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Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 1
Silicon-Thin-Film Photovoltaicmakes solar power economically viable
Photovoltaic in Switzerland30. 06.2011 SwissLaser Network Workshop
Dr. Andreas Baechli
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 2
Agenda
1 Oerlikon and Oerlikon Solar
2 Silicon Thin Film
3 Competitive Analysis
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 3
Enabling High Technology
The Oerlikon Group is one of the mostinnovative industrial groups in the world.
Oerlikon is active in various markets around the globe:machine and plant engineering,solar technology, thin film coating,vacuum systems, textile machines,drive systems as well as semiconductors and nanotechnology.
With over 16,000 employees more than 150 sites in 36 countries, we develop solutions for leading industry applications and future-oriented markets.
Oerlikon Solar
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 4
Oerlikon is a provider of clean-technology solutions100 years history of turning innovations into sales
Oerlikon Vacuum
Oerlikon Coating
Leading coatings in the automotive sector:- 10x durability- 4% less energy consumption
Vacuum solutions for the solar and wind industry
Loose gears and gearboxes for wind turbines
Advanced nanotechnology for solar cells, thermo-electric generators and batteries
Oerlikon Fairfield
Oerlikon Systems
Transmissions for hybrid and electrical cars
Oerlikon Solar
Leading provider of silicon based thin film solar technology
Oerlikon Graziano
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 5
Cooperation with Schott Solar on thin film silicon development 40 MWp equipment
contract with Schott Solar
Start of first Micromorph® production at Inventux
First Micromorph® end-to-end production line contract
SunWell ramps and celebrates SOP for first Asian end-to-end line
VHF PECVD deposition technology
Oerlikon displays first functional 1.4 m2 a-Si module
Light trapping by TCO & intermediate reflector
PV lab at IMT by Prof Arvind Shah
Micromorph® solar cell (tandem amorphous, microcrystalline)
First R&D equipment delivered to Schott Solar
15 years of R&D experience and industrial mass production since 2005
Oerlikon founds own R&D lab and enters thin film silicon PV
Oerlikon presents first Micromorph® tandem module ~125 W
First 40MWp front end line contract with Ersol
Opportunity identification
Concept and product Commercialization Globalization
Inventux achieves record efficiency with Micromorph® 120 W (> 9% efficiency)
Recorded full size module performance of 151 W (> 11% efficiency)
Tianwei SOP for 46 MW
Hevel contracts for end-to-end solutions for 130 MW
HelioSphera SOP for 30 MW of total 60 MW
1986 1989 1995 2003 2004 2005 2007 2008 2009 2010
Astronergy upgrade to 75 MW Amorphous & Micromorph®
Tianwei upgrade to 75 MW Micromorph®
Gadir Solar reaches SOP
SOP for HelioSphera second line of 30 MW to total 60 MW
UL Master Certification for all Oerlikon Solar technologies
TUV certification for a new 130 W module design
Astronergy reaches SOP
Launch of the ThinFab™ with € 0.50/Wp Cost of Ownership
Champion cell with 11.9% efficiency
DongXu orders 2 KAI 1200 & Gongchuang order FAB 1200
2011
Multiple equipment order from DongXu
New office premises in Shanghai
1st ThinFab™ sold
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 6
Oerlikon Solar at a Glance
The leading supplier of production lines for thin film silicon modules
More than 750 MW contracted to-date and more than 450 MW delivered to 11 customers meeting all performance targets
Approximately 700 employeesincluding 300 scientists and engineers as well as 200 global customer personnel
R&D investments of MCHF 70 in 2010Serving from 13 locations
in 9 countries
Oerlikon Solar’s vision is to make solar power economically viable.
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 7
CdTe CIGSTF-Si
Concentrated Solar Power Photovoltaic (PV)
Wafer based Thin Film Technologies
c-Si
… concentrate sunlight to heat source fluid for a con-ventional power plant. CSP cannot be deployed at small scale and geographic range is limited.
… direct conversion of sunlight into electricity through photoelectric effect. PV supports broad functional applications from roof-tops to large farms at competitive energy value.
Solar Power
Market Share 79% 9% 10% 2%
Oerlikon Solar .. a pioneer in Thin Film Silicon technology
Solar Technologies Overview
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 8
Oerlikon Solar thin film silicon technology
Cell Structure
Thin Film
Cell Cross Sections
a-Si
AmorphSingle
Junction
a-Si
µc-Si
Micromorph®
Tandem Junction
Spectral Cell Sensitivity
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
300 400 500 600 700 800 900 1000 1100
W l th [ ]
Quan
tum
Effi
cien
cy [a
.u.]
Micromorph®Amorph
THINFAB™ with next generation equipment
Laser (LSS ThinFab™) PECVD (KAI MT) LPCVD (TCO ThinFab™) Micromorph® absorber
deposition system capable of depositing a-Si and µc-Si layers with 40 MHz technology
Equipped with 30 reactors enabling 43 m2 of glass processing in single prod.
50% less footprint & 50% faster cleaning
60% higher throughput and 40% lower costs
Best-in-class transmittance and light trapping enables a high efficiency thin absorber layer
In-house front contact TCO enables cost-efficient local bare glass sourcing
World leading laser scribe dead zone of 180 µm for TF silicon mass production
Doubled throughput since last generation
Improved process stability – 96% uptime
Page 9 Oerlikon Solar Company Presentation / Intersolar Munich 2011
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 10
PanelZoomed:
Scribes P1-P3
Cells
Top View
+
Schematic overview – not to scale
P1P2
P3
Contact area
Contact area
The layout for a panel defines the cells and thus reduces the ohmic losses and defines the voltage
Cell n
Cell n+1
Cell n+2
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 11
FrontcontactGlass substrate
TF silicon
Back contact
P1 P2 P3 P1 P2 P3
Current Flow
Low electrical loss connections between cellsGeneration of high parallel & low serial resistances
Clean PECVDTCO TCOLaser Laser Laser VocaSi-ucSiPattern 1 Pattern 2 Pattern 3FC BC
Assem-blyLaser
Edge Iso.
P1 P2 P3
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 12
Module Efficiency 10% / 143 WpTechnology Micromorph®
Module Size 1.1 x 1.3 m2
Annual Output 120 MW /~850‘000 ModulesYield 97%
THINFAB™
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 13
Ground-mounted PV
Systems (GMS)
Thin Film Silicon PV Applications
Utility scale PV power plants
Grid-connected Ground based
installation Typical system
size > 1000 kWp
Commercial Rooftop PV
Systems (CRT)
Residential Rooftop PV
Systems (RRT)Off-grid
PV Systems BIPV
Large rooftop PV power plants
Grid-connected Sloped industrial
roofing Industrial flat roof Typical system
size 10 to1000 kWp
PV systems on residential homes
Grid-connected Retrofit rooftop BIPV rooftop/
façade Typical system
size 1 to 10 kWp
Pumping systems Rural electrification Standalone
systems Mini-grids Remote site power
supply Mobile power
Roof Integration External facades Semi-transparent
facades Skylights Shading systems Noise barriers
Source: blitzstrom.com
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 14
Development of costs for PV solutions
4Q10E2Q103Q094Q08
2.2
2Q08
2.5
0.7 Feedstock (Poly) CostProcessing Cost
Mod
ule
Cos
t (€/
Wp)
c-Si Cost Structure
0.8
0.20.6
1.0
0.3
0.6
1.2
0.5
0.61.5
0.7
1.8
Thin Film Si Cost Structure
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 15
THINFAB™Economically Viable Solar Power with
Thin Film Silicon – NOW!
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 16
PV Cost Structure Breakdown
Electricity costs further driven by Energy Yield System Degradation Capital Structure Inflation Rate Tax Rate and Credits (Accelerated) Depreciation
PV Panel
• Materials• Gases• Investment• Labor• Utilities
Balance of System (BoS)
• Inverters• Mounting• Cabling• Transformer• Labor
EPC
• Engineering• Procurement• Construction
Operation and
Maintenance
• Maintenance• Land Lease• Insurance• Monitoring• Cleaning
Project Financing
• Capital Structure• Projects IRRs
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 17
Cost of Electricity with Oerlikon Solar Technology10 MW Solar Farm in Bari, Italy
Assumptions: 10 MW solar farm in Bari, Italy, Average Energy Yield: 1690 kWh/kWp/year, Module power 143 Wp, BoS Based on OS EU estimates in 2012, 14% EPC Margin included, Annual Land Lease Costs ~ 2000 EUR/ha, Corporate Tax 30%, Inflation Rate 2.5%, O&M costs/yr: 0.8% of System Cost, Project life 25 yrs.
* Including WACC 8.5%
Module Production Cost 0.50 €/WpModule Margin (35%) 0.27 €/WpModule Price 0.77 €/WpBOS Price 0.91 €/Wp
Total system cost 1.68 €/Wp
Electricity Cost 0.07 €/kWh
Electricity Price* 0.12 €/kWh
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 18
CdTe CIGSTF-Si
Concentrated Solar Power Photovoltaic (PV)
Wafer based Thin Film Technologies
c-Si
… concentrate sunlight to heat source fluid for a con-ventional power plant. CSP cannot be deployed at small scale and geographic range is limited.
… direct conversion of sunlight into electricity through photoelectric effect. PV supports broad functional applications from roof-tops to large farms at competitive energy value.
Solar Power
Market Share 79% 9% 10% 2%
Oerlikon Solar .. a pioneer in Thin Film Silicon technology
Solar Technologies Overview
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 19
From champion cell to record modules
86
100
114
129
143
157
172
Nov 07 Jun 08 Dez 08 Jul 09 Jan 10 Aug 10
Stab
ilize
d M
odul
e Po
wer
[Wp]
6
7
8
9
10
11
12
Stab
ilize
d C
ell E
ffic
ienc
y [%
]
World record with11.9% efficiency
Record Stabilized Cell Efficiency [%]Record Stabilized Module Power at Pilot Line [Wp]
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 20
Record* Micromorph® Tandem ModuleDegradation Results
00.20.40.60.8
11.2
0 50 100 150 200
Cu
rren
t (A
)
Voltage (V)
1.4m2 Micromorph moduleIni.Power: 163.5 WAct.area η: 12.2Total area η: 11.4Voc/cell: 1.347 VJsc: 1.22A
I-V Curve
Highly stable top cell, improved bottom cell and excellent light trapping lead to 11.4% total area initial efficiency
0.0
2.0
4.0
6.0
8.0
10.0
12.0
14.0
140.0
145.0
150.0
155.0
160.0
165.0
0 500 1000
deg.
rel.
[%]
P [W
]
Degradation [hrs]
T 982_1, 163.2W ini
P [W]
Deg [%]
Initial Degradation Curve
Degradation corresponds to > 10% stable total area efficiency
*Results achieved consecutively on the Oerlikon Solar 1MW pilot line.
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 21
2009 10 11 12 13 14 201570
90
110
130
150
170
Pow
er (s
tabi
lized
) / W
att
2009 10 11 12 13 14 2015
Champion cell
Champion module
Today(mass production in existing fabs)
Structured glass
New Module Design
Thin layers 200/800nm
ThinFab™ process
Advanced bottom cell process 11.9%
4.9%
6.3%
7.7%
9.1%
10.5%
Efficiency
Key innovations already identified
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 22
Thin Film® is well-positioned for future markets
World market 2010
World market 2020
Reduced subsidy levels, markets shifting to sun-belt regionsFavorable high-temperature performance for TF Si
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 23
Oerlikon Solar Outdoor Test Facility, Switzerland1
1.5
2
2.5
3
3.5
7:00 9:00 11:00 13:00 15:00 17:00 19:00
Daytime
Nor
mal
ized
out
put p
ower
(a.u
.)
CrystallineMicromorph (R)
Relative Energy Gain: Up to 13% compared to c-SiOerlikon Solar Micromorph® technology
Sunrise Sunset
Clear Day
Due to Thin Film Silicon Micromorph® lower tempe-rature coefficient higher energy yield is achieved at higher temperatures compared to crystalline.
Stabilized modules were used. All data at module level (DC side) to allow comparison of module technologies and exclude inverter influences. Normalized to sunrise.
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 24
Oerlikon Solar Outdoor Test Facility, Switzerland
020406080
100120140160180200
Feb-
09
Apr-0
9
Jun-
09
Aug-
09
Oct
-09
Dec-
09
Feb-
10
Apr-1
0
Jun-
10
Aug-
10
Time
Ener
gy Y
ield
YA
[kW
h/kW
p]
Micromorph®Crystalline
More than 9% higher energy yield compared to c-SiOerlikon Solar Micromorph® technology
c-Si modules from European manufacturer, best modules in the batch used. All data at module level (DC side) to allow comparison of module technologies and exclude inverter influences
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 25
Life cycle assessment of Oerlikon Solar Micromorph® module
Materials & EnergyWastes & EmissionsRecycling
Raw materialacquisition
Fabricationof PV module Installation Use DisposalMaterial
processing
Recycling
System Boundary
162034424595
400
850900
-96%
Bio mass
Geothermal c-Si Thin Film (OS µc-Si)
WindNuclearGas CC
Coal Oil
Carbon Footprint(g Co2 eq/kWh)
Energy Payback Time(yrs)
Source: Axpo, Oerlikon, Fthenakis V., BNP Paribas
0.98
Thin Film Si (OS µc-Si)
CdTe
1.00
CIGS
1.90
c-Si
3.00
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 26
Overview Technology Competitive Analysis
Thin Film Si (OS ThinFab)
Thin Film CdTe (captive with First Solar)
Thin Film CIGS
Best Cost c-Si(China> GW
Scale)
Efficiency
Capex Captive FSLR
Module Cost
Energy Yield (Performanc, Suitability to hot climates)
Electricity Cost
Energy Payback
Toxic Composition
Raw material Scarcity
Attractiveness
Very Low
Low
Medium
High
Very High
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 27- OERLIKON SOLAR CONFIDENTIAL -
Installation by Oerlikon Solar customers4 million panels produced as of today
2.7 MWp, Saarbrucken, GermanyModules produced by Oerlikon Solar customer Heliosphera
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 28
Competitive !
Clean !
and also Sustainable !
Three reasons to invest into THINFAB™
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 29
This presentation is based on information currently available to management. The forward-looking statements contained herein could be substantially impacted by risks and influences that are not foreseeable at present, so that actual results may vary materially from those anticipated, expected or projected.
Disclaimer
Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30th 2011 / page 30
Thank you for your attention.