l'industrie photovoltaïque : comment la recherche ... · 2008 2020 silicon km2 0 200 400 600...
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L'industrie Photovoltaïque : Comment la recherche contribue à l'atteinte du seuilde compétitivité
Dr. Philip BoydellTechnology Manager EMEADuPont Photovoltaics Solutions
Ecole Polytechnique8 novembre 2010
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Ordre du jour
• DuPont
• L’Industrie Photovoltaique
• Les Innovations de DuPont pour l’Industrie Photovoltaique
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Megatrends ���� OpportunitiesMegatrendMegatrend DuPont SolutionsDuPont Solutions
Increasing Food Production
Seeds, Crop Protection Products, Food and Nutrition Products,Food Packaging Materials
Decreasing Dependence on Fossil Fuels
PV, Fuel Cell Components, Energy Efficient Tyvek® Materials, Light Weight Polymer Composites for Transportation, Biofuels, Biomaterials
Protecting Lives and theEnvironment
Kevlar®, Nomex® and Tyvek® for Worker Protection, SentryGlas®, Safety Services, Environmental Protection Material Solutions
Growing in Emerging Markets
Agricultural Products, Materials for Construction and Infrastructure Projects, Coatings, Photovoltaics, Food Packaging
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R&D Investment: $1.4 billion in 2009
Electronics: 9%
Chemicals and Materials: 14%
Protecting Lives and the Environment: 12%
Decreasing Dependenceon Fossil Fuels : 15%
Increasing Food Production: 50%
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Fiber Science& Engineering
PrecisionPatterning
Coating& Color Science
Particle &Dispersion
Science
Surface &Colloidal Science
Catalysis
FluoroChemical &
PolymerSynthesis
Inorganic /Organic
Synthesis
RheologyControl
Inorganic-Organic
Composites
PolymerProcessing
FormulationScience
Polymer Synthesis
FermentationEngineering
MolecularBiology
ConventionalBreeding
Microbiology
Molecular Breeding
PlantGenetics
ProteinEngineering
Bio-informatics
Genomics
Cell / TissueCulture
Plant Physiology/
Disease
Agronomy
MetabolicEngineering
GeneRecombination& Regulation
Entomology
Biochemistry
Film Fabrication
ChemicalEngineering
Nanoscience
Enabling TechnologiesChemical Sciences Biological Sciences Materials Science
Engineering, Analytical Science, Scientific Computing, Modeling & Simulation, Toxicology, Environmental Science, Regulatory Science, Application Development
DuPont Core Technologies
© 2010 E.I. du Pont de Nemours and Company. All rights reserved,
Fiber Science& Engineering
PrecisionPatterning
Coating& Color Science
Particle &Dispersion
Science
Surface &Colloidal Science
Catalysis
FluoroChemical &
PolymerSynthesis
Inorganic /Organic
Synthesis
RheologyControl
Inorganic-Organic
Composites
PolymerProcessing
FormulationScience
Polymer Synthesis
FermentationEngineering
MolecularBiology
ConventionalBreeding
Microbiology
Molecular Breeding
PlantGenetics
ProteinEngineering
Bio-informatics
Genomics
Cell / TissueCulture
Plant Physiology/
Disease
Agronomy
MetabolicEngineering
GeneRecombination& Regulation
Entomology
Biochemistry
Film Fabrication
ChemicalEngineering
Nanoscience
Enabling TechnologiesChemical Sciences Biological Sciences Materials Science
Engineering, Analytical Science, Scientific Computing, Modeling & Simulation, Toxicology, Environmental Science, Regulatory Science, Application Development
DuPont Core Technologies
© 2010 E.I. du Pont de Nemours and Company. All rights reserved,
DuPont Core Technologies
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DuPont Photovoltaic Solutions © DuPont
Solar Resource Dwarfs All Other Energy Sources
Source: SunEdison April 2008
© Richard Perez, et al.
Coal
SOLAR
World Energy Use
Petroleum
Natural Gas
Wind
Biomass
Hydro
Waves
Uranium
PV is only ~0.1% of Total Global Generating Capacity
Fossil Fuels &Nuclear
Other Renewables
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DuPont Materials in the History of PV
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DuPont Photovoltaic Solutions © DuPont
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DuPont Photovoltaic Solutions © DuPont
Grid Parity
Leve
lized
cost
of
elec
tric
ity
time
From PV
From grid
Market
Today
Primary FuelDistribution
Market structure
Incentivized
TechnologyScale
‘Free market’
Grid parity
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2.86.2
7.9
126.8
129.9
18.6
7.6
14.4
0
10
20
30
40
50
60
70
2008 2012
Materials Play a Critical Role in Total Cost
PV Industry Value Breakdown
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MarketValue($bn)
63
System Design/ Install (~20%)
Balance of System(~30%)
Modules/Cells (~20%)
Poly-Silicon
Other Materials
All Materials(~30%)
All Materials(~30%)
Source: Photon Consulting, Linx Consulting 1Q 2009 Reports
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Market Growth Driving Strong Materials Demand
kt
0
200
400
600
800
2008 2020
Silicon
km2
0
200
400
600
800
2008 2020
Glass
t
0
2000
4000
6000
8000
2008 2020
Silver Paste
km2
0
200
400
600
800
2008 2020
Backsheet
km2
0
500
1000
1500
2008 2020
Encapsulant
t
0
5,000
10,000
15,000
20,000
2008 2020
Aluminum Paste
600kt600kt 650km2650km2
600km2600km2 1,300km21,300km2
6,000t6,000t 12,000t12,000t
Global materials volume projections (assuming growth to 100GWp in 2020)
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Major Investments Needed to Support Growth
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DuPont Apollo ‘C’ series
amorphous silicon / microcrystalline silicon>9% efficiency
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Key Drivers for Photovoltaics competitiveness
Cost€ installed
Yield kWh/y
R&D must deliver improvements in these areas
Quality &Reliability
years to amortize
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PV Innovation Pipeline
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Cost€ installed
Yield kWh/y
Quality &Reliability
years to amortize
•N-type silicon wafers•Improved cell metallization•Higher aspect ratio metallization•Improved anti-reflective coatings•Textured tabbing ribbons•Improved transparent conductive oxides•Better reflector films•Higher blue light transparent materials•More temperature resistant substrates•Thermally conductive substrates
Key Drivers for Photovoltaics competitiveness
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Ag Metal
Al Metal
Emitter Layern-type Base Layer
p-type
Antireflective Coating
SiNx:H 80nm n-pjunction
Frontside Ag pastes
Backside Al Backside Ag tabbing
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Improving Cell Performance: Metallization Roadmap
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Local BSF with rear surface passivation
Two problems affect all Al pastes
1) Al has poor adhesion to the SiNx unless it has some glass frit 2) If the Al paste has glass frit voids form at the edge of the Al-Si contact area
We are working to maximize adhesion and minimize the voids
Aluminium
BSF
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Higher Efficiency Metallization Pastes
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Polymeric Frontsheet Materials
���� A flexible, protective, durable transparent film as frontsheet for PV modules.
Desired Features
• High light transmission
• Easier-cleaning• Lightweight• Flexible• Anti-glare• UV resistant• Cut Resistance • Good adhesion
Benefits
• Higher Power output• Less breakage• Easier handling• More design options• Low maintenance
costs• Long-life durability• Light weight
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Polymeric Frontsheet Materials
EVA
DuPont Fluoropolymer / rigid substrate
DuPont Fluoropolymer
Rigid substrate
Conventional Glass/ Back sheet
c-Si Cell
3.8mm Glass
1mm EVA
Backsheet
9kg/m2Photo ‘Lumeta PowerPly’ courtesy DRI Industries
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Frontsheet Materials with Better transmission
Transmission:
1-3% Improvement
Weatherability:
20yr Outdoor Aging
Teflon® FEP FilmsHigh durabilityLow moisture permeabilityHigh transparencyWide operating temperature
Integrated Frontsheets with Teflon®FEP
Frontsheet + encapsulants
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Power Improvement and Durability
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Damp Heat Aging Heat-FreezeCycling
UV Aging
Film yield point
Pass / Fail point
Pmax W
77.4
76.877.0
78.4
76.0
77.0
78.0
79.0
Teflon®2mil FEP
Teflon®2mil ETFE
Competitive 2mil ETFE
Competitive 2mil PVDF
Power output for Commercial BIPV Modules 1:
1-2% Improvement
0.94
0.96
0.98
1.00
1.02
1.04
1.06
1.08
ETFE/EVA FEP/EVA
Frontsheet Type
Pp
(Arb
itrar
y)
Power output for Commercial BIPV
Modules 2:5% Improvement
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Reflective Back Encapsulant
Thin film Si module
Source: DuPont
avant après
Whitepaint
PVB
White PVB
“DuPont™ PV5223”
• PV5223 0250100 reflective encapsulant films introduced to market in April 2010
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Lower material consumption
0.45mm thick new DuPont™ PV5223 – 0250100 white PVB encapsulant sheetMore than 40% lighter than traditional 0.76mm clear PVB.
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0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
350 450 550 650 750 850 950 1050Wavelength, nm
Ref
lect
ance
PV5223 - 0250100
White paint
Increase power output
Higher Reflection
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DuPont™ Kapton® films for flexible thin film substrates
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Cost€ installed
Yield kWh/y
Quality &Reliability
years to amortize
Key Drivers for Photovoltaics competitiveness
Thinner Si wafersLower quality UMG (upgraded metallurgical grade) siliconFaster lamination cycle timeSimpler mounting & racking systemsLess moisture sensitive encapsulantsThinner encapsulant filmsThinner backsheet filmsNew backsheet constructions Lighter weight materials
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10kg/ 1.1m x 1.4m module15kg/ 1.1m x 1.4m module > 30% WeightReduction
1.8mm PV5300
PV5300 with 2 x Ultrafine float Glass
1.1 mm UFF
1.1 mm UFF
Conventional Glass/ Back sheet
c-Si Cell
3.8mm Glass
1mm EVA
Backsheet
DuPont™ PV5300 ionomer
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Glass robustness with polymer lightweighting
Tougher (5x), stiffer (100x) than PVB
DuPontTM PV5300 Ionomer Ultrafine float glass
0.3mm to 1.1mm
Laminationtechnology
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0
50
100
150
200
250
-20 -10 0 10 20 30 40 50 60
Glass/Ionomer/Glass Glass/EVA/Glass Glass/PVB/Glass
EVA
PVB
Temperature (deg.C)
���
(N)
Fig. Shimadzu Autograph (AG-X)1kN load cell, 3 point bending, Sample : 15*90*t3.0mm
The bending test showed highest strength for laminated glass with ionomer
142N
65N 51N
Bending test
(PV5300)
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DuPont™ Gevity™ PV Intégré
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Ses avantages
Peu de pièces
Peu de bois (liteau et planche) à rajouter lors de l’installation
Pas de mise à la terre requise
Pas de cote à prendre (gabarits)
Pas de vis apparente, donc possibilité de bâcher, si besoin, en coursd’installation
Coins spéciaux facile à mettre en place
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Cost€ installed
Yield kWh/y
Quality &Reliability
years to amortize
Improved encapsulantsImproved anti-soiling/fouling coatingsMore durable backsheetsBetter edge sealingHigher reliability invertersThermally conductive substratesMicroinvertersFlexible moisture barriers
Key Drivers for Photovoltaics competitiveness
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PV Module Lifetime – Reliable Power Generation
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JRC study shows consistent low power loss of TPT backsheetin PV modules over the >20 year test period
40
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Backsheet Adhesion to Encapsulant After Damp Heat
pull
EVAglass
Backsheet
EVA: Bixby BixCure®
* Adhesion not measurable due to backsheet break+ EVA peel from glass indicating strong EVA/backsheet adhesion
0
20
40
60
80
100
120
140
160
PET THV PFAVE PVDF G1 TPT G2 TPT G3 TPT G2 TPE
EV
A p
eel (
N/c
m)
0h
500h
1000h
* * * * + *
Loss of EVA adhesion for PET and other fluoropolymerbased backsheets
THV
PET
EVA
PVDF
PET
PE
PFAVE
PET
EVA
PVF1
PET
PVF1
PVF2
PET
PVF2
PVF3
PET
PVF3
PVF2
PET
EVA
PET
PET
primer
PFV1=PV2000 seriesPVF2=PV2100 seriesPVF3=PV2400 series
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Transparent Flexible Ultrabarrier
Enables flexible CIGS modules
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PV5300 limits Moisture Ingress v EVA
ASTM D7191 - Moisture analysis (uncalibrated)
0.000
0.001
0.002
0.003
0.004
0.005
0.006
0 2 4 6 8 10 12Distance from Edge (cm)
Moi
stur
e (g
H2O
/gto
tal )
1000h - Fickian Diffusion for EVA
1002h Commercial EVA Encap B
1020h - Encap C
1003h - Encap D
1005h - Encap E
1006h - PV5300
Cost savings of $3/panel by elimination of edge sealing
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Key Drivers for Photovoltaics competitiveness
Cost Yield
R&D is and must continue to deliver improvements in these areas
Quality &Reliability
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Material Innovation will play a critical role in driving the industry to grid parity this decade.
• Importance of a system approach
• The key role of Open Innovation and collaborative partnerships
PV Application Lab, Meyrin (Switzerland)Opened Feb 1, 2010
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