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Cheap Solar Panels Made With An Ion Cannon

MrSeb writes "Twin Creeks, a solar power startup that emerged from hiding today, has developed a way of creating photovoltaic cells that are half the price of today's cheapest cells, and thus within reach of challenging the fossil fuel hegemony. As it stands, almost every solar panel is made by slicing a 200-micrometer-thick (0.2mm) wafer from a block of crystalline silicon. You then add some electrodes, cover it in protective glass, and leave it in a sunny area to generate electricity through the photovoltaic effect. There are two problems with this approach: Much in the same way that sawdust is produced when you slice wood, almost half of the silicon block is wasted when it's cut into 200-micrometer slices; and second, the panels would still function just as well if they were thinner than 200 micrometers, but silicon is brittle and prone to cracking if it's too thin. Using a hydrogen ion particle accelerator, Twin Creeks has managed to create very thin (20-micrometer), flexible photovoltaic cells that can be produced for just 40 cents per watt; around half the cost of conventional solar cells, and a price point that encroaches on standard, mostly-hydrocarbon-derived grid power."

47 of 395 comments (clear)

  1. Ion Cannon by necro81 · · Score: 5, Funny

    And here I thought ion cannons were only useful for disabling Star Destroyers. Now we can use them to disable the evil Oil Empire!

    1. Re:Ion Cannon by stevegee58 · · Score: 4, Funny

      Only from Low Earth Orbit.

    2. Re:Ion Cannon by Chris+Mattern · · Score: 4, Funny

      Nonsense, they're great for incernating Nod terrorists from orbit, too!

  2. Cost of machinery by Anonymous Coward · · Score: 3, Interesting

    What about the cost of the ion accelerator itself? Is it cheap enough to make this manufacturing method scaleable?

  3. Get ready for....nothing! by Rossman · · Score: 3, Insightful

    Man how many times have we seen these stories already - "cheap solar power discovery, will make solar pv affordable" but then years later nothing has changed.

    It would be great if some of these things actually got productizd, I would set up solar pv all over my property if it was just a bit more cost effective...

    1. Re:Get ready for....nothing! by Baloroth · · Score: 4, Informative

      Because the story comes out when the technology is still in fairly early stages of development, and then it takes 5-10 years from that point for people to work out the engineering difficulties to actually bring it to full-scale production (or it turns out not to be practical).

      Also, oblig xkcd.

      --
      "None can love freedom heartily, but good men; the rest love not freedom, but license." --John Milton
    2. Re:Get ready for....nothing! by sycodon · · Score: 3, Insightful

      Well, to use the common argument against drilling, if it will take more than just a few years to see the benefit, then why even bother with it?

      --
      When Fascism comes to America, it will call itself Anti-Fascism, and tell you to give up your guns.
    3. Re:Get ready for....nothing! by Alwin+Henseler · · Score: 5, Insightful

      Yes, we here many of these stories, and then years later nothing has changed... Other than the fact that the cost/watt of pv has continued to drop a significant percentage year after year after year. If that doesn't suit one's definition of progress, redefine "nothing has changed"...

      (..), I would set up solar pv all over my property if it was just a bit more cost effective...

      If I'm not mistaken, pv already is cost-effective if not cheaper than conventional energy sources in a variety of places, be it with a significant upfront investment (but with cost-effective = including that investment). Any progress in the cost/watt department will simply increase the # of places where it pays to put up solar panels.

    4. Re:Get ready for....nothing! by TheRaven64 · · Score: 4, Informative

      I looked at solar panels for my house two years ago, and I looked again recently. The efficiency of the available cells has increased by about 50% for the same cost. So saying nothing has changed is a bit misleading.

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      I am TheRaven on Soylent News
    5. Re:Get ready for....nothing! by Teppy · · Score: 3, Informative

      The prices we're seeing today are based on discoveries/improvements made several years ago. Look at how module prices have (mostly) dropped over the years: http://solarbuzz.com/facts-and-figures/retail-price-environment/module-prices

    6. Re:Get ready for....nothing! by TheRaven64 · · Score: 4, Insightful

      Uh, that's not the argument against drilling. The argument against drilling is that the benefit will be short term, i.e. that it will only last 1-2 years. The benefit of R&D lasts much longer - even when this technology is obsolete, the next one is likely to be based on what was learned developing it.

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    7. Re:Get ready for....nothing! by TheRaven64 · · Score: 4, Informative

      Uh, what? Customers don't pay for power, they pay for energy. $0.40/watt, assuming 8 hours of useable sunlight per day, means about 3kWh/year. Customers pay $0.10/kWh in places where electricity is cheap. After one year, customers would pay at least $0.30, so the payback period is one and a third years, make it two years to cover installation / transmission costs and so on. In some places in the USA, electricity costs $0.40/kWh, so this would pay for itself in 4 months.

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    8. Re:Get ready for....nothing! by jandrese · · Score: 3, Insightful

      Really, the problem is that Solar cells used to be 10x too expensive to be worthwhile for most people. Now they're only 2-3x too expensive. In a few more years they could actually start to become commonplace.

      --

      I read the internet for the articles.
    9. Re:Get ready for....nothing! by MrQuacker · · Score: 4, Informative

      The $/watt number refers to the cost of the PV chips. So it costs them $0.40 to create a chip that outputs 1 watt.

      At $0.40/w you're paying $400 for a 1Kw panel. At that cost it will take 4000 Kwh @ $0.10/Kwh to pay for itself. That's about 2 years if it gets ~8hrs of sun a day. Everything produced after that 4000Kwh is "free", and since panels last for 10, 15, even 20+ years, that's a lot of "free" power. If grid electricity costs more than $0.10/Kwh, then payback is even faster. (I'm assuming perfect efficiencies to keep the math simple, but you get the point)

    10. Re:Get ready for....nothing! by TheRaven64 · · Score: 5, Insightful

      With the subsidy factored in, they're actually a reasonably good investment now. The problem is that the current rate of development means that if I wait for a few years I'll get a much better system. This isn't a problem for something like a computer, because it's relatively cheap and I'll replace it in a few years anyway. Something like a solar power system I'd want to last for at least 10 years. If I can get one twice as good for the same price in two years, it's worth waiting...

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      I am TheRaven on Soylent News
    11. Re:Get ready for....nothing! by BetterSense · · Score: 4, Insightful

      Actually, photovoltaic cells have a fundamental efficiency limit, and we are already close (well within an order of magnitude) of that already.

      Also, it's more than that. Mostly, solar energy is not concentrated. People are just spoiled by semiconductor integrated circuits. Photovoltaics have been steadily improving, but the fact is solar power is not very dense...actual sunlight is not a concentrated source of energy. There's only so many watts per square meter that fall, and the sun doesn't always shine. The only way to get real gains is to set out more solar panels. So there is going to be no "breakthrough" like there sometimes is with other technologies that are enabled by integrated circuits; even if somebody invents the absolute perfect solar cell that sucks up every uJ of energy that hits it.

      People set their expectations based on technologies that are enabled by integrated circuits, but fail to realize that more fundamental technologies can't be doubled in speed or cut to 1/4 the cost just be printing more of them on the same amount of silicon.

    12. Re:Get ready for....nothing! by Artraze · · Score: 4, Insightful

      Well, it also doesn't hurt that when the technology comes out you get the marketing number only.

      Sure, the panels are 40c/W, but put them in a box, pay the employees and overhear and then they're $1/W. Install them with a conversion system and batteries and all of a sudden they're $3-$7 per Watt much like they've always really been. (And of course, that's peak, and the average cost it probably more like $10-$25 / Watt.)

      Developments like these are positive, to be sure, but the cells themselves are only part of a pretty pricy equation. Even if this tech pans out, it probably won't end up reducing the price much more than 20%. Nice, but no where near the "half" that they like to tell you.

    13. Re:Get ready for....nothing! by mattiaza · · Score: 5, Insightful

      We are very close to the fundamental efficiency limit of *power per square meter*. Which is a valid, but secondary concern. If solar cells are cheap enough, there is plenty of space for them in deserts, suburban roofs, and perhaps even parking lots! A manhattan skyscraper won't be able to power itself, but a 30km*30km plot of land in Nevada receives enough sunlight over 24 hours to power the entire U.S. with electricity. The important metrics for any energy source are: * cost per watt over the entire lifetime of the system * pollution caused and non-renewable materials used per watt over the entire lifetime of the system. This research improves the cost per watt metric. As soon as it is better than coal, we will see huge solar cell power stations.

    14. Re:Get ready for....nothing! by Wraithlyn · · Score: 3, Informative

      solar panels still never even come close to putting out energy that comes close to the energy used in manufacturing the panels

      Hmm. I wonder what I'll turn up if I google "solar myths".

      Myth #5: Making solar panels takes more energy than it could ever produce.

      A report by the National Renewable Energy Lab shows that solar photovoltaic panels actually payback the energy used to produce the panels in 1 to 4 years depending on the type of panel. Because solar panels last at least 30 years, PV systems will provide at minimum 26 to 29 years of pollution-free electricity for your home!

      Source

      --
      "Mind, as manifested by the capacity to make choices, is to some extent present in every electron." -Freeman Dyson
    15. Re:Get ready for....nothing! by Iskender · · Score: 5, Informative

      Sure, solar power doesn't produce infinite power per area. But that doesn't matter. In fact, I'd argue it still produces quite a lot.

      It's been known for a long time that the price of manufacturing per watt is the important thing for solar, and that goes down all the time. There is no known lower limit to prices here.

      I think you're underestimating how much space there is when you say solar isn't very dense. A good sunny day will give 1000W solar input for one square metre. There are a million square metres in a square kilometre, meaning a gigawatt of solar input. That's a typical nuclear reactor's worth. But not all of that can be used. Let's assume 10% efficiency, meaning 10 square kilometres/nuclear reactor. Add half for support equipment and it's 15 square kilometres.

      That's a square less than four kilometres wide. For a nuclear reactor this would be an acceptable safety zone - it's pretty small really.

      There is plenty of space for solar if it only becomes cheap enough. It is already cheap enough in places like Hawaii, and it will only get cheaper while fossil fuel prices will keep going up.

    16. Re:Get ready for....nothing! by Dodgy+G33za · · Score: 5, Informative

      You will only get 8 hours of usable sunlight per year if you have a solar tracker and live in a particularly sunny spot. Here in Sydney, (which is on the same latitude sun wise as LA for you North Americans) PV installers base calculations on on 4 hours at the rated value for fixed PV.

      So a 200w panel costing $600 would give you 300 KW per year. At our electricity prices that is $68 a year, so paid off in 9 years and a ROI of 280% over the 25 years of installation. Sounds okay. Sounds even better when you take into account that buying grid energy from renewables in Australia commands a 40% premium on the price, and that there is a connection fee of $160 per year, and that energy prices will continue to rise.

      The problem is that the cost of the panel is only about a third of the cost of the installation for home solar, even if you do it yourself. To make matters worse the batteries have a much shorter life than the panels.

    17. Re:Get ready for....nothing! by jeff4747 · · Score: 3, Interesting

      Yeah, 'cause we're not all paying massive oil subsidies....oh wait.

    18. Re:Get ready for....nothing! by epine · · Score: 3, Insightful

      Goody! I can have renewable energy, and all I have to do is make my fellow citizens pay for it!

      The great thing about hating the government is never having to think. In many situations such as this one, where society needs to navigate a large infrastructure change, the early adopters provide a public good so that it becomes possible to achieve a Libertarian price point in the fat lump of the adoption curve sooner rather than later. You can argue that I'm wrong in this case, but it requires two orders of magnitude more mental input than your original comment.

      My father installed a 1st generation heat-pump technology in the early 1980s. It was hardly painless. Mostly worked pretty good, but some components were failing every 18 months, until design problems were identified and resolved.

      And that's nothing compared to what we pay bankers to fail on our behalf. If my father got a subsidy, it went right back out the door on expected unexpected maintenance costs. The bankers sent their subsidies straight to Switzerland.

  4. no way by Anonymous Coward · · Score: 5, Interesting

    whatever, I'm sure this was all true a year or 2 ago before module ASPS plummeted. however, these guys are now working against a commodity and china has demonstrated they are cool with 7% GM on modules. Polysilicon prices fell off a cliff and economies of scale have worked. wafer costs are 57c for the Chinese leaders now and their targets are under 50c by 2013, which means the competitive advantage of this process is zilch. This idea had legs in 2007-2008. No longer. Heck, even CdTe thin film lost its production cost advantage compared to China. Regular multi / quasi-mono cells will deliver terawatts of power. This other shit is a side show.

  5. So this is the year? by 140Mandak262Jamuna · · Score: 4, Funny

    So this is the year of the solar panels? Hope it goes as well as the year of Linux desktop.

    --
    sed -e 's/Chuck Norris/Rajnikant/g' joke > fact
  6. Wait, WHAT! by Anonymous Coward · · Score: 3, Funny

    WE HAVE ION CANNONS?!?!?!

  7. Re:Hegemony, schmegemony by rolfwind · · Score: 5, Insightful

    Even with the losses, I always though hydrogen would be the way to go for excess energy stored up through the day. Of course, on a large scale, I wouldn't be using photovoltaics but perhaps some type of concentrator and steam electrolysis. Molten salt may also be a way to go at that level.

    On a small level, how problematic would hydrogen be to store if used for things like heating a house? I realize it wouldn't power cars at its density level (natural gas already takes up too much space).

    Another solution may be storing the energy as compressed air.

  8. Selling the Shovels by necro81 · · Score: 4, Insightful

    This company isn't a solar panel manufacturer, per se, but rather a company that wants to manufacture semiconductor wafers that are thinner than you can get right now, with less waste. So, they are like those enterprising fellows that sold the shovels and pickaxes to gold prospectors back in the day. They didn't care who struck it rich so long as they could sell the equipment and supplies to all comers. They aren't Xerox or a publishing company; these guys want to sell reams of paper.

    This is great stuff – an innovation that can benefit the whole industry. There are other companies that are working along similar lines, though with different technology. 1366 Technologies is one that comes to mind.

  9. Re:Hegemony, schmegemony by Anonymous Coward · · Score: 5, Interesting

    Flywheels, the most efficient means of energy storage we have. Large ones, in sealed units, buried underground like a septic tank, that remain there 50 years or so, and can power your house for week or two in case of outages.

    Several companies are working on exactly this.

  10. Fuel cells are overrated. by mosb1000 · · Score: 4, Interesting

    You can burn the hydrogen in a combined cycle plant and get 70% efficiency. Fuel cells are overrated.

    1. Re:Fuel cells are overrated. by fyngyrz · · Score: 3, Interesting

      Ultracaps... that's where we need to go for short term storage. If they can stem the leakage they're prone to, then long term as well. Other than storage density, they're really a spectacular well of desirable characteristics already.

      But these new solar cells... the question is, when can we buy them, as it always seems to be with these breakthroughs. And for my area, how well will they withstand hail?

      --
      I've fallen off your lawn, and I can't get up.
  11. Oil gives the world 160 exajoules per year... by gestalt_n_pepper · · Score: 4, Insightful

    is all I can think when I read these stories.

    --
    Please do not read this sig. Thank you.
  12. Re:Hegemony, schmegemony by Fallingwater · · Score: 3, Interesting

    I was thinking flywheels too. They can't easily be adapted to automotive use, but if you can dedicate a whole room to a flywheel system size and weight are no longer a concern. However, they'd have to be more underground than the average basement, so if a flywheel breaks apart the resulting destruction doesn't bring the whole building down. Tons of potential kinetic energy stored in such a small area makes for a spectacular show if released all at once.

  13. They don't make cells, they make machines by Kagato · · Score: 4, Insightful

    Twin Creeks doesn't make solar cells. They make machines used for making the major component of the cells. They have production ready machines for sales right now. According to the Wall Street Journal article they are quite happy to sell the machines to Red China and the WSJ thinks that's who's going to buy most of them given they have the capital and they don't have irrational politicians that think "green" is a bad word. We could be making the cells here in the US. But that's not going to happen because it's more politically expedient to sell out the countries future for short term gains. The end result is this technology will create a few hundred jobs in the US to make the specialized machines. Most of the end products will be purchased by European and Asian customers who have a long term energy policy.

  14. Re:Hegemony, schmegemony by englishknnigits · · Score: 3, Informative
  15. Re:Watt vs KW/hr by MrQuacker · · Score: 4, Informative

    No. The $/watt number refers to the cost of the PV chips. So it costs them $0.40 to create a chip that outputs 1 watt.

    At $0.40/w you're paying $400 for a 1Kw panel. At that cost it will take 4000 Kwh @ $0.10/Kwh to pay for itself. That's about 2 years if it gets ~8hrs of sun a day. Everything produced after that 4000Kwh is "free". If grid electricity costs more than $0.10/Kwh, then payback is even faster. (I'm assuming perfect efficiencies to keep the math simple, but you get the point)

  16. Re:Challenge the fossil fuel ..??? by jandrese · · Score: 3, Insightful

    You don't have to solve every problem on day 1. Simply reducing the load on Coal power plants and letting more people charge their (electric) cars off of solar would already make a huge dent in the fossil fuel consumption across the globe. Maybe in 5-10 years such a setup will be practical, depending on advances in battery and solar technologies. It's hard to predict. Airplanes will still use fossil fuels (or maybe biofuels if that pans out), but that's alright because the pressure on them will be lessened from several other sectors of the economy.

    --

    I read the internet for the articles.
  17. and i'll bet you.... by Lumpy · · Score: 3, Informative

    They also last half as long as today's cheapest cells.

    the ONLY cells that have any longevity are the grown crystal types. The garbage that you see at the low price end lose 20% of their power generating capacity each year.

    the 45 watt harbor freight kit will be generating 2 watts in 4 years, even in a northern climate.

    Call me when these new "cheap" solar cell techniques will last 40 years under airizona sun. I still have 4 old panels from the 80's that have turned dark brown and they generate 70% of their new rated capacity, and they were retired from a solar farm in 1993.

    --
    Do not look at laser with remaining good eye.
  18. Re:Isn't light absorption the problem with Si? by cyfer2000 · · Score: 4, Informative

    30 micron is good enough, people actually measured this.

    --
    There is a spark in every single flame bait point.
  19. Re:Hegemony, schmegemony by necro81 · · Score: 5, Informative

    The energy stored in a flywheel is I * omega ^ 2. With the materials we have available now and the size you want to allocate to such a thing, manufacturers have found it works best to have a flywheel with a modest moment of inertia and crank the rotational rate way up high (100,000 rpm for starters). To keep the flywheel from spontaneously shattering, high speed flywheels are mostly made from carbon fiber. And with the flywheel spinning so fast, the only way to keep them from losing energy to friction is to have them spin in a vacuum on magnetic bearings. Then you add in a high efficiency motor/generator, with some serious power electronics to commute the phases at ~kW power levels. These are all proven technologies (see Beacon Power), but compared to a bank of lead acid batteries, it isn't an affordable solution for a home.

  20. Re:Hegemony, schmegemony by jklovanc · · Score: 3, Informative

    Costs are still a bit high for flywheels. Here is a quote from this article; "Costs of a fully installed flywheel UPS are about $330 per 15 seconds at one kilowatt." So to supply 1kW for a week it would cost 330*4*60*24*7= $13.3m.
    Flywheels are great for instant power to level output but not yet viable for long term storage. A flywheel to give power overnight would even be $800k.

  21. Re:Hegemony, schmegemony by Anonymous Coward · · Score: 3, Informative

    This sounds more like eddy current braking
    http://en.wikipedia.org/wiki/Eddy_current_brake

  22. Re:Hegemony, schmegemony by Knuckles · · Score: 3, Interesting

    Obviously this won't power a car on its own anytime soon, but I thought you might find it interesting anyway: http://www.williamshybridpower.com/
    Williams Hybrid Power is a spin-off of the Williams F1 race team that competes in Formula One. They developed this flywheel storage for use in their F1 race car, but IIRC under the particular restrictions of Formula 1 battery systems proved more competitive. It's been used to provide power for a "boost button" in Porsche high-performance cars though, and they are teaming up with other manufacturers, like Audi.

    --
    "When I first heard Daydream Nation it quite frankly scared the living shit out of me." -- Matthew Stearns
  23. Re:watts/sq. ft? by AlienIntelligence · · Score: 3, Insightful

    Meh, the world isn't lacking in area that could be covered with solar panels.

    Lol, the young and ignorant.

    Here's a slight fact that you seem to forget... all this land you are referring to,
    hosts some type of flora or fauna that the environmental groups will not allow
    you to kill or modify the territory of.

    And while I'm not at the height of tree hugging... stopping the use of fossil fuels
    to remedy one issue by creating another one, isn't exactly the greatest of ideas.

    Rooftops are the key, that is what this article is about. This company has devised
    a cheaper method of production and at the same time, made a solar cell that is
    flexible. That means more rooftop installs. More on the side of water storage tank
    installs. Farmer Brown gets to make some money cause his corn silos have some
    solar cells wrapped around them, and there's solar on his barn roof, etc.

    The solution to fossil fuel independence, isn't killing indigenous plants and animals
    to install large solar heaters. It is making each person grid independent. And to
    get them off of fossil fuels by providing an at-home electrical solution.

    -AI

    --
    For me, it is far better to grasp the Universe as it really is than to persist in delusion
  24. Re:Hegemony, schmegemony by TheRaven64 · · Score: 4, Informative

    No they wouldn't. In direct sunlight, the amount of power hitting the Earth is about 1kW/m^2. The top of my laptop is 0.09m^2, so the total solar energy hitting the back (assuming I'm sitting in direct sunlight with the back of the screen perpendicular to the Sun - and have you ever tried that?) is 90W. The most efficient solar cells ever made are 45% efficient. Most are about 10-20%. At 20% efficient, that's 18W. Still not bad, but once you're out of direct sunlight and into somewhere where you can actually see the screen, that drops to under 5W. Not worth bothering with. You can, however, get parasols with solar panels on top. These will quite happily power a laptop...

    --
    I am TheRaven on Soylent News
  25. Re:Hegemony, schmegemony by Caerdwyn · · Score: 3, Interesting

    The problem with batteries is sourcing the materials to make them.

    The best batteries currently are all variants on lithium-ion. Where does the lithium come from? Much of it is in Bolivia, China, and Afghanistan. I'm not sure if changing control of a critical infrastructure mineral from the current oil producing cast of clowns to cocaine cartels, masters of corruption and religious fanatic heroin-pusher fucktards is a win. Who is worse; the House of Saud or the Taliban? Also, how much lithium is there? How much lithium would we need to replace automotive motors with battery systems? I'll leave as an exercise to the reader whether we'd run out of oil or minable lithium first if we converted fossil fuel surface-based* vehicles and homes/businesses to electric. Add up the energy capacity of the fuel tanks when filled with gas/diesel. You might not like the answer.

    *Battery-powered air vehicles are a no-go. No battery technology comes close to the energy density per gram of hydrocarbon. You can move an airplane, its cargo and its fuel halfway around the globe with JP-A. Can't do that with batteries. Just not enough joules per gram of battery, plus batteries don't become (appreciably) lighter as you discharge them; spent chemical fuel doesn't have to be carried once it's burned.

    --
    Everybody gets what the majority deserves.
  26. Re:Hegemony, schmegemony by FishTankX · · Score: 4, Informative

    As far as I know the energy input and retrieval is still entirely mechanical, but the major advancements in flywheels have been magnetic bearings, and very high vacuums, which dramatically reduce friction losses.