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Bigger, Cheaper Solar Cells

Phenombecile800 writes "First Solar, a start-up from Arizona, is making photovoltaic cells at a fraction of the usual cost. Their secret: increasing the light-catching area 'from postage-stamp to traffic-sign dimensions,' reducing the manufacturing time to 1/10th of the competition's, and thinning the active element to 1/100th the usual thickness over a glass substrate, which enables the production of large panels. IEEE Spectrum provides some technical details about the production process. 'Glass is placed on rollers and fed into the first chamber, where it is heated to 600 C. Then it is transferred into the second chamber, which is full of cadmium sulfide vapor, formed by heating solid CdS to 700 C. The vapor forms a submicrometer deposit on the glass as it moves through this cloud, after which a similar process in a third chamber adds a layer of micrometers-thick CdTe in about 40 seconds. Then a gust of nitrogen gas rapidly cools the panels to 300 C in a fourth chamber, strengthening the material so that it can withstand hail and high winds.'"

17 of 370 comments (clear)

  1. The old green question by gilgongo · · Score: 5, Interesting

    It's probably unanswerable, but I wonder how much energy it takes to make these cells, and how long it takes for them to offset that?

    --
    "And the meaning of words; when they cease to function; when will it start worrying you?"
    1. Re:The old green question by ScrewMaster · · Score: 4, Insightful

      On the other hand, that's not the only criteria for using solar power. The upfront cost of the physical plant is significant of course, as are maintenance costs and the payback period. However, if widespread use of solar reduces overall environmental impact and lowers petroleum consumption it might still be worth it, even if the cells themselves are expensive.

      What everyone seems to be waiting for is a cost-per-watt that is low enough so that ordinary people will decide to start buying them in large quantities without government subsidization. Suppose you're having a new house built: if you could install a ten or fifteen kilowatt solar plant and inverter for ten grand, you might figure it's worth it to borrow a little more money from the bank. I think we'll see more of that as our distribution grid continues to deteriorate and utility power becomes less and less reliable.

      --
      The higher the technology, the sharper that two-edged sword.
    2. Re:The old green question by Anonymous Coward · · Score: 5, Interesting

      It's probably unanswerable, but I wonder how much energy it takes to make these cells, and how long it takes for them to offset that?

      We can answer anyway without even RTFA. The summary says that the cells are made out of glass (not hewn out of a crystalline ingot of silicon). Assuming 10% efficiency and 20% availability of sunlight (due to weather and geometry), you get approx 20W/m^2, or 1 kWh every two days.

      Given that glass beer bottles cost a few cents each, a square meter of glass probably takes no more than a few dozen kWh of energy to produce. Even if the vapor deposition doubles or triples that, you still would end up with an energy surplus after just a couple of months of operation.

    3. Re:The old green question by Animats · · Score: 5, Informative

      The head of Applied Materials solar division said in a talk at Stanford last year that their solar panels took two years of their own output in energy to make. They hope to get the energy breakeven point down to six months. He said the sputtering process they use in coating is energy-inefficient, and they're trying to develop something better.

      Total installed energy cost is probably higher. Home solar installations are about 50% installation cost. The big open-field installations are cheaper; they have economies of scale.

      Forbes mentions that Mojave Desert real estate is becoming more valuable because many companies want to build solar facilities there. There's plenty of space in California, Nevada, and Arizona for solar panels.

      Mike Splinter of Applied Materials (the largest maker of semiconductor fab gear) likes to say "Everybody else's costs (in the energy business) are going up, and ours are going down. We're nowhere near market saturation. This is a great business for us."

    4. Re:The old green question by rah1420 · · Score: 4, Informative

      What everyone seems to be waiting for is a cost-per-watt that is low enough so that ordinary people will decide to start buying them in large quantities without government subsidization.

      You won't see it from FSLR, unfortunately. Their output is currently (no pun intended) earmarked for commercial ventures only, no retail/residential sales. Pity. Hope that changes.

      --
      Mit der Dummheit kämpfen Götter selbst vergebens.
    5. Re:The old green question by djarum72 · · Score: 5, Informative

      Article gives the size of the glass, and some temps, so it may just be answerable. Googling for: how much energy does it take to manufacture glass, 5 hit (no direct link since its a f***in word doc)

      The Recipe For 1 Ton Of Glass (Resources)
                            1300 Pounds Sand

                                400 Pound Soda Ash

                                400 Pounds Limestone

                                150 Pounds Feldspar

                        24000 Gallons Water

                            4400 KWH of Energy

      So, 4400 KWH per ton.

      How much do the panels weigh?

      (.6 m) * (1.1 m) * (.5 cm) * (2 500 (kg / (m^3))) = 8.25 kilograms

      (8.25 kilograms) * 4 400 (KWh / ton) = 144 Mj

      Apart from making the glass, there is heating the glass, heating the cadmium sulfur and telluride, mining all those chemicals, etc.

      Glass specific heat is .84 J/g K.

      (.84 (J / g)) * 8.25 kg * 580 = 4 019 400 joules

      So I've calculated 148Mj for the glass manufacture and heating.
      Ignoring the cadmium, sulpher, telluride chemical mining, what do you get out of it?

      (85 watts) * 25 years = 6.7 Ã-- 10^10 joules

      How much coal is that? http://www.newton.dep.anl.gov/askasci/eng99/eng99187.htm

      6.7E10 joules) / (4.11E6 (joules / pound)) = 7 400 kg

      Remember how I ignored the energy of mining those chemicals?
      How does the energy compare for mining the GRAMS it would take to deposit a film of telluride compares to the energy for mining TONS of coal.

      The answer to what you did ask, at least for the glass + heating, is pretty easy to answer:
      (148E6 / 85) * s = 480 hours. Less than a month.

    6. Re:The old green question by Lonewolf666 · · Score: 4, Insightful

      What everyone seems to be waiting for is a cost-per-watt that is low enough so that ordinary people will decide to start buying them in large quantities without government subsidization.

      And that is exactly what you need in countries that don't have a subsidization program. In the USA, I can see some of the more "green" states like California providing subsidies, but the current federal government seems more inclined to support the petroleum industry. How much change Obama would bring remains to be seen.

      So a cost-per-watt that doesn't need subsidies will be an important step forward in making solar power widespread. A deteriorating distribution grid will also do its part, especially if the cost-per-watt-hour of batteries decreases. Here I guess that new Li-Ion chemistries will do their part when more manufacturers make them and competition kicks in.

      --
      C - the footgun of programming languages
    7. Re:The old green question by bcrowell · · Score: 5, Informative

      What everyone seems to be waiting for is a cost-per-watt that is low enough so that ordinary people will decide to start buying them in large quantities without government subsidization. Suppose you're having a new house built: if you could install a ten or fifteen kilowatt solar plant and inverter for ten grand, you might figure it's worth it to borrow a little more money from the bank.

      A couple of things to keep in mind here:

      1. The cost per watt is already low enough that it makes sense for a lot of people, like me, to buy photovoltaics. It depends on what latitude you live at, how much sunny weather you get, which way your roof faces, how much shade there is on your roof, what the local price of electricity is, and what you expect the local price of electricity to be over the 25-year life of a photovoltaic system.
      2. When you talk about government subsidies, you should do an apples-to-apples comparison with the alternative, which is typically electricity that comes from burning fossil fuels. Fossil fuels enjoy massive government subsidies here in the U.S. We've fought three extremely expensive wars recently in the middle east, and I don't think we would have been involved in any of those wars if there hadn't been oil there; my grandkids will be paying for my generation's deficit-funded oil wars. There's also a huge amount of environmental damage done by burning fossil fuels, and that damage affects both this generation and future generations. If people paid the real costs of that environmental damage up front, then gas would be a lot more expensive. In places like Europe that don't subsidize fossil fuels as much, gas costs about twice what it does in the U.S.
  2. Re:Great big solar cells? by UnknowingFool · · Score: 4, Informative

    The story doesn't say larger is better per se. The story says that these cells are cheaper because they can be manufactured on a different scale. The most efficient solar cells are unfortunately only in labs at the moment and may not make it to consumers because of cost. Such it is with a lot of technology. The efficiency/cost ratio is important for more widespread adoption of solar technology.

    --
    Well, there's spam egg sausage and spam, that's not got much spam in it.
  3. their tech by opencity · · Score: 5, Informative

    Cadmium Telluride is also a direct bandgap semiconductor which yields more watts per kg than the indirect bandgap semiconductor materials. Solar cells become less efficient at converting solar energy into electricity as their temperatures increase but Cadmium Telluride is less susceptible to cell temperature increases than traditional semiconductors generating relatively more electricity under high ambient temperatures. It's also more efficent at converting low and diffuse light to electricity more efficiently than conventional cells under cloudy weather and dawn and dusk conditions.

    They also have a recycling plan in place for the lifetime of the product - somewhat at odds with the traditional landfill methods of yore. But, no retail. They don't sell to individuals and only deal with utility companies. Finance trivia: Their stock has grown spectacularly since the IPO and there is a large investment from the Walton family (insert TV joke here)

    --
    Physics is like sex: sure, it may give some practical results, but that's not why we do it.
  4. Environmental impact of cadmium? by BlueParrot · · Score: 4, Insightful

    So how much cadmium is needed, and how much leaks during the manufacturing process? Given that the opposition to nuclear power worries about toxic materials that decay with time, one would imagine there would be some concern about carcinogens that remain a danger forever, and cannot be destroyed.

  5. Re:The old black question by dubbayu_d_40 · · Score: 4, Interesting

    What's a better use of oil, making persistent sources of energy, or driving to 7-11 for nachos?

  6. Re:Article in two sentances: by D.+Taylor · · Score: 5, Informative

    Maybe you should have spent two hours reading the article - you might summarize it correctly then.

    The article states that current silicon photocells sell for around $3-$4 per watt.

    The new CdS/CdTe cells cost $1.14/W to produce and sell for $2.45/W.

    To reach "grid parity" they need to reduce the manufacturing costs to $0.60-$0.75/W and increase efficiency from "over 10 percent" to over 12 percent. The maximum theoretical efficiency for CdTe cells is over 20% and cells with an efficiency of 16.5% have already been made.

  7. Re:Obama's "Manhattan Project" On Alternative Ener by curmudgeon99 · · Score: 4, Insightful

    WE just had a spill caused by human stupidity and penny pinching [oil tanker in the Mississippi that leaked all that heavy oil after a barge hit it] and so I have no faith in the Prince-William-Sound fouling oil industry to not have major accidents and ruin our common coastlines and all the wildlife and environments that live there. You're missing the point entirely. Oil is not a long-term solution. Why waste another dime on trying to extend the supply. We have clearly had something change in our weather patterns. We know oil is a fossil fuel that is destined to run out. Look at them flailing in China to clean up their air in time for the Olympics. Oil is just bad all around. So, according to your view, it is the best choice to direct our attention towards squeezing out those last few drops of oil, which--according to the 80-20 rule--will be the hardest, most expensive and lease safe of all? You're short sighted. To use an analogy that would be understood by all the slashdotters, you're the guy whose advocating that we rebuild our company's systems in COBOL rather than Java/.NET/ or whatever newer. Coal and oil do not need time or attention wasted on them. They are dirty, and only enrich a few people at the top of coal companies. We need diverse and varied sources of energy that are renewable. We need to try several things and let the marketplace choose which ones are the best. The real problem is that the oil industry is allowed to dump a byproduct of their commodity into the atmosphere and the waterways without accounting for that damage. If you accounted for the damage oil is doing to our environment, and made oil companies sell their product while paying for that damage, we would all see that the current petroleum-oriented economy is terrible. Anybody who roots for more oil drilling is just some deluded troglodyte who really doesn't care what happens to this world as long as they can get rich in it, and "have theirs". Well, we've had enough of people who are willing to get theirs even if it means they have to go out late Saturday nights and tip over a 50-gallon-drum of toxic waste into the local creek. If it saves them some money, they're all for it. We've had enough of that type of bastard.

  8. Reliability? by Ankh · · Score: 4, Insightful

    Currently you can expect a home solar panel installation to pay for itself within 7 years (here in southern Ontario). If you combine it with wind turbines you can get your money back sooner, and if you spend the extra to be able to sell electricity back to the grid, you can get a payback much sooner because Ontario hydro (the power company here) pays you more than it would charge for the electricity (no distribution fee).

    Ideally you want the installation to last for 10 years or more without significant failures, though.

    Often "thinner and cheaper" translates to "more easily broken" and "less reliable" - for example, when the units flex in high winds. So my main worry would be about the expected (and achievable) lifetime of the units. Maybe if they gave a five or ten year warranty I'd be OK with it.

    --
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  9. Re:The old black question by Anonymous Coward · · Score: 5, Funny

    I think you may be seriously underestimating the deliciousness of nachos.

    Albeit not from the 7-11.

  10. Re:Obama's "Manhattan Project" On Alternative Ener by curmudgeon99 · · Score: 5, Insightful

    The reason none of these things have gone on line is because of the attitudes of people like you. There has been no concerted investment, ala the Manhattan Project. In lieu of any concentrated, directed effort to achieve a goal, nothing gets accomplished.

    The sun shines reliably for a large fraction of the day--why not invest in that?

    I find it curious how your standards of acceptability change: in the case of the alternatives available: switch grass, solar, wind, you play the pessimist. In the case of oil available off the coasts, suddenly you're an optimist. The US Department of Energy [you know, the one with all the Bush appointees in it] has said that 1.) offshore oil will not enter the supply chain for ten years minimum, not "a couple years" [implying 2], as you allege.

    Next you toss out the red-herring [meaning irrelevant] point of the Chinese drilling in Cuba--a claim which has been shown to be false so clearly that former GOP Candidate Rudy Guilliani himself uses future tense to describe this alleged problem, which is still a red herring. Do two wrongs make a right? [China allegedly drilling around Cuba and the US drilling off Florida?]

    Again, when you address the oil industry, it's all solid to you. When it comes to alternatives, it's "pie-in-the-sky". What are you, an oil-industry flack? You reluctant to learn new things or something?

    Though Nuclear does have the benefit of no greenhouse gases, it still has the same fundamental problem that oil does: it's business model is predicated on NOT dealing with its wastes! We STILL doe not have a solution to the incredibly toxic wastes we've been generating for decades. The only solution is to hide the waste. You think this is a viable alternative? Or, are you a Nuclear Energy devotee who has some business interest in that industry. When you advocate dirty technologies, how can we take you seriously?

    By the way, I lived in Houston and there is mass transit which I used while working for HP

    . And the solution is not--duh--biking 30 miles, it's moving closer to your work and downsizing your stuff.

    As I can re-iterate: I have lived all over the United States and this model in NYC is the only one I see as being viable. I've lived and commuted in Omaha, Phoenix, Houston, Cincinnati and Salt Lake City. I always chose to live as close as possible to work.

    Such name calling as labeling environmentalism "psychobabble" is convincing fewer and fewer people, my friend. The babble is coming from you fools who seem to prefer fouling your own nests.