05 Centrotherm Faller - PPT Ohne Extra Slides - PDF Web PDF

PV Panels for the US
Make - not Buy!

Frank Faller
centrotherm photovoltaics USA Inc.
Silicon & Wafer

Solar cell & Module
Thin film module
Semiconductor
Centrotherm: Provider of Equipment and Turnkey Solutions
for the Production of ...
Poly Silicon Ingot

Ingot Wafer
Wafer Cell Module
Module PV Farm
© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 2

Outline
 Introduction Centrotherm
 Market
 Value Chain Poly Silicon Route
 PV Panel Production

History: In PV Equipment Business since 1979
2010
 Major order for the construction of a poly-silicon factory in Qatar
 Cooperation with Reis Robotics in the area of integrated process and automation technology
2009
 Realization of the largest to-date turnkey solar cell production line of 250 MW annual capacity
 “First Silicon Out" at poly silicon equipment customers in Asia
 Expansion of turnkey product range: crystalline module production
2008
 Foundation of centrotherm SiTec GmbH - Bundling of expertise in the solar silicon area
 Foundation of sales and service companies in Italy and the USA
 Acquisition of FHR Anlagenbau GmbH (Sputtering equipment)
2007: IPO of centrotherm photovoltaics AG; Admission to the TecDAX
2006
 Entry into the solar silicon business
 Delivery of first turnkey solar cell production lines
2005: Foundation of centrotherm photovoltaics AG
2004 – 2003
 Separation of business units
 Foundation of centrotherm thermal solutions GmbH & Co. KG
2002 – 2001
 Cooperation agreement for research projects with the University of Konstanz, Germany
 Primary supplier of key equipment to well-known solar cell producers
2000
 Joint research projects with the Fraunhofer Institute für Solare Systeme, Germany
 Entry into the Asian market
1979: First photovoltaic products supplied to well-known Fraunhofer Gesellschaft and Telefunken Systemtechnik GmbH
1976: Foundation of centrotherm Elektrische Anlagen GmbH

Centrotherm International Presence
centrotherm HQ, Blaubeuren CTPV Korea
GP Solar, Constance CTPV Shanghai

Zaporozhye, Ukraine (Project
company)
Marietta, Treviso, Italy
Georgia, USA Suwon, Korea
Shanghai, China
Taiwan
FHR, Dresden
Frankfurt/Oder
Hanover
Singapore
CTPV Taiwan
Ottendorf-Okrilla
Dresden
CTPV Singapore
Abensberg
Martinsried
Blaubeuren Headquarters
Burghausen
Constance Locations in Germany and International Sales & Service Companies
India and Qatar in foundation

Group Structure

Key Financial Figures 2009
Sales Breakdown by Region and Product 2009
Consulting &
in million € Engineering
Rest of World Other
16.1 (3.2%)
46.3 (9.1%) 3.0 (0.6%)
Service &
Rest of Europe Turnkey
Replacement
Production
parts
53.8 (10.6%) Lines
16.8 (3.3%)
117.8 (23.1%)
Germany
Total:
47.2 (9.3%) Total:
509.1 Asia 509.1
361.9 (71.1%)
Single
Equipment
355.3 (69.8%)
Export Quota: 90.7%
Revenue 2010 as of June 30: € 278 million

Market position of centrotherm photovoltaics AG
Source: VLSI Research

Selected References
Silicon & Wafer Solar cell & Module Thin film module
Sunshine
Asia
Silicon

Outline
 Market

US Renewable Resources
Resource Solar PV/CSP) Wind Geothermal Water Power Biopower

Theoretical 206,000 GW 8,000 GW 39 GW 140 GW 78 GW
Potential (PV) (onshore) (conventional)
11,100GW 2,200 GW 520 GW
(CSP) (offshore to (EGS)
50 nm) 4 GW
(co-produced)

The Sun provides every hour as much energy as mankind
consumes in one year
Source: EPIA

Global PV Production Capacities
Source: Photon International, March 2010

Leading Companies
Source: Photon International, March 2010

Market
Source: SEIA

Market
Source: SEIA

Largest PV Installation in the US

Centrotherm Research
Market Development and Segmentation until 2013
GW
30
ground mounted systems 26
25 commercial roof top
Thin film gaining
residential roof top
19 market share
20 Source: centrotherm photovoltaics, EuPD
15 14
c-Si
10
10 dominant
7
6
5 3
0
2007 2008 2009 2010 2011 2012 2013
• shortfall of Spanish market & finance crisis 2009 mainly affecting ground
mounted PV systems
• Additional FIT cut discussion in Germany for second half 2010
(no support for farmland solar system and 16% cut)
 nevertheless bright outlook dominated by c-Si technology

EPIA: Market Scenarios until 2014

EPIA: US Market Scenarios

Cost of PV Electricity
Source: U.S. DOE Solar Energy Technologies Program.
Note: Retail price in most East Coast US states as well as California is 0.15 $ / kWh;
this gives rise to PV electrcity being competitive in these markets today

PV Electricity vs. Actual Consumer Rate
• NREL study
looked at 1000
cities nationwide
•Meaningful population
centers at or near
„Grid Parity“

+0.5% p.a.
• 2015 with 0.5%
annual rate hike
•Includes:
•ITC only
•Falling system
prices
•Almost half of market

below grid parity
• 98% within
5 cents/ kWh

+1.0% p.a.
• 2015 with 1.0%
annual rate hike
•Includes:
•ITC only
•Falling system
prices
•Almost two thirds

of market below
grid parity
• 99% within
5 cents/ kWh
 no concern about
demand for PV
 But what does it mean for building manucacturing facilities??

“Unlimited” Market with Grid Parity (consumer electricity rate)
World at 2.5 €/Wp cost of installed PV system
0.40
Average household electricity price in €/kWh
0.35
0.30 Installed
System Price
2.50 € / Wp
Above
Grid Blue Line:
0.25 Hawaii Parity
Grid Parity
Italy
0.20 Germany
Portugal
0.15 California
France
Spain
0.10
Australia
Greece Texas
0.05 Taiwan India
bubble size = market size

0.00
700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200
Sun Irradiation [kWh/m²/year]

Outline
 Market

Polysilicon Production
Solar
Silicon Ingot/ Wafer Module
Cell
 Main stream today:

TCS / Siemens technology
 Feedstock mg-Si: 1.3 – 1.6 t/t Polysilicon
 Electricity consumption:
165 … > 200 kWh/kg
Other
10%
Key drivers of production cost 45% Depreciation

26%
 Electricity (site selection!)
 CAPEX depreciation (=> output of reactors and
converter technology: ) Electricity
Production cost: 24 … 33 €/kg 17% 2%

(including feedstock: mg-Si) Materials Labor cost

Ingot/Wafer Manufacturing
Solar
Cell
 Competition between multi and mono

material
 Key processes: crystallisation, bricking,
wafering
 Wafer thickness typical 2010:
200 µm (low end 180 µm)
Other
Key drivers of processing cost (multi): Electricity
4%
4%
 Line throughput (= CAPEX depreciation) Depreciation
 Materials: 30%
- crucibles
- slurry
- wire
2%
Labor cost
Processing cost: 0.73 … 0.90 €/wafer 60%
Materials
(excluding feedstock: polysilicon)

Solar Cell Manufacturing
Silicon Ingot/ Wafer Solar Cell Module
 Solar cell device technology today: screen

printed cell moving towards selective emitter
technology
 Typical production line size 50 – 100 MW
 Industry average efficiency 2010: 15.8 –
16.6% on multi wafer
Other
Key drivers of processing cost Electricity
5%
3%
 Solar cell efficiency (=> Wp!)
 Line throughput (= CAPEX depreciation) Depreciation
37%
 Materials:
- Ag / Al pastes
- Process media
52%
Processing cost: 0.18 … 0.27 €/Wp Materials
3%
(excluding feedstock: wafers) Labor cost

Module Manufacturing
Solar
Cell
 Typical module design today:

- 60 cells per module, 220 Wp
- glass / backsheet laminate
- framed
 Key processes:
- stringing, tabbing, interconnection
- lamination
Courtesy of Reis Robotics Other

Electricity Depreciation
0% 8% Labor cost
Key driver of processing cost: Materials! 1% 2%
 Glass 1.6 m2/module
 EVA 3.2 m2/module
 Backsheet 1.6 m2/module
 Frame 5.2 m/module
 Junction box 1 pcs/module
Materials
Processing cost: 0.30 … 0.40 €/Wp 89%
(excluding feedstock: solar cells)

Single Factories versus Integrated Factory
Single Polysilicon plant Module line +

Ingoting & Wafering Solar cell line
Administration
factories
Ingoting
Wafering
Integrated
factory Solar cell line
Module line
MG Silicon Plant
Solar academy
Power plant
Polysilicon plant Administration

From Ton‘s of Silicon to MW‘s of Modules: 2010
Silicon Ingot/ Wafer Solar Cell Module
single
factories -0.5% -0.5%
2010
2700 t 105 Mio 387 MW 379 MW

Wafer Cells Modules
fully
integrated
factory 2010
2700 t 107 Mio 403 MW 395 MW
Wafer Cells Modules

From Ton‘s of Silicon to MW‘s of Modules: 2013
Fully
integrated
factory 2013
2700 t 124 Mio 498 MW 488 MW
Wafer Cells Modules
Wafer thickness 170µm Efficiency 17.6% Embedding loss 2.5%

45.8 wafer/kg Poly Yield (cell fab): 96.5% Yield (module fab): 98%
Transport losses 0% Transport losses 0%
Silicon utilization 5.5 g/Wp

Outline
 Market

Crystalline Solar Module
Module structure:
 >90% of c-Si based modules consist of this structure; typical values and data in ()
Aluminum frame (h = 45 mm)
Tempered cover glass (3,2 ~ 4 mm)
Encapsulation foil 1 (e.g. EVA, 500 µm)
Stringed solar cells (60 – 72 pcs.; ≤ 180 µm)
Encapsulation foil 2 (e.g. EVA, 500 µm)
Back sheet (electrical insulation

and humidity sealing; 350 µm)
Junction box

Crystalline Solar Module
Competitive Module Power with Selective Emitter Cells
Multi Mono
and
Basis: 60 cells per module, module area: 1,64 m²

Multi Mono
FlexLine FlexLine+ FlexLine FlexLine+
Cell efficiency 16,2% 16,8% 17,4% 18,2%
Encapsulation Loss* 3,0% 3,5% 5,0% 5,5%
Encapsulated cell efficiency 15,7% 16,2% 16,5% 17,2%
Module power** 229 W 236 W 237 W 247 W
Area utilization 88,9% 88,9% 87,4% 87,4%
Module efficiency 14,0% 14,4% 14,5% 15,0%
* Assumption, depends on various factors, e.g. ribbons, nitride, glass, EVA
** Module power was calculated
Cell efficiency represent the guaranteed values in centrotherm turnkey lines.

Module power represents target value for power guarantee in turnkey integrated factories
Fab Planning: Standard Turnkey Module Line
Sorting and packaging of the modules
Repairing places 2nd EVA – foil, Taping Junction

Edge trimming
Glass washing, for strings and Back sheet –foil and Box
labelling and 1st matrices Soaping Setting
EVA - foil
~ 14 m
(Hot Spot Framing Flipping

measuring) Flashing and
and visual
optional classification
inspection
Foil cutting, EVA Stringer Interconnection Laminator
and Lay - Up 3 steps, 1 stage
~ 90 m
Floorspace required: ~1260 sqm. = 14,000 sq.ft.

Module Line Design

Module Line Design

Module Line Design

String Matrix Lay-up

Interconnect of Strings

Automated Framing

Fab Planning
Solar Module Factory - Layout
Module Tester
Back end
Laminator
Interconnection 2nd foil setting
Stringer
Layup Station
1st foil setting
Glass washing

15 MW Module Line

100 MW Module Line

Turnkey Package includes
 Consulting for Building requirements

 Facilities (requirements)
 Production tools
 Production support tools
 Solar module design and technology
 Manufacturing technology
 Process / production control
 Documentation, staff training and support
 Module Certification (IEC 61215 (c-Si), IEC 61730 (safety), UL 1703)

Cost of Manufacturing PV Panels
Production Cost Contributions

1.4% Key Figures 60 MW Module Line Project
75% 0.4% - Total Capex ~$10m (bldg, facil., eqpmnt)
Depreciation Equipment - Output 31 modules per hour, each ~227 Watt
3.2% - Processing cost ~0.4 $/Wp
Depreciation Facility &
Building
- 24/7 operation, 360 days
Labor - 70 operators, total 85 employees
21% Materials and running cost
Feedstock
Processing Cost Contributions

6% 2%
Depreciation Equipment
12% Depreciation Facility &
Competitiveness Building
Labor
-Cost advantage in Asia is small
-Running operation effectively and long-term Materials and running
realization of economy-of scale is key cost
-Production near markets is beneficial
-Meaningful part of market in US will fall
under „Buy American Provision“
-Local brands have been able to
secure price premium (e.g., SolarWorld) 80%

Conclusion
 Markets & demand are strong and growing
 Robust technology: C-Si produces reliable, low-risk and

bankable product (look at $/kWh – not $/Wp!!)
 Turnkey solutions for production lines available
 Solid business plan executable
 Make – not Buy!

Thank you for your attention!
centrotherm photovoltaics USA Inc
1395 South Marietta Pkwy

Silicon & Wafer Bldg. 200, Suite 208
Silicon & Wafer
Solar cell & Module Marietta, GA 30067, USA
Solar cell & Module Phone +1 678-996 3900
Thin film module
Thin film module USA@centrotherm.de
Semiconductor
Semiconductor www.centrotherm.de

05 Centrotherm Faller - PPT Ohne Extra Slides - PDF Web PDF

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PV Panels for the US

Make - not Buy!

Silicon & Wafer

Poly Silicon Ingot

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 2

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 3

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 4

centrotherm HQ, Blaubeuren CTPV Korea

GP Solar, Constance CTPV Shanghai

India and Qatar in foundation

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 6

Sales Breakdown by Region and Product 2009

Revenue 2010 as of June 30: € 278 million

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 7

Source: VLSI Research

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 8

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 9

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 10

Resource Solar PV/CSP) Wind Geothermal Water Power Biopower

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 11

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 12

Source: Photon International, March 2010

Source: Photon International, March 2010

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 15

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 16

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 17

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 18

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 19

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 20

Source: U.S. DOE Solar Energy Technologies Program.

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 21

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 22

•Almost half of market

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 23

•Almost two thirds

 But what does it mean for building manucacturing facilities??

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 24

bubble size = market size

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 25

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 26

 Main stream today:

Key drivers of production cost 45% Depreciation

Production cost: 24 … 33 €/kg 17% 2%

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 27

 Competition between multi and mono

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 28

Silicon Ingot/ Wafer Solar Cell Module

 Solar cell device technology today: screen

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 29

 Typical module design today:

Courtesy of Reis Robotics Other

Processing cost: 0.30 … 0.40 €/Wp 89%

(excluding feedstock: solar cells)

Single Polysilicon plant Module line +

Polysilicon plant Administration

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 31

Silicon Ingot/ Wafer Solar Cell Module

2700 t 105 Mio 387 MW 379 MW

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 32

Wafer thickness 170µm Efficiency 17.6% Embedding loss 2.5%

Silicon utilization 5.5 g/Wp

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 33

© centrotherm photovoltaics AG 2010 Texas Renewables, San Antonio Nov 7-10 34