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3. Results and Accomplishments 3.1 PV Manufacturing R&D Management To measure progress toward contributing to the Solar Program, the PVMR&D Project completed its FY 2005 milestone to “Analyze U.S. PV Industry Cost/Capacity/Recapture data and produce capacity-weighted, industry average results.” This milestone provides input to DOE and NREL decision makers on the growth of the U.S. PV Industry in support of the MYTP Milestone 14, Task 3 (due in FY 2006). Both historical and projected values for manufacturing cost and capacity were compiled in collaboration with PV industry partners. An evaluation of the FY 2004 data, completed in May of 2005, indicates progress toward achieving the Solar Program’s cost goals, as well as demonstrating cost savings directly related to project participation. Figure 1 shows the cost/capacity results of the FY 2004 survey of PV module manufacturers. Total PV manufacturing capacity has increased from 14 MW at the project’s inception to 240 MW at the close of 2004. This increase in capacity represents a 27% compound average annual growth rate over the 12-year period examined. Direct manufacturing costs, in 2004 constant dollars, declined from $5.70/Wpeak to $2.44/Wpeak over the same time period, a 6.8% compound average annual reduction. Fig. 1. FY 2004 U.S. PV module manufacturing cost/capacity In addition, the PVMR&D project tracks the manufacturing cost savings resulting from improvements implemented under project subcontracts (also completed in May 2005). Public recapture of investment (shown in Fig. 2) is calculated based on the amount of measurable cost reductions passed on to the customer, whereas industry recapture of investment (also shown in Fig. 2) is based on the amount of measurable cost reduction retained by the manufacturers. For both the public and private sectors, the estimated recapture exceeded both public and private investments during 1998. Fig. 2. Recapture of public and industry investment in PVMR&D 3.2 In-Line Diagnostics and Intelligent Processing Under this subtask, the PVMR&D milestone to “complete reviews and required redirection for remaining subcontracts” focused on guiding the IDIP project to a successful conclusion and addressing the MYTP Milestone 25, Task 6 (due in FY 2005). This milestone was completed in December of 2005. Other significant achievements under this subtask were accomplished by individual subcontractors, and are described in the following. Sinton Consulting “Development of an In-Line Minority-Carrier Lifetime Monitoring Tool for Process Control during Fabrication of Crystalline Silicon Solar Cells” (Not funded in FY 2005) • Received an R&D 100 Award for the quasi- steady-state photoconductance Silicon Evaluation System developed under an FY 2004 IDIP subcontract for the measurement of bulk minority-carrier lifetime. SpecializedTechnologyResources,Inc. “Development of New, Low-cost, High- performance PV Module Encapsulant/Packaging Materials” 53 • • Developed a new encapsulant that is a flame retardant. Developed a new faster-cure encapsulant. Photovoltaic R&D Advanced Materials and DevicesPDF Image | DOE Solar Energy Technologies Program
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