Low Cost Utility Solar Farms Using Supersized Modules

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- Utility solar farm market drivers
- Minimizing solar farm capital costs
- Crystalline silicon supersized module manufacturing
- Solar farm systems cost reduction through the use of supersized modules
- Minimizing utility solar farm LCOE by on-site deployment of supersized modules
Roger Little, Chairman & CEO, SPIRE

Published in: Business, Technology
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Low Cost Utility Solar Farms Using Supersized Modules

  1. 1. Low Cost Utility Solar Farmsby Onsite Manufacturing of Supersized Modules Roger G. Little January 20, 2010
  2. 2. The Turn-key Solar CompanySpire Provides:• Capital Equipment• Turn-key Production Linesfor photovoltaic modulemanufacturing.
  3. 3. Discussion• Utility Markets Will Drive PV. • Foreign Competition will be relentless.• To Compete specialty products integrated  with downstream  needs.  • Larger modules offer potential.• Minimize utility solar farm LCOE by on‐site manufacturing.    
  4. 4. Utility Solar Farm Onsite Factory Model
  5. 5. U.S. Utility PV Pipeline 2,000  1,791  1,500  1,019 Megawatts 1,000  455  500  251  ‐ 2010 2011 2012 2013Source: PV News, Greentech Media, Dec 2010
  6. 6. 1GW Projects are on the Horizon 1,200 1000 1,000 800Megawatts 600 550 400 --- 250 200 80 0 2010 2011 2012 ‐‐‐ 2015Source: international.pv-tech.org, Jan 2011
  7. 7. Factory Module Assembly from Cells Wafers Polycrystalline Cells Ingot Modules PolysiliconSand Systems Integration
  8. 8. Module Line Equipment Cells Cell Sorter Assembler LaminatorModule Simulator
  9. 9. 40MW Super Sized Module Line
  10. 10. Super Sized Module Overview  1005 WModule Size:  5.4 ft x 12.6 ft Module weight: 331 lbsPmax: 1005 W DC module 240 cells 230 W η cell:  17.2% η module :  16.1% 1 kW AC inverter
  11. 11. 1 kW Module Cost vs. Cell Cost $4.00  $3.61  η cell: 17.2% $3.50  $3.11  $3.00  $2.61  $2.50  $1.81 Module Cost $2.11 Module Cost  $2.00  ($/W) $1.61  $1.50  $1.11  $1.20/W Cell Cost $1.00  $0.61  $0.50  $‐ $‐ $0.50  $1.00  $1.50  $2.00  $2.50  $3.00  Cell Cost ($/W)
  12. 12. PV Systems Cost ReductionExcess Wire • MultipleManagement Grounding Points 230W 230W 230W 230W • Excess16 Extra HandlingMechanicalFasteners 1005WCantilever • LaminatedFrame diodes simplifyDesign busing and terminal box
  13. 13. Super Sized KW Module Installation ComparisonBOS Component 1005 W 4 x 230 WGrounding Points 1 4Wire Connections 1 4Module to Rail Fasteners N/A 16Materials & Transportation $5.28 $100.84Assembly Labor 0.19 hrs 1.25 hrAssembly Cost $3.79 $25.46Micro‐inverter $320 $624 Total Cost $329.07 $750.29
  14. 14. Systems Cost ($/watt) - 2012 Module BOS $3.50 Total $3.07 $3.00 Total $2.57 $2.50 $1.62 $2.00 $1.13$/W $1.50 $1.00 $1.44 $1.45 $0.50 $- 1005W module 4 x 230W
  15. 15. Levelized Cost of Energy Estimated LCoE LCoE After FTC $0.25 $0.20 $0.194 $0.145 $0.135 $0.15 LCoE $0.102($/kWh) $0.10 $0.05 $0.00 1005 W Module: 4 x 230 W: $2.57/W $3.07/W
  16. 16. Achieving 1GW Solar FarmInvestment in Facility: $15MAnnual Facility Output: 40MW (cumulative over 25 years: 1 GW Project Capacity)PPA: $0.10/kWhSREC: $0.08/kWhSystem Install Cost: $1.80/W after 30% FTCSolar Intensity: 1.573kWh/WpDegradation: 0.5% / yearO&M Costs: 0.5% Install Cost / Year
  17. 17. Cash Flow over Life of Project $2,000 1 GW Solar Farm Achieved $1,500 $1,000Cumulative Free Cash Flow ($M) $500 $0 0 5 10 15 20 25 30 ‐$500 Years from Investmemt
  18. 18. Summary• Utility Systems heading toward 1 GW.• Specialty Modules integrated with downstream needs for competitive advantage.• Solar Farm Onsite Manufacturing of supersized modules for lowest LCOE.
  19. 19. Lake Placid Ironman 2010
  20. 20. Spire CorporationOne Patriots ParkBedford, MA 01730NASDAQ: SPIR
  21. 21. Super Sized PV Module Onsite Factory• Utility market • Solar “farms” Supersized • Transportation expanding (250MW – 1GW) 1 kW modules for considerations will favor onsite• 20 GW by 2020 • Due to RPS • lower materials manufacturing • lower BOS expenses System Cost Reductions, Local Manufacturing, U.S. Job Creation
  22. 22. Module Line Process Flow Feed, Cut & Load Glass on Wash, Rinse, Glass In Place EVA on Conveyor Dry Glass Glass Test & Sort Fabricate Cell Inspect Cell Align Strings & Place StringsCells In Cells Strings Strings Trim End Tabs on EVA/Glass QC QC Dark I-V & Feed, Cut & Attach Buses Visual Place EVA & Laminate Trim Edges & Diodes Inspection Back Sheet on Strings QC Performance High Voltage Attach Frame Install J-boxes Modules Out (I-V) Test Isolation Test QC QC
  23. 23. Spire Across the Value Chain x‐Si & CPV PV PV Systems  PV Material  Research Production EPC, Design  Turnkey Lines Supplies and Integration and EquipmentDevelopment
  24. 24. Minimizing solar farm capital costs ($/W) Component  • Reduce Rack Requirements  Cost Reduction • Reduce Electrical Connections Labor Cost  • Minimize in field installation labor • Plug‐and‐Play electrical installation Reduction • Specialized on‐site installation Improve System  • Improve cell efficiency Efficiency • Increase module level AC efficiency
  25. 25. Timberman 70.3 Ironman 2010
  26. 26. Foster Grant 70.3 Ironman 2010
  27. 27. World Championship Ironman Kona 2010
  28. 28. World Championship Ironman Kona 2010

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