Building a local PV industry case study of Nice technology production units in Tunisia and Algeria

Transcription

1 PRODUCTS SMAL SOLAR MODULE ASSEMBLY LINE NICE TECHNOLOGY Building a local PV industry case study of Nice technology production units in Tunisia and Algeria

2 STATUS OF THE DIFFERENT TECHNOLOGIES The dominant technology on the PV market is still the Crystalline Silicon technology representing more than 80% of the total market end 2013 and more than 60% expected by 2020 The thin film was a competitor with lower prices per Wp till end 2011, but the c-si price drop during 2012 and the lower efficiency per m2 make it difficult to compete against c-si technology The new technologies are expected on the market not before 2020 as proven technologies (organic cells, nanofab, etc). The actual investment costs are very high and the industry needs to be built after the actual consolidation

3 1. NICE vs. Standard Cell Front glass EVA (Ethylene-Vinyl Acetate) EVA (Ethylene-Vinyl Acetate) Tedlar Standard Cell ribbons soldered to the cell Front glass Rear glass Cell Cell Under-pressure NICE Technology Pressure force due to the inside underpressure Interconnection ribbons pressed on the cell 3

4 Solar Module Assembly Line NICE Technology WHY CHOOSING OUR TECHNOLOGY? Key arguments :

5 SOLAR MODULE ASSEMBLY LINE NICE TECHNOLOGY - The first interest is the encapsulation process : double glass system under vacuum, room temperature process, no lamination and no soldering - Today we started the encapsulation of c-si cells which represents the biggest market share of all PV chain - Tomorrow the NICE process will work to encapsulate not only c-si cells but also new products like multi-junction cells, organic cells, CIGS. It is one of the biggest advantage of our fully automatic line and encapsulation process

6 NICE (New Industrial Cells Encapsulation) Main benefits : 30% direct cost reduction of module manufacturing (CoO w/o cells) Less number of raw materials to produce the modules Only 5 operators per shift. (3 times less than the other systems) Cycle time reduction per module from >10 min (EVA) to 2 min (NICE fully automatic 50 MW line) 2 times less footprint New sealing process and material for improved humidity tightness. Stable long term module performance for more than 30 years. Fully recyclable modules.

7 NICE Advantages INNOVATIVE New industrial encapsulation and electrical interconnection of solar cells based on long term technological expertise RELIABLE Glass-Glass module with new sealing technology and soldering free cell interconnection Fully automated inline production with high reproducibility and narrow distribution of output power IEC & certified by TÜV Rheinland (Germany) HIGH PERFORMANCE Long module lifetime of 30+ years Very low power degradation even in extreme climatic conditions Higher performance ratio within the module lifetime COST EFFICIENCY Less consumables required Reduced industrial footprint Less manpower needed AESTHETICS Frameless version Lighter visual appearance Transparent in between cells PRODUCTION ENVIRONMENT Clean Factory No evaporation of solvents (solder flux) Room temperature processes SAFETY Front and rear glasses fully tempered Few flammable organic components Inherent DC current interruption in case of fire ENVIRONMENTALLY FRIENDLY Module components easy to separate and recycle Less toxic components Low carbon footprint

8 NICE versus Lamination Technology Laminated Module NICE Module Electrical series contacts Soldering Pressure Metal connectors Copper/solder Copper Encapsulant EVA (Ethylene vinyl acetate) N2 (under pressure) Sealing / tightness EVA (Ethylene vinyl acetate) PIB (Poly-isobutylene) Back sheet Tedlar / Glass Glass Industrialisation Laminated Module NICE Module Full Costs (without cells) 0,30 0,32 USD 0,20-0,22 USD Automation Possible Complete Number of operators 5 for 10 MW 1 for 10 MW Cycle time 10 minutes 2 minutes Sealing tightness Limited by EVA Complete Lifetime 25 years > 30 years Non recyclable parts EVA None

9 Comparison of c-si module costs W/O CELLS 0,35 Coût étape module ($/Wc) 0,30 0,25 0,20 0,15 0,10 0,05 0,00 0,20 0,20 0,20 0,22 0,23 0,24 0,24 0,24 0,26 0,29 (source: GTM research 07/2012) The NICE process is competitif in Europe vs the biggest Chinese manufacturers. All these costs are announced for >500 MW capacity except NICE (50 MW)

10 NICE: Process Steps Placement of rear sheet Glue deposition Cells and connectors placement Placement of module busbars Deposition of sealing Placement of front glass + transport of assembly to press for nitrogen flooding and creation of underpressure Pressing of assembly Placement of external connectors Deposition of secondary sealing

11 NICE Industrialisation Energy Industrie, Tunisia First Industrial 30 MW NICE line in Bou Salem, Tunisia Module press Station for sealing deposition Busbar deposition station Pick & Place stations for ribbons and cells Station for gluing Production started in July W modules with mono-c, mono-facial cells.

12 NICE: PID tests at NREL - Methodology NICE modules have been tested for potential PID using the in house test-to-failure protocol at NREL The NICE modules under test were industrial multi-c modules with 60 cells. The PID tests were carried out between 01/2013 and 12/2013 according to the following sequence: Alternating sequences of 1000h -600V and 200 TC Total of 6 rounds EL inspection and IV characterisation after every round 2 modules exposed to degradation cycles, 1 module kept for reference

13 NICE: PID tests at NREL - Results Power evolution after each round compared to 6 other standard modules (EVA + crystalline Si cells) NICE modules perform 2 nd best According to NREL no signs of PID related degradation on NICE modules NICE

14 Cells breakage in laminated modules Impact of 600 Thermal Cycles from -40 C to +85 C µ-cracks and solder problems in laminated modules

15 Cells breakage in NICE modules Impact of 600 Thermal Cycles from -40 C to +85 C Optimized underpressure: hardly no cracks, no solder problem and no contact disconnection at high temperature

16 R&D NICE: Thermal cycling general results Impact of Thermal Cycling test (-40 C / 85 C) Power Variation (%) Thermal Cycles (-40 C to +85 C) Power degradation < 3% after 1000 thermal cycles Power degradation after 200 thermal cycles and 1000 h damp heat test average : 0,1% Great stability of electrical parameters

17 3. NICE TECHNOLOGY CERTIFICATIONS PRODUCTS 2013 The NICE modules have been certified by TÜV Rheinland: IEC EN IEC EN PIB & sealant 2- Glass 3- Cells 4- Copper 5- Frame

18 4. PRODUCTION SITES SITES TUNISIA Bou Salem En cours ALGERIA Batna

19 THANK YOU FOR YOUR ATTENTION!