed – in final permitting � Hardware being ordered � Hardware being ordered � Deposition system designed, being ordered 12 12
Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory 13
Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory Capabilities � Fully Integrated Module Fabrication • Glass through encapsulation • Generic patterning, interconnection and packaging G i tt i i t ti d k i � Physical Vapor Deposition • Sputtering, Evaporation, Close Space Sublimation � In-Situ Diagnostics � In Situ Diagnostics • Glass integrity, composition and thickness monitoring � Stability Testing � Stability Testing 14
Deposition System Deposition System Deposition System Deposition System •Initial design combines chambers to increase versatility with limited funds limited funds • Substrate is 1 ft 2 glass • Initial technology: single junction CIGS • Evolve to high efficiency tandem E l t hi h ffi i t d 15
Project Overview Project Overview Project Overview Project Overview Milestones/ Timeline : Milestones/ Timeline : Milestones/ Timeline : Milestones/ Timeline : Year 1 Year 1 - - Facility operational, sub Facility operational, sub- -module module experiments underway experiments underway i i t t d d Sub-module Experiments � CIGS experiments underway at USF to help guide design of large area system g g g y � CIGS-related experiments underway at UF and UCF to provide additional options and UCF to provide additional options and enhancements 16 16
Single Junction CIGS Single Junction CIGS Single Junction CIGS Single Junction CIGS Potential Module Efficiency – 15% Use and refine known processes. 17
Single Junction CIGS Single Junction CIGS Single Junction CIGS Single Junction CIGS 18
19 Single Junction CIGS Single Junction CIGS
Tandem Junction Tandem Junction Tandem Junction Tandem Junction Potential Module Efficiency – 25% 20
Tandem Junction Tandem Junction Spectral Splitting � More effective use of the solar spectrum Candidate Materials/ Work in Progress Copper Gallium Diselenide – USF, UF, UCF Copper Indium Disulfide – UCF, USF Cadmium Selenide - USF 21
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