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SEMI Northeast Forum
The Impact of Materials on PV Technology
Stanley Merritt Global Business Development Manager DuPont Photovoltaic Solutions
September 28, 2011
© DuPont
To be the world’s most dynamic science company,
creating sustainable solutions
essential to a better, safer, healthier life for people everywhere.
The Vision of DuPont
We are a market-driven science company.
© DuPont
DuPont is a Global Leader in PV Materials
Cell Materials
Module Materials
Balance of SystemMaterials
Teflon®
frontsheets
Elvax®
IonomerPVBencapsulants
Solamet®
metallizations
Kapton®
substrates
Niapure®
sodium metal
Tedlar®
films for backsheet
Rynite®
frames
Kalrez®
Zalak®
parts & seals
Vespel®parts
Kapton® photo courtesy of Solarion AG
© DuPont
2010 2016
FS Ag13%
Backsheet10%
Encapsulant7%
Glass7%Silicon
44%
Jcn Box6%
Other13%
Metaliz's15%
Glass10%
Other10%
Backsheet13%
Silicon38%
Encap Film9%
Jbox-Inverter3%
Wet Chem1%
FntSheet1%
Other25%
Jcn Box5%
Frame16%
Gases/ Targets
10%
Substrate26%
Encapsulant7%
Backsheet11%
Frontsheet28%
Substrate7%
Cell (Gases/ Targets)
41%
Jcn Box9%
Encapsulant4%
Backsheet11%
Addressable Market in PV Materials
High EfficiencyStandard
CIGSa-Si
c-Si ModulesBill of Materials
TF Flex ModulesBill of Materials
$37B$37B$17B$17B
$1.2B$1.2B$0.3B$0.3B
Source: DuPont
© DuPont
Materials Cost Impact on PV Cells & Modules
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
Crystalline Silicon Thin Film
Silicon Metal(42%)
Cost ofMaterialsin US$/W
Metal Paste (17%)
Backsheet (10%)
Front Glass (10%)
Encapsulant (7%)Junction Box (3%)Other Mat’ls (11%)
TCO Front Glass (36%)
Module Frame (13%)
Backsheet (18%)
Targets (7%)
Encapsulant (5%)
Junction Box (5%)Gasket/Edge Seal (4%)Packaging (2%)Other Materials (3%)
Source: DuPont
Bill of Materials
Gases (6%)
© DuPont
Materials Impact Three Critical Areas Essential to Achieving Grid Parity
1. Efficiency 2. Lifetime 3. Cost
Drive Lower PV LCOE to Achieve Grid Parity
© DuPont
Grid Parity Expected in Most Major Electricity Markets by 2020
ItalyBrazilSpainMexico
ChinaJapanIndia
GermanyUK
AustraliaFrance
S.KoreaTaiwan
Canada
USARussia
S. AfricaIran
UkraineSaudi Arabia
ItalyBrazilSpain
JapanGermany
USAIndia
ChinaCanadaTaiwanAustralia
MexicoFrance
S. KoreaUK
RussiaS. AfricaUkraine
Saudi Arabia
Iran
Note: Electricity usage in Top 20 countries accounts for 80% of global demand Source: Q-Cells
2020+ 2020+
Industrial Markets at Grid ParityResidential Markets at Grid Parity
© DuPont
11
6.610.2
0
5
10
15
20
25
UnsubsidizedPV Cost
Avg Resid'l gridprice (2010)
UnsubsidizedPV Cost
Avg Comml gridprice (2010)
UnsubsidizedPV Cost
Avg Industrialgrid price
(2010)
Achieving Grid Parity in the U.S. Requires ~50% Further Reduction in PV LCOE
PV LCOE and
Grid Price (US ¢/kWh)
~14c/kWh(CdTe)
(Large Scale)
~23 c/kWh(c-Si)
(Small Scale) 52%
53%
Residential UtilityCommercial
~19 c/kWh(c-Si)
(Med Scale)46%
Source: DuPont, US DOE
© DuPont
Roadmap to Grid Parity – Industry Technology Roadmaps
SystemCost
ModuleLifetime
Bankable Capacity >10 GW
<$2/W< 8 cents/kWh
PV LCOE
20-25 yrwarranties
30-40yrwarranties
2010 2011 2012 2013 2014 2015Timeline
AverageModule
Efficiency
14% 21%c-Si
TF 10% 14%
Standard Selective Emitter Back Contact
Tandem Junction High Efficiency Tandem
TF Flex 6% 13%
a-Si on Flex CIGS on Flex Roll-to-Roll CIGS
25-30 yrwarranties
Retail Grid Parity in portions of EU & US
© DuPont
Key Drivers of PV Levelized Cost of Electricity
PV LCOE
• System Efficiency• System Life• Insolation• Annual Degradation• Shading• Low-light performance• Component failures
÷
• Modules• BOS• O&M• Financing
SystemRevenue
IRRIRRSystem
Cost
Lifetime Power Output
© DuPont
Materials Impact Three Critical Areas Essential to Achieving Grid Parity
1. Efficiency 2. Lifetime 3. Cost
Industry roadmap to 20+% c-Si cells,
enabled bynew materials
Robust materials enabling >25 year
module lifetimes with high performance
Lower cost, light- weight polymers to replace glass and
metals
© DuPont
1. Efficiency 2. Lifetime 3. Cost
Industry roadmap to 20+% c-Si cells,
enabled bynew materials
Robust materials enabling >25 year
module lifetimes with high performance
Lower cost, light- weight polymers to replace glass and
metals
© DuPont
PV Technology Roadmap: c-Si Cells/Modules
High Efficiency Cells
Selective EmitterLocal BSF
Rear PassivationN-type Wafers
Conventional Cells
Back Contact Cells
Metal Wrap-thruEmitter Wrap-thruInterdigitated BC
>20%Module
Efficiency
~14%Module
Efficiency
Source: DuPont
2005-2011 Improved metallization pastes have enabled improvements in conventional cell designs ~1.5% / year (relative)
2011-Future Additional metallization improvements required for new cell designs
© DuPont
1. Efficiency 2. Lifetime 3. Cost
Industry roadmap to 20+% c-Si cells,
enabled bynew materials
Robust materials enabling >25 year
module lifetimes with high performance
Lower cost, light- weight polymers to replace glass and
metals
© DuPont
PerformanceUltra Violet (UV)
Temperature
Corrosion
Electrical Insulation
• Transmitted• Reflected
• Peak• Cycling
• Precipitation• Humidity
• Shock• Shorting
Backsheet Requirements
Reliability
Durability
Safety
Time
Pow
er O
utpu
tPo
wer
Out
put
Time
1: Ross, R. G., Jr. and Smokler, M. I. (1986) Electricity from photovoltaic solar cells: Flat-Plate Solar Array Project final report. Volume VI: Engineering sciences and reliability. JPL Publication, 86-31, volume VI. NASA , Springfield, VA2: Joint Research Centre (JRC), The Results of Performance Measurements of Field-aged c-Si Photovoltaic Modules, Prog. PV: Res. Appl, 2009.
Joint Research Center: In-Field Study2
Power Loss of 204 Field Aged c-Si Modules
Materials Choices Drive Real Differences in Lifetime Power Output
Materials Impact Module Lifetime & Performance
© DuPont
Relying on “Tier 1” Status Alone Does Not Guarantee Quality Modules
Financial Impact
• Cell corrosion • Polymer discoloration• Loss of insulation (unsafe for use) • Power degradation: -1.4%/yr
compounded vs. expected -0.5%/yr
Module : 125 W c-Si Module from Tier 1, “Bankable” Module MakerManufactured in 1998 with PET backsheets
Module : 125 W c-Si Module from Tier 1, “Bankable” Module MakerManufactured in 1998 with PET backsheets
106
~10% Reduction in Energy Value over life of project =
~$500,000 in Present Value
*Financials projected with System Adviser Model from NREL, Nominal Values ShownAssumptions: 1MW System, 12c/kWh flat sell rate, 8% Discount Rate, 2.5% Inflation
Degradation Issues
0
100
200
300
400
500
600
700
800
900
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0
Ener
gy V
alue
(US$
000
's)
Years
Lifetime Energy Value Reduction ~10% or US$500,000 in Present Value
(1MW System @ 12¢/kWh*)
Lifetime Energy Value Reduction ~10% or US$500,000 in Present Value
(1MW System @ 12¢/kWh*)
© DuPont
1. Efficiency 2. Lifetime 3. Cost
Industry roadmap to 20+% c-Si cells,
enabled bynew materials
Robust materials enabling >25 year
module lifetimes with high performance
Lower cost, light- weight polymers to replace glass and
metals
© DuPont
Metal & Glass Replacement Reduces Both Weight and Total Installed Cost
Conventional New Design
Module Front Glass Fluoropolymer film
Module Frame Aluminum Polymer composite
Racking System Aluminum or Steel Polymer composite
Number of Parts Dozens 3
Installed Cost Standard 25% reduction
System Weight Standard > 50% reduction
Source: DuPont
© DuPont
Dozens of Materials Innovations in Development
Lifetime
Cost
EfficiencyN-type silicon wafers
Improved cell metallization Higher aspect ratio metallizationImproved anti-reflective coatings
Textured tabbing ribbonsImproved transparent conductive oxides
Better reflector films Higher blue light transparent materialsMore temperature resistant substrates
Thermally conductive substrates
Improved encapsulantsImproved anti-soiling/fouling coatings
More durable backsheetsBetter edge sealing
Higher reliability invertersThermally conductive substrates
MicroinvertersFlexible moisture barriers
More durable interconnects
Thinner Si wafersUpgraded metallurgical grade silicon
Faster lamination cycle timeSimpler mounting & racking systems
Lower moisture sensitivity encapsulantsThinner encapsulant filmsThinner backsheet films
New backsheet constructions Lighter weight materials
>20% by2012
30+ yearsby 2015
$2/WpInstalledby 2015
LCOE(US ¢/kWh)
LCOE(US ¢/kWh)
2010 2015 14 - 23 7 - 12 2010 2015 14 - 23 7 - 12
Source: DuPont
© DuPont
Summary
• Reduce PV LCOE by 50% to achieve broad-based grid parity
• Materials improvements deliver improved efficiency, lifetime performance and cost
• Clear roadmap to grid parity…driven by materials innovations
• Understanding material choices and specifications is critical to delivering your targeted project returns
For More Information on PV Materials:photovoltaics.dupont.com
© DuPont
© DuPont
Backsheet Type Has Significant Impact on Module Power Degradation
Materials Choices Drive Real Differences in Lifetime Power Outputand are Seldom Reflected in Financial Models Used by Banks & Developers
1: Ross, R. G., Jr. and Smokler, M. I. (1986) Electricity from photovoltaic solar cells: Flat-Plate Solar Array Project final report. Volume VI: Engineering sciences and reliability. JPL Publication, 86-31, volume VI. NASA , Springfield, VA2: Joint Research Centre (JRC), The Results of Performance Measurements of Field-aged c-Si Photovoltaic Modules, Prog. PV: Res. Appl, 2009.
• Standard Reliable Module Design
• Key Safety Standards
• Functional and Reliability Requirements
All modules approved in the final specification contained Tedlar®
0
10
20
30
40
50
60
70
80
Glass Plastic Polyester,Al
Silicone Tedlar®,Al
Tedlar®
Joint Research Center: In-Field Study2
Power Loss of 204 Field Aged c-Si Modules (19-23 years outdoor exposure)
Perc
ent P
ower
Los
s (%
)Consistent low power loss of TPT
TM
backsheet in PV modules over >20 years
Backsheet Type
JPL: Module Performance Study1