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We attended a tour of the First Solar 25-MWp facility before the ceremony. Substantial progress has been made in terms of (1) the new 25-MWp coater, which is now fabricating about 20% of the product; (2) reducing maintenance costs by substantially enhancing materials utilization rates; and (3) automating and improving most aspects of production. During his speech, Hambro stated that First Solar is now breaking even. He also provided information on his sales price and volume that would allow us to estimate his costs as among the lowest in all of PV. Separate discussions with Marketing Director Ken Schultz centered on plans to move to a cost structure that would allow the installation of $3/Wp ground-mounted PV systems in the not too distant future. The DOE Solar Program and NREL, the National Center for Photovoltaics (NCPV), and the Thin Film PV Partnership have supported the research and development of this very promising thin PV technology at First Solar for the past several years. First Solar uses a very rapid vapor transport deposition technique to deposit the semiconductor films in less than one minute, which gives it a significant advantage over its competitors. The deposition process won a prestigious R&D 100 Award in 2003 shared by NREL. “These accomplishments strengthen the position of U.S. manufacturers as leaders in the next generation of thin film solar technologies and accelerate our nation’s drive to make solar electricity competitive with conventional electricity,” said David Garman, Assistant Secretary, Energy Efficiency and Renewable Energy, and Under Secretary, U.S. Department of Energy. 3.2 Uni-Solar 25-MWp Factory Expansion The Uni-Solar a-Si factory is working at full capacity of about 2 MWp/month. Due to the silicon shortage, module prices have been rising, and profitability is increasing. Recently, Uni-Solar announced plans to build a second 25-MWp plant, also in Michigan. In describing the competitiveness of Uni-Solar technology, company President Subhendu Guha made the case that their peel-and-stick roofing material is directly competitive with all other rooftop PV approaches (including c-Si and CdTe) because of the ease of installation (e.g., reduced balance of system costs) and superior aesthetics and durability (see Fig. 3). He mentioned two major “wins” over such competition to large commercial rooftop projects, one for 1 MW on the GM building and another for 750 kW in California. Photovoltaic R&D Advanced Materials and Devices Fig. 3. The Uni-Solar a-Si factory produces peel- and-stick thin-film PV roofing material. The product’s easy installation is demonstrated on a building in China. Of interest, First Solar and Uni-Solar have different, but complementary, focus markets: Uni- Solar on commercial roofs and First Solar for large, ground-mounted systems. In both markets, they are quite competitive. 3.3 Completion of Four DOE Joule Milestones Four DOE Joule milestones were completed within the Partnership. Three of them are related to achieving a higher efficiency thin-film module, progressing from 10% to 11% (the final milestone) by the end of the fiscal year. These milestones were all achieved by Shell Solar Industries (a Technology Partner) for selenized CIGS modules. The other Joule milestone concerned the completion of the Partnership’s latest recompetition Letters of Interest and the signing of all the awardees in a timely manner. 3.4 Global Solar Fabricates Record CIGS Module Global Solar Energy (GSE) fabricated a 10.2%- efficient, 88.9-W thin-film CIGS power module, the highest wattage CIGS module in the world. This result meets a level-4 milestone in the Thin Film Partnership/NCPV project due 8/31/05. ITN Energy Systems (ITN/ES), Littleton, CO, developed the intelligent processing system for improved processing conditions and yields for cell and module fabrication that helped produce this module. The module parameters are as follows: Isc = 4.07 Amp, Voc = 36 V, FF = 0.606, area = 8709 cm2. Stainless steel (ss) web lengths of 1000 feet were used for the roll-to-roll processing of the devices. The typical cell structure is ITO/CdS/CIGS/Mo/ss. CIGS is deposited by 44PDF Image | DOE Solar Energy Technologies Program
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