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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.

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SLIDE 1

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: Students: R. Anders, K. Jayadevan, B. Satya Kanth 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

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SLIDE 2

Project Overview Project Overview

Objectives Objectives: :

Establish a world Establish a world class thin film PV module class thin film PV module Establish a world Establish a world-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

  • f-the

the- art generic thin film module facility art generic thin film module facility

2

TASK 3 DFT Modeling

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SLIDE 3

Why Thin Film? Why Thin Film?

Crystalline Silicon

  • Expensive single crystal
  • r multi-crystalline growth

Thin Films

  • Deposited in large area layers by

numerous inexpensive methods y g

  • Wafering

kerf loss

  • 300 – 400 μm thick
  • Individual cells must be

p

  • 1 – 5 μm thick
  • Monolithic

patterning and

  • Individual cells must be

handled and connected together

  • Monolithic

patterning and interconnection

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SLIDE 4

Why Thin Film? Why Thin Film?

Crystalline Silicon

  • Expensive single crystal
  • r multi-crystalline growth

Thin Films

  • Deposited in large area layers by

numerous inexpensive methods y g

  • Wafering

kerf loss

  • 300 – 400 μm thick
  • Individual cells must be

p

  • 1 – 5 μm thick
  • Monolithic

patterning and

  • Individual cells must be

handled and connected together

  • Monolithic

patterning and interconnection Thin Films have a significant cost advantage, but commercial

thin film modules are 10% efficient vs. 15% for Silicon modules.

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SLIDE 5

Why Thin Film? Why Thin Film?

Crystalline Silicon

  • Expensive single crystal
  • r multi-crystalline growth

Thin Films

  • Deposited in large area layers by

numerous inexpensive methods y g

  • Wafering

kerf loss

  • 300 – 400 μm thick
  • Individual cells must be

p

  • 1 – 5 μm thick
  • Monolithic

patterning and

  • Individual cells must be

handled and connected together

  • Monolithic

patterning and interconnection 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…

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SLIDE 6

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

  • f 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 10% y %

  • No

No significant significant commercialization commercialization

6

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SLIDE 7

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

  • ther
  • ther 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 instability problem problem has has slowed slowed progress progress j j y p p g p 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 lab cell cell efficiency( efficiency(13 13-14 14%) limits limits upside upside potential potential for for modules modules

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Low Low lab lab cell cell efficiency( efficiency(13 13 14 14%) limits limits upside upside potential potential for for modules modules

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SLIDE 8

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

  • f 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

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SLIDE 9

Which Thin Film? Which Thin Film?

Copper Indium Gallium Copper Indium Gallium Diselenide Diselenide

  • Most

Most complex complex material material of

  • f 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 C i l C i l d l d l i i 11 11 12 12%

  • Commercial

Commercial modules modules are are nearing nearing 11 11 - 12 12%

  • Lab

Lab cell cell efficiency( efficiency(20 20% %) ) provides provides good good upside upside potential potential for for modules modules

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SLIDE 10

Which Thin Film? Which Thin Film?

Copper Indium Gallium Copper Indium Gallium Diselenide Diselenide (T St t) (T St t) (To Start) (To Start)

Additional Advantage: Additional Advantage: Most expertise among State University System Faculty: USF, UF, UCF

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SLIDE 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 i t d i t d experiments underway experiments underway 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

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SLIDE 12

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 i t d i t d experiments underway experiments underway Facility Design completed – in final permitting Hardware being ordered Hardware being ordered Deposition system designed, being ordered

12 12

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SLIDE 13

Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory

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SLIDE 14

Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory Solar PV Laboratory

Capabilities Fully Integrated Module Fabrication

  • Glass through encapsulation

G i tt i i t ti d k i

  • Generic patterning, interconnection and packaging

Physical Vapor Deposition

  • Sputtering, Evaporation, Close Space Sublimation

In-Situ Diagnostics In Situ Diagnostics

  • Glass integrity, composition and thickness monitoring

Stability Testing

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Stability Testing

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SLIDE 15

Deposition System Deposition System Deposition System Deposition System

  • Initial design combines chambers to increase versatility with

limited funds limited funds

  • Substrate is 1 ft2 glass
  • Initial technology: single junction CIGS

E l t hi h ffi i t d

15

  • Evolve to high efficiency tandem
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SLIDE 16

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 i t d i t d experiments underway experiments underway 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

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SLIDE 17

Single Junction CIGS Single Junction CIGS Single Junction CIGS Single Junction CIGS

Potential Module Efficiency – 15%

Use and refine known processes.

17

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SLIDE 18

Single Junction CIGS Single Junction CIGS Single Junction CIGS Single Junction CIGS

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SLIDE 19

Single Junction CIGS Single Junction CIGS

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SLIDE 20

Tandem Junction Tandem Junction Tandem Junction Tandem Junction

Potential Module Efficiency – 25%

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SLIDE 21

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

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SLIDE 22

Conclusions Conclusions Conclusions Conclusions

  • The TF piloting lab is in final permitting
  • A versatile deposition system has been designed and is
  • A versatile deposition system has been designed and is

being ordered

  • A processing approach based upon single junction CIGS is

being developed for initial operations

  • Ongoing lab-scale experiments at USF,UCF,UF will help

develop additional choices and options p p

  • Efficiencies

up to 25% can be attained with tandem structures

  • Initial discussions with industrial collaborators are being
  • Initial discussions with industrial collaborators are being

conducted

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