Silicon-Thin-Film Photovoltaic makes solar power economically viable

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Silicon-Thin-Film Photovoltaic makes solar power economically viable Photovoltaic in Switzerland 30. 06.

1 Silicon-Thin-Film Photovoltaic makes solar power economically viable Photovoltaic in Switzerland SwissLaser Network Workshop Dr. Andreas Baechli Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 1

2 Agenda 1 Oerlikon and Oerlikon Solar 2 Silicon Thin Film 3 Competitive Analysis Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 2

textile machines, drive systems as well as semiconductors and nanotechnology.

3 Enabling High Technology The Oerlikon Group is one of the most innovative 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. Oerlikon Solar With over 16,000 employees more than 150 sites in 36 countries, we develop solutions for leading industry applications and future-oriented markets. Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 3

Oerlikon is a provider of clean-technology solutions

Oerlikon Coating Leading coatings in the automotive

Advanced nanotechnology for solar cells, thermoelectric

Solar Leading provider of silicon based thin film solar

Oerlikon Fairfield Oerlikon Vacuum Vacuum solutions for

and electrical cars Oerlikon Graziano Andreas Bächli /

4 Oerlikon is a provider of clean-technology solutions 100 years history of turning innovations into sales Oerlikon Coating Leading coatings in the automotive sector: - 10x durability - 4% less energy consumption Advanced nanotechnology for solar cells, thermoelectric generators and batteries Oerlikon Systems Oerlikon Solar Leading provider of silicon based thin film solar technology Loose gears and gearboxes for wind turbines Oerlikon Fairfield Oerlikon Vacuum Vacuum solutions for the solar and wind industry Transmissions for hybrid and electrical cars Oerlikon Graziano Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 4

5 15 years of R&D experience and industrial mass production since 2005 Astronergy upgrade to 75 MW Amorphous & Micromorph Tianwei upgrade to 75 MW Micromorph Gadir Solar reaches SOP PV lab at IMT by Prof Arvind Shah VHF PECVD deposition technology Oerlikon founds own R&D lab and enters thin film silicon PV 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-toend production line contract 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 SunWell ramps and celebrates SOP for first Asian end-to-end line Champion cell with 11.9% efficiency DongXu orders 2 KAI 1200 & Gongchuang order FAB Light trapping by TCO & intermediate reflector Micromorph solar cell (tandem amorphous, microcrystalline) First R&D equipment delivered to Schott Solar Oerlikon displays first functional 1.4 m2 a-si module First 40MWp front end line contract with Ersol Oerlikon presents first Micromorph tandem module ~125 W 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 Multiple equipment order from DongXu New office premises in Shanghai 1 st ThinFab sold Hevel contracts for end-to-end solutions for 130 MW HelioSphera SOP for 30 MW of total 60 MW Opportunity identification Concept and product Commercialization Globalization Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 5

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

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 employees including 300 scientists and engineers as well as 200 global customer personnel R&D investments of MCHF 70 in 2010 Serving 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 30 th 2011 / page 6

Solar Technologies Overview Solar Power Concentrated Solar

into electricity through photoelectric effect.

large farms at competitive energy value.

7 Solar Technologies Overview Solar Power Concentrated Solar Power concentrate sunlight to heat source fluid for a conventional power plant. CSP cannot be deployed at small scale and geographic range is limited. Wafer based Photovoltaic (PV) direct conversion of sunlight into electricity through photoelectric effect. PV supports broad functional applications from roof-tops to large farms at competitive energy value. Thin Film Technologies c-si TF-Si CdTe CIGS Market Share 79% 9% 10% 2% Oerlikon Solar.. a pioneer in Thin Film Silicon technology Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 7

1 Amorph Single Junction Micromorph Tandem Junction 0 300 400 500 600 700 800 900 1000 1100 W l th [

8 Oerlikon Solar thin film silicon technology Cell Structure Cell Cross Sections Spectral Cell Sensitivity 0.9 Thin Film a-si a-si µc-si Quantum Efficiency [a.u.] Amorph Single Junction Micromorph Tandem Junction W l th [ ] Amorph Micromorph Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 8

THINFAB with next generation equipment Laser (LSS ThinFab )

dead zone of 180 µm for TF silicon mass production Doubled

96% uptime Micromorph absorber deposition system capable of

Equipped with 30 reactors enabling 43 m2 of glass processing

50% less footprint & 50% faster cleaning 60% higher throughput

trapping enables a high efficiency thin absorber layer

9 THINFAB with next generation equipment Laser (LSS ThinFab ) PECVD (KAI MT) LPCVD (TCO ThinFab ) World leading laser scribe dead zone of 180 µm for TF silicon mass production Doubled throughput since last generation Improved process stability 96% uptime 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 Page 9 Oerlikon Solar Company Presentation / Intersolar Munich 2011

Cells Cell n+2 Contact area + Schematic overview not to scale Cell n Cell n+1

10 The layout for a panel defines the cells and thus reduces the ohmic losses and defines the voltage Panel Contact area Top View Zoomed: P1 P2 P3 Scribes P1-P3 Cells Cell n+2 Contact area + Schematic overview not to scale Cell n Cell n+1 Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 10

Low electrical loss connections between cells Generation of high

TCO Laser Voc Pattern 1 asi-ucsi Pattern 2 BC Pattern 3 Laser Edge

contact Glass substrate P1 P2 P3 P1 P2 P3 Andreas Bächli / WS

11 Low electrical loss connections between cells Generation of high parallel & low serial resistances Clean TCO FC Laser PECVD Laser TCO Laser Voc Pattern 1 asi-ucsi Pattern 2 BC Pattern 3 Laser Edge Iso. Assembly P1 P2 P3 Back contact TF silicon Current Flow Front contact Glass substrate P1 P2 P3 P1 P2 P3 Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 11

12 THINFAB Module Efficiency 10% / 143 Wp Technology Micromorph Module Size 1.1 x 1.3 m 2 Annual Output 120 MW /~ Modules Yield 97% Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 12

Thin Film Silicon PV Applications Groundmounted PV Systems (GMS)

(RRT) Off-grid PV Systems BIPV Source: blitzstrom.

installation Typical system size > 1000 kwp Large rooftop PV power

Typical system size 10 to1000 kwp PV systems on residential homes

size 1 to 10 kwp Pumping systems Rural electrification Standalone

Integration External facades Semi-transparent facades Skylights

13 Thin Film Silicon PV Applications Groundmounted PV Systems (GMS) Commercial Rooftop PV Systems (CRT) Residential Rooftop PV Systems (RRT) Off-grid PV Systems BIPV Source: blitzstrom.com Utility scale PV power plants Grid-connected Ground based installation Typical system size > 1000 kwp 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 Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 13

Development of costs for PV solutions c-si Cost Structure Thin Film Si Cost Structure Module Cost ( /Wp) 2.5 Processing Cost 0.7 2.2 Feedstock (Poly) Cost 1.

14 Development of costs for PV solutions c-si Cost Structure Thin Film Si Cost Structure Module Cost ( /Wp) 2.5 Processing Cost Feedstock (Poly) Cost 1.8 2Q Q Q Q Q10E Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 14

15 THINFAB Economically Viable Solar Power with Thin Film Silicon NOW! Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 15

PV Cost Structure Breakdown PV Panel Balance of System (BoS) EPC Operation and Maintenance

Transformer Labor Engineering Procurement Construction Maintenance Land Lease Insurance

Energy Yield System Degradation Capital Structure Inflation Rate Tax Rate and Credits

16 PV Cost Structure Breakdown PV Panel Balance of System (BoS) EPC Operation and Maintenance Project Financing Materials Gases Investment Labor Utilities Inverters Mounting Cabling Transformer Labor Engineering Procurement Construction Maintenance Land Lease Insurance Monitoring Cleaning Capital Structure Projects IRRs Electricity costs further driven by Energy Yield System Degradation Capital Structure Inflation Rate Tax Rate and Credits (Accelerated) Depreciation Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 16

Cost of Electricity with Oerlikon Solar Technology 10 MW Solar Farm in Bari, Italy Module Production Cost 0.50 /Wp Module Margin (35%) 0.27 /Wp Module Price 0.77 /Wp BOS Price 0.

17 Cost of Electricity with Oerlikon Solar Technology 10 MW Solar Farm in Bari, Italy Module Production Cost 0.50 /Wp Module Margin (35%) 0.27 /Wp Module Price 0.77 /Wp BOS Price 0.91 /Wp Total system cost 1.68 /Wp Electricity Cost 0.07 /kwh Electricity Price* 0.12 /kwh 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% Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 17

18 Solar Technologies Overview Solar Power Concentrated Solar Power concentrate sunlight to heat source fluid for a conventional power plant. CSP cannot be deployed at small scale and geographic range is limited. Wafer based Photovoltaic (PV) direct conversion of sunlight into electricity through photoelectric effect. PV supports broad functional applications from roof-tops to large farms at competitive energy value. Thin Film Technologies c-si TF-Si CdTe CIGS Market Share 79% 9% 10% 2% Oerlikon Solar.. a pioneer in Thin Film Silicon technology Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 18

19 From champion cell to record modules 172 Record Stabilized Cell Efficiency [%] Record Stabilized Module Power at Pilot Line [Wp] World record with 11.9% efficiency 12 Stabilized Module Power [Wp] Stabilized Cell Efficiency [%] 86 Nov 07 Jun 08 Dez 08 Jul 09 Jan 10 Aug 10 6 Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 19

20 Record* Micromorph Tandem Module Degradation Results Current (A) m 2 Micromorph module Ini.Power: W Act.area η: 12.2 Total area η: 11.4 Voc/cell: V Jsc: 1.22A Voltage (V) P [W] T 982_1, 163.2W ini P [W] Deg [%] Degradation [hrs] deg. rel. [% ] I-V Curve Highly stable top cell, improved bottom cell and excellent light trapping lead to 11.4% total area initial efficiency 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 30 th 2011 / page 20

21 Key innovations already identified 170 Champion cell Structured glass Advanced bottom cell process 11.9% 150 Champion module 10.5% Power (stabilized) / Watt Thin layers 200/800nm New Module Design ThinFab process 9.1% 7.7% Efficiency % Today (mass production in existing fabs) 4.9% Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 21

22 Thin Film is well-positioned for future markets World market 2010 World market 2020 Reduced subsidy levels, markets shifting to sun-belt regions Favorable high-temperature performance for TF Si Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 22

Relative Energy Gain: Up to 13% compared to c-si Oerlikon Solar Micromorph technology Normalized output power (a.u.) 3.5 3 2.5 2 1.

higher energy yield is achieved at higher temperatures compared to crystalline. Crystalline Micromorph (R) Sunrise Daytime Sunset Stabilized modules were used.

23 Relative Energy Gain: Up to 13% compared to c-si Oerlikon Solar Micromorph technology Normalized output power (a.u.) Clear Day Oerlikon Solar Outdoor Test Facility, Switzerland 7:00 9:00 11:00 13:00 15:00 17:00 19:00 Due to Thin Film Silicon Micromorph lower temperature coefficient higher energy yield is achieved at higher temperatures compared to crystalline. Crystalline Micromorph (R) Sunrise Daytime Sunset 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 30 th 2011 / page 23

24 More than 9% higher energy yield compared to c-si Oerlikon Solar Micromorph technology Energy Yield YA [kwh/kwp] Oerlikon Solar Outdoor Test Facility, Switzerland Micromorph Crystalline 0 Feb-09 Apr-09 Jun-09 Aug-09 Oct-09 Dec-09 Feb-10 Apr-10 Jun-10 Aug-10 Time 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 30 th 2011 / page 24

25 Life cycle assessment of Oerlikon Solar Micromorph module System Boundary Raw material acquisition Material processing Fabrication of PV module Installation Use Disposal Materials & Energy Wastes & Emissions Recycling Recycling 3.00 Energy Payback Time (yrs) % Carbon Footprint (g Co 2 eq/kwh) c-si CIGS CdTe Thin Film Si (OS µc-si) Coal Oil Gas CC Bio mass Geothermal c-si Thin Film (OS µc-si) Nuclear Wind Source: Axpo, Oerlikon, Fthenakis V., BNP Paribas Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 25

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 Attractiveness Very Low Low Medium High Very High Toxic Composition Raw material Scarcity Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 26

7 MWp, Saarbrucken, Germany Modules produced by Oerlikon Solar customer

27 Installation by Oerlikon Solar customers 4 million panels produced as of today 2.7 MWp, Saarbrucken, Germany Modules produced by Oerlikon Solar customer Heliosphera Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland - OERLIKON June 30 SOLAR th 2011 CONFIDENTIAL / page 27 -

28 Three reasons to invest into THINFAB Competitive! Clean! and also Sustainable! Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 28

29 Disclaimer 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. Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 29

30 Thank you for your attention. Andreas Bächli / WS SwissLaser Network: Photovoltaic in Switzerland June 30 th 2011 / page 30

Field Performance of. Forrest Collins juwi solar Inc. February 2 nd, 2010

Field Performance of. Forrest Collins juwi solar Inc. February 2 nd, 2010 Field Performance of Thin-Film Forrest Collins juwi solar Inc. PHOTON 2nd Thin Film Conference February 2 nd, 2010 Overview Background on juwi Organization juwi Exprience with Thin-Film Data from the Field