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Low Cost Utility Solar Farms Using Supersized Modules
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Low Cost Utility Solar Farms Using Supersized Modules

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- Utility solar farm market drivers …

- 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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  • 1. Low Cost Utility Solar Farmsby Onsite Manufacturing of Supersized Modules Roger G. Little January 20, 2010
  • 2. The Turn-key Solar CompanySpire Provides:• Capital Equipment• Turn-key Production Linesfor photovoltaic modulemanufacturing.
  • 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. Utility Solar Farm Onsite Factory Model
  • 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. 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. Factory Module Assembly from Cells Wafers Polycrystalline Cells Ingot Modules PolysiliconSand Systems Integration
  • 8. Module Line Equipment Cells Cell Sorter Assembler LaminatorModule Simulator
  • 9. 40MW Super Sized Module Line
  • 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. 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. PV Systems Cost ReductionExcess Wire • MultipleManagement Grounding Points 230W 230W 230W 230W • Excess16 Extra HandlingMechanicalFasteners 1005WCantilever • LaminatedFrame diodes simplifyDesign busing and terminal box
  • 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 $750.29
  • 14. Systems Cost ($/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. 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. 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. 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 ‐$500 Years from Investmemt
  • 18. Summary• Utility Systems heading toward 1 GW.• Specialty Modules integrated with downstream needs for competitive advantage.• Solar Farm Onsite Manufacturing of supersized modules for lowest LCOE.
  • 19. Lake Placid Ironman 2010
  • 20. Spire CorporationOne Patriots ParkBedford, MA 01730NASDAQ: SPIR
  • 21. Super Sized PV Module Onsite Factory• Utility market • Solar “farms” Supersized • Transportation expanding (250MW – 1GW) 1 kW modules for considerations will favor onsite• 20 GW by 2020 • Due to RPS • lower materials manufacturing • lower BOS expenses System Cost Reductions, Local Manufacturing, U.S. Job Creation
  • 22. Module Line Process Flow Feed, Cut & Load Glass on Wash, Rinse, Glass In Place EVA on Conveyor Dry Glass Glass Test & Sort Fabricate Cell Inspect Cell Align Strings & Place StringsCells In Cells Strings Strings Trim End Tabs on EVA/Glass QC QC Dark I-V & Feed, Cut & Attach Buses Visual Place EVA & Laminate Trim Edges & Diodes Inspection Back Sheet on Strings QC Performance High Voltage Attach Frame Install J-boxes Modules Out (I-V) Test Isolation Test QC QC
  • 23. Spire Across the Value Chain x‐Si & CPV PV PV Systems  PV Material  Research Production EPC, Design  Turnkey Lines Supplies and Integration and EquipmentDevelopment
  • 24. Minimizing solar farm capital costs ($/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. Timberman 70.3 Ironman 2010
  • 26. Foster Grant 70.3 Ironman 2010
  • 27. World Championship Ironman Kona 2010
  • 28. World Championship Ironman Kona 2010