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solarworld.com
Energy for you and me
How we make solar panels to harness the sun’s abundant power
2
Energy crisis
Lifeʼs power plant
RETURNING TO THE SUN
Over the past two centuries, humans learned to harness fossil fuels on a vast scale to power an industrial
revolution. This quantum advance in machine automation, mass production and labor division drove unparalleled
improvements in the health, economics and comforts of citizens of industrialized nations.
But today, the benefits come at great, unpaid environmental costs. Fossil fuels cannot continue to be humanity’s
primary source of energy. It’s time for an energy foundation in harmony with the planet. It’s time for a solar
revolution.
Perpetually renewing power from the sun has fueled life on Earth since its first spark. From cellular to mammalian
forms, the sun has supplied a critical ingredient in the recipe for living beings. More practically, humans have relied
on solar power – to warm water, dry clothes and prepare food – as far as history’s record reaches.
The sun emits so much energy that solar experts compete to put the output in terms we can grasp. Here’s just
one: Earth receives enough solar radiation in an hour to supply the planet’s electrical needs for a year.
“Environmental ills and climate change pose global crises
for our planet. Any answer to these problems must be
powerful. Fortunately, we need only tap the power source
of life’s history for answers: the sun and its ample energy.”
Dr.-Ing. E. h. Frank Asbeck, SolarWorld chairman and CEO
3
Gathering the sunʼs bounty
Now people are re-tapping their roots in a solar world by using panels of photovoltaic (PV) cells to generate power
from the sun’s rays. As reliable as the sun itself, the technology is simple and clean. Cells are built on wafers of
silicon made from ordinary sand and quartz. Assembled into solar panels and exposed to the sun, the cells directly
convert light into electricity – without polluting emissions, resource depletion or moving parts.
SolarWorld, extraordinary because it undertakes all phases of PV manufacturing and makes no other products,
builds panels in four steps, starting with sand and ending with sun.
Turn the page to begin the story behind SolarWorld’s core mission to put the technology to work for homes
and businesses around the world.
Of the 92 elements, silicon (Si) is the Earth’s
most prevalent semiconductor – and
second most common element of any kind,
after oxygen. Appearing in silicon oxides
such as sand (silica), quartz, rock crystal,
amethyst, agate, flint, jasper and opal, sili-
con makes up about a quarter, by weight, of
the Earth’s crust. Photovoltaic manufactur-
ing starts with polysilicon, a refinement of
silicon materials.
Photovoltaic. The word photovoltaic comes
from the words photo, meaning light, and
volt, meaning electricity. In short, the term
PV means electricity from light.
PV FACT
WORD TO KNOW
4
ROOTS OF A RENEWABLE ENERGY SOURCE
1970s1960s1950s
1954 Bell Labs announces inven-
tion of the first modern silicon
solar cells, with energy-conversion
efficiency of about 6 percent.
1955 Western Electric licences
commercial solar cell technolo-
gies.
1957 ATT employees Gerald
L. Pearson, Daryl M. Chapin and
Calvin S. Fuller receive patent
US2780765, “Solar Energy
Converting Apparatus.”
1958 Hoffman Electronics-
Semiconductor Division creates
9%-efficient solar cells.
Vanguard 1, the first solar-po-
wered satellite, is launched with
.1 watt solar panel.
1960 Hoffman Electronics
creates a 14%-efficient solar cell.
1961 United Nations stages
“Solar Energy in the Developing
World” conference.
1962 The Telstar communica-
tions satellite is powered by
solar cells.
1963 Viable photovoltaic panel is
produced out of silicon solar cells.
1964 Yale University Press
publishes Farrington Daniels’
landmark book, “Direct Use of
the Sun’s Energy.”
1967 Soyuz 1 becomes first
manned spacecraft using solar.
1973 Solar cells power Skylab,
the first U.S. space station.
1974 A home in New Mexico is
the world’s first to be powered
only by solar and wind energy.
1975 Engineer and entrepreneur
Bill Yerkes creates Solar Technolo-
gy International.
1977 Yerkes sells his manufactu-
ring startup to Atlantic Richfield
Co., forming ARCO Solar, but he
remains president.
1979 In Camarillo, Calif., ARCO
Solar dedicates world’s largest PV
factory to making silicon crystal
ingots, wafers, photovoltaic cells
and panels.
World annual PV array production (MWp)
The history of the solar industry and SolarWorld are intermixed,
each with one foot squarely positioned in the United States and the
other in Germany – the two markets that have led the industry’s
development. In the U.S., SolarWorld began as ARCO Solar. Siemens
and Shell then owned the unit before SolarWorld acquired it.
5
Pioneering relativity theorist Albert Einstein won the
Nobel Prize in 1921 – but not for his renowned relativity
equation E=mc². The prize actually celebrated his 1905
discovery of exactly how light caused what was then
called the photoelectric effect – essentially, photovolta-
ics. Today, SolarWorld issues its annual Einstein Awards
to honor PV researchers.
Photon: A photon is neither a wave nor a particle, but
instead a packet of light energy. Solar radiation arrives
on the surface of photovoltaic cells in the form of pho-
tons, providing the main energy that activates cells to
produce electricity.
PV FACT
WORD TO KNOW
2000s1990s1980s
0
10,000
1,000
100
10
1990 Siemens acquires ARCO
Solar, forming Siemens Solar. 	
1996 Siemens Solar celebrates
100 MW of installed power from
panels made in Camarillo.
1997 Siemens becomes first
company to offer 25-year
warranty.
1998 SolarWorld forms as start-
up business, entering Germany’s
burgeoning solar market.
1999 Germany requires utilities
to pay “feed-in tariffs” at fixed
premium rates to owners of solar
systems for power contributed
into grid.
2002 Royal Dutch Shell ac-
quires Siemens Solar, creating
Shell Solar.
2006 SolarWorld aquires
Shell Solar.
2007 Investors begin offe-
ring free installation in return
for long-term power purchase
agreements (PPAs), which
become common financing
arrangements.
2008 SolarWorld opens
480,000-square-foot plant
in Hillsboro, investing $500
million to establish 500 MW
of annual capacity and 1,000
employees there.
Yellow = SolarWorld’s
U.S. lineage
1980 ARCO Solar becomes first
company to produce more than 1
megawatt of PV panels in one year.
A 105.6-kW system is dedicated at
Natural Bridges National Monu-
ment in Utah, using panels of ARCO
Solar, Motorola and Spectrolab.
1982 ARCO Solar commissions
world’s first 1 MW grid-connected PV
installation in Hisperia, Calif., using
panels on 108 dual-axis trackers.
1983 Worldwide photovoltaic pro-
duction exceeds 20 MW and sales
surpass $250 million.
1985 Australia’s University of New
South Wales creates silicon cells
with 20% efficiency in laboratory.
6
FROM SAND TO SOLAR PANEL
The journey that starts with silicon and ends
with a large-scale solar facility is long, with
many stops along the way. As one of the largest
solar companies in the world, SolarWorld attach-
es great importance to the highest quality –
at every stage of production.
Silicon Solar wafer
Silicon is the starting point of our solar production cycle.
It is extracted from sand, which is made up primarily of
silicon dioxide. As the second most common element
of the earth’s crust, there is an almost endless supply.
In the second production step, highly pure silicon
forms into crystal structure at 2,500 degrees Fah-
renheit and it then hardens. The crystallized silicon
is then shaped into rectangular columns. These co-
lumns are cut into extremely thin slices, or wafers,
using state-of-the-art wire-cutting technology.
After cleaning and thorough final testing, the mo-
nocrystalline and polycrystalline wafers form the
basis for the production of solar cells.
7
Solar cells Solar panel
Thewafersarefurtherprocessedintosolarcellsinthe
third production step. They form the basic element of
theresultingsolarpanels.Thecellsalreadypossess all
of the technical attributes necessary to generate
electricity from sunlight. Positive and negative
charge carriers are released in the cells through
light radiation, causing electrical current (direct
current) to flow.
Solar cells are merged into larger units – the panels
– in panel production. They are framed and wea-
ther-proofed. The solar energy panels are final
products, ready to generate power. Sunlight is
converted into electrical energy in the panels. The
direct current produced this way is converted to
alternating current by a device called an inverter so
that it can be fed into the utility grid or, if applica-
ble, straight into the house.
8
GROWING CRYSTAL FROM ROCK
Charging Melting
The magic starts with about 250 pounds of polysilicon
rocks carefully stacked in a quartz crucible. The only
other ingredient is a silicon disk impregnated with a
tiny amount of boron. The addition of the boron do-
pant ensures that the resulting crystal will bear a pos-
itive potential electrical orientation. The crucible is
encased within thick walls of insulating graphite and
locked inside a cylindrical furnace.
As the crystal-growing furnace heats up to tempe-
ratures ranging around 2,500 degrees Fahrenheit,
its silicon contents liquefy into a shimmering melt.
Once computerized monitors register the right
temperature and atmospheric conditions, the
alchemy begins. A silicon seed crystal, hung from a
narrow cable attached to a rotary device atop the
furnace, is slowly lowered into the melt.
In its monocrystalline process, SolarWorld heats and melts poly-
silicon rock until it forms a white-hot liquid, then re-solidifies
the molten silicon into a single giant crystal in which all atoms
are perfectly aligned in a desired structure and orientation.
Quartz
crucible
Steel furnace
encasement
enveloping
graphite
insulation
Polysilicon
rock with
boron-doped
silicon disk
Polysilicon
Seed
9
The method that SolarWorld
uses in the United States to grow
silicon crystal is known as “Cz”
(pronounced CEE-ZEE). Cz is an
abbreviation for the Czochral-
ski process, named after Polish
scientist Jan Czochralski, who
discovered the method in 1916
as he researched crystallization
rates of metals.
Crystal: A crystal is a solid with
molecular building blocks, such as
atoms or ions, that have arranged
themselves in an identically re-
peating pattern along all three
spatial dimensions.
PV FACT
WORD TO KNOW
Growing Cooling
The crucible starts to turn, and the seed crystal
begins to rotate in the opposite direction. The
siliconmeltfreezesontotheseedcrystal,matching
the seed’s crystalline structure. The crystal grows,
the cable and seed slowly ascend, and the crystal
elongates at a controlled diameter. As the growth
depletes the silicon melt, the crucible also rises.
Flash forward about 3½ days since the crucible
was charged with polysilicon: After hours of cool-
ing to about 300 degrees Fahrenheit, the furnace
hood and shaft lift away from the crucible encase-
ment to reveal a completed cylindrical crystal,
ready to move to the second step and next pro-
duction room.
Crystal
emerging
from melt
Crystal
measuring
8 inches wide
and about
5 ½ feet long
10
CUTTING CRYSTAL INTO WAFERS
Cutting Squaring
First, a saw cuts off the crystal’s so-called top and tail,
so that a crystal of uniform width remains. Typically,
wafering saws draw thin wire bearing a liquid abrasive
across the crystal’s surface. (Above, a machine moun-
ted with a giant donutlike steel blade does the cutting.)
Wire saws also cut the crystal into ingots measuring
2 feet long. Steel holders are mounted on one end of
these ingots for the next step.
Mounted ingots are placed standing on end in
a rack bearing 16 at a time inside another wire-
slicing machine. There, wire running in a lattice
configuration descends on the ingots to shear off
four rounded segments, leaving flat sides. The re-
sult: The ingots now have a square cross-section,
except for still-rounded corners.
A silicon crystal must change shape several times before it
winds up as the precisely calibrated wafers that form the
foundations of photovoltaic cells.
Crystal ingot
Saw wire
Ingots standing on
end beneath wire
lattice used to
square them
11
Wafering saws use spools of wire
to carry the mineral abrasive sili-
con carbide, effectively forming
a miniscule strand of sandpaper.
The spools bear wire measuring
about 400 miles long. Stretched
out from SolarWorld’s U.S.
headquarters in Hillsboro, Ore.,
the wire would reach roughly to
Missoula, Mont.
Silicon carbide: Silicon carbide
(SiC), silicon bonded with carbon,
is another member of the silicon
family of materials used in the PV
industry. It is a common abrasive
in many industries, used in every-
thing from grinding to sandblast-
ing. At SolarWorld, crushed SiC
is mixed into a water slurry and
applied to saw wires. Silicon
carbide, not wire, actually does
the cutting.
PV FACT
WORD TO KNOW
Slicing
The next wire saw is more intricate yet. A wire winding hundreds of times
between two cylindrical drums forms a web of parallel, tightly spaced seg-
ments. As the wire unspools through the machine, ingots mounted side-
ways on glass and metal holders are pressed two at a time through the wire
web, slicing them into the thickness of slim business cards. Each millimeter
of crystal yields about 2½ wafers. Detached from their holders, the wafers
are loaded into carriers, or boats, for transport to the next step.
About 100 wafers fit
within a transport
carrier, or boat
Saw wire
6”
12
CONVERTING WAFERS INTO CELLS
Texturing Diffusing
In the only phase requiring a designated clean room, a
series of intricate chemical and heat treatments con-
verts the blank, grey wafers into productive, blue cells.
A so-called texture etch, for instance, removes a tiny la-
yer of silicon, relying on the underlying crystal structure
to reveal an irregular pattern of pyramids. The surface
of pyramids – so small they’re invisible to the naked eye
– absorbs more light.
Next, wafers are moved in cartridges into long, cy-
lindrical, oven-like chambers in which phosphorus
is diffused into a thin layer of the wafer surface.
The molecular-level impregnation occurs as the
wafer surface is exposed to phosphorus gas at a
high heat, a step that gives the surface a negative
potential electrical orientation. The combination
of that layer and the boron-doped layer below cre-
ates a positive-negative, or P/N, junction – a criti-
cal partition in the functioning of a PV cell.
At this point, a wafer is no more capable of producing electricity
than a sliver of river rock. The wafer is the main building block of
a PV cell, but so far its only notable characteristics are its crystal
structure and positive potential orientation. All of that changes in
the third, multistep, cell-production phase of PV manufacturing.
Chemical bath
Clean suits ensure a
sterile environment
13
In the PV and semiconductor
industries, the word tool has
a special meaning. Instead of
referring to an implement that
can be applied to a manufactur-
ing mechanism, tools in these
fields refer to entire machines
or assembly lines that perform
a step or series of steps. In both
industries, tools are highly auto-
mated so that most workers are
employed to install, finetune and
operate the tools, rather than lift-
ing or moving product. Spider-like
devices lift and move wafers and
cells on and off conveyor belts for
multiple tests along their journey
from wafer to cell.
Micron: In cell production,
manufacturing steps occur in
dimensions measured in microns.
In the metric system, a micron is
one millionth of a meter, or one
thousandth of a millimeter. For
reference, a human hair measures
about 100 microns across.
PV FACT
WORD TO KNOW
Coating Printing
The burgeoning, still-grey cells move in trays into
heavy vacuum chambers where blue-purple sili-
con nitride is deposited onto their tops. The coa-
ting with silicon nitride – yet another member of
the silicon family of materials – is designed to re-
duce reflection even further in the energy-dense
blue end of the light spectrum. It leaves the cells
with their final, dark color.
Now, the cells can optimally gather photons and
produce electricity. They lack, however, any me-
chanism to collect and forward the power. So, in
a series of silkscreen-like steps, metals are printed
on both sides of the cell, adding pin-stripe “fin-
gers” and bus-bar circuitry. A functioning cell is
born–onlysunshineisneededtoproduceelectricity.
Drying oven
Wafer
Printing template
14
STRINGING CELLS INTO PANELS
Soldering and laminating Framing
At SolarWorld, panel manufacturing is a highly auto-
mated process, relying on robust steel robotics to un-
dertake the increasingly heavy lifting of assembling
lightweight PV cells into panels weighing around 45
pounds apiece. Each robotic tool works within a safety
fence that, by design, prevents human access. First, cells
are soldered together into strings of 10, using an over-
under-over-under pattern of metal connectors to link
the cells. Six strings are laid out to form a rectangular
matrix of 60 cells. Each matrix is laminated onto special
solar glass.
To become a solar panel, however, each laminate
requires not only a frame to provide protection
against weather and other impacts but also a
junction box to enable connections among panels
or with an inverter-bound conduit. Robots affix
those, too.
Clean suits ensure a
sterile environment
Cell string
Each phase of production depends on processes with flavors all
their own. Careful control of heating and cooling dominates
crystal growing. Wafering employs abrasion and cutting. Cell
production concentrates on chemistry. Any factory process
would be incomplete without a final assembly step, and in
PV such a step is known as panel assembly, or moduling.
15
Inspecting and shipping
Carefulcleaningandinspectionprovidefinaltouches
before each solar panel can be boxed for delivery to
homes and businesses. However, inspection does
not only take place at the end of the production
line. Digitized and automated checks take place at
key steps from silicon crystallization through panel
assembly, and human inspection of each and every
cell and panel.
SolarWorld is a manufacturer. It
sells Sunmodule™ solar panels
mostly through distributors,
integrators and contractors. But
the company also sells Sunkits®
systems – configurations of
panels, inverter and parts that
include everything that licensed
electrical contractors need for
specific projects at specific loca-
tions. SolarWorld pioneered this
approach in the 1990s.
Module: Within the industry,
solar panels are called modules,
because they link together evenly
and interchangeably use electri-
cal connectors to form a circuit
within an array, with a building
or with a utility grid. To make a
module, cell-matrix laminants are
mounted into sturdy aluminum
frames. The resulting module is
robust enough to withstand 50
mph hailstone impacts and up
to 112 pounds per square foot of
wind or snow load.
WORD TO KNOW
PV FACT
16
HOW A PV CELL MAKES ELECTRICITY
Under the sun, a photovoltaic cell acts as a photosensitive
diode that instantaneously converts light – but not heat –
into electricity.
Cell
cutaway
Light-absorbing layer
Metal contact
N (negative type)
P (positive type)
P/N juction
Metal back
Positive doping Negative doping
(1) Recall that in the crystallization step a
small amount of the dopant boron was
added to the polysilicon chunks before
they were melted. Boron lacks one elec-
tron and therefore takes on an electron
from silicon as an acceptor. Because the
electron is missing, leaving an electron
hole, the semiconductor becomes p-con-
ductive (positive-conductive).
(2) Remember that in cell production phosphorus was
applied to those layers of the silicon wafer closest to
the surface. This dopant, as compared with silicon,
has one extra electron, which it can easily release.
Thus the silicon becomes n-conductive (negative-
conductive).
1
2
17
Electron
PhotonA
B
C D
E
It takes all kinds of workers to
produce PV, ranging from doc-
toral engineers troubleshooting
arcane problems to entry-level
machine operators learning basic
process steps. Within SolarWorld,
the four stages of production run
as semi-autonomous but interde-
pendent factories, all with teams
of production engineers, mainte-
nance engineers, technicians
and operators.
Conversion efficiency: This
measure gauges the percentage
of solar (light) power reaching a
panel that is converted into elec-
trical power. Conventional cells
now range in the high percentage
teens. Theoretical and labora-
tory conversion rates typically
are much higher than rates from
mass production.
PV FACT
WORD TO KNOW
Cell layers Sun activation
The top, phosphorus-diffused silicon layer
therefore carries free electrons – unan-
chored particles with negative charges.
The thicker, boron-doped bottom layer
contains holes, or absences of electrons,
that also can move freely. In effect, precise
manufacturing has instilled an electronic
imbalance between the two layers.
A) Photons bombard and penetrate the cell.
B) They activate electrons, knocking them loose in both
silicon layers.
C) Some electrons in the bottom layer sling-shot to the
top of the cell.
D) These electrons flow into metal contacts as electricity,
moving into a circuit throughout a 60-cell panel.
E) Electrons flow back into the cell via a solid contact
layer at the bottom, creating a closed loop or circuit.
18
Powering homes and businesses
Current leaving a panel, or array of panels, passes through a wire conduit leading to an
inverter. These devices, which are shaped like suitcases and come in various sizes, invert
direct current, which flows with a fixed current and voltage, into alternating current,
which flows with oscillating current and voltage. Appliances worldwide operate on AC.
From the inverter, the solar-generated power feeds into circuitry of a household, business
or power plant and onto the region’s electrical grid. A remote, or independent, power sy-
stem also can form a self-contained circuit without connecting to the grid. The off-grid
system, however, requires batteries to store power for times, such as night, when panels
do not capture enough light energy from the sun.
Inverter
PV panels
InverterFuse boxElectrical grid Electrical devices (TV etc.)
SOAK UP THE SAVINGS
The sun provides abundant clean energy every single day,
even when it’s cloudy – and it never sends a bill. The sun
provides enough energy to serve the entire world’s energy
needs hundreds of times over.
19
Environmental benefits
Solar panels reduce the amount of electricity coming from fossil fuels by supplying your home with clean, renewable
energy from the sun. By providing more energy and lasting longer than other brands, SolarWorld Sunmodule™ pa-
nels are the best choice for cutting your carbon footprint down to size while maintaining a comfortable lifestyle.
SolarWorld Sunmodule panels are made from pure silicon, glass and aluminum. Our manufacturing processes
avoid or minimize the use of toxic materials such as cadmium and arsenic, which are used in many low-grade thin
film panels. SolarWorld factories strive to continuously improve these processes and lead the industry in sustai-
nable manufacturing practices.
SolarWorld pioneered the high-yield process of recapturing the main components of silicon, glass and aluminum
so that at the end of their useful lives Sunmodules can be reprocessed for reuse, instead of relegated to landfills.
For products that can last more than 30 years, that’s thinking ahead.
*	CO₂ emissions avoided over 25 years:
	 94 tons
*	Equivalent miles not driven:
	306,376
*	Equivalent trees planted:
	 1.6 acres
* Based on a 3 kilowatt system
in Southern California.
GOOD FOR
THE PLANET
20
Solar energy’s present
YOU ENTER THE EQUATION
Grid parity – the point where energy costs the same whether from solar technology or fossil fuels – has arrived in
many U.S. markets. It’s about time, too. Though fossils have gotten us where we are today, they also have caused
enormous environmental harms. The time has arrived to use slivers of rock – silicon – to reliably produce electricity
for decades rather than burning up tons of rock and oil extracted from the Earth just one time.
To promote energy market competition, various government and nonprofit agencies offer an array of incentives
for solar purchases. However, the cost of solar has already fallen so much that in some markets, those agencies
are starting to phase out some incentives.
PV technology is largely a U.S.
original. But foreign ingenuity has
grasped the industryʼs leadership
by applying market mechanisms
that jumpstart higher investment
returns. Creating higher demand,
these policies build economies of
scale that force down pricing. But
it takes people – you – to make
choices for a better planet. Now
the U.S. is reawakening to the
promise of solar energy.
21
Solar market incentives
Incentives vary among nations, states and even cities, but they typically fall into these categories:
Rebates: Some organizations distribute outright reimbursements for a portion of system costs.
Tax incentives: The U.S. government and several states may offer investment tax credits or accounting provisions
allowing extraordinary terms for asset depreciation. On Jan. 1, 2009, for instance, the federal government remo-
ved a $2,000 cap on a 30 percent credit for residential systems.
Net metering: This alternative to feed-in tariffs allows solar power producers to generate and use power with the
same pricing and according to a single meter. When a home system, for instance, makes more power than it uses,
its meter rolls backward.
Feed-in tariffs: Dozens of countries have implemented feed-in tariff systems – set premium rates that utilities
are required to pay for power from solar systems. The rates remain fixed for a set number of years, perhaps 20. A
power producer, such as a homeowner or business, separately pays normal market rates for power from the grid.
So how much power does a typical PV sys-
tem produce – and at what cost? A modest
rooftop system for a home might combine
1.5-3 kW in panels and produce the equiva-
lent of about one-third of the home’s power
needs. In some locations, the ultimate
costs to the system owners – figuring in
all incentives – might amount to 30 cents
on the dollar. In that case, a hypothetical
system priced at $25,000 actually would
cost about $7,500. Returns on investment in
many cases exceed average typical interest
on certificates of deposit.
Falling solar prices will cross rising prices of fossil fuels
With government incentives, then without, rising solar demand and falling
unit pricing are leading to grid parity.
Insolation: Sunlight varies by region.
Insolation is a measure of the solar radia-
tion energy in a given region. It is usually
expressed as the intensity of light energy
per unit of land area. As a whole, the U.S.,
especially the sunny Southwest and South-
east, offers strong insolation. By compari-
son, Germany, the PV industry’s leader, gets
little better sun than Alaska.
PV FACT
WORD TO KNOW
Priceperwatt
NowTime
Solar with
incentives
Solar
Fossil fuels
22
FOR ROOFTOPS AND BEYOND
These days, PV technology is extend-
ing beyond rooftops into locations that
have never known the benefits of
electricity. As on-grid applications
bring cleaner power to wired homes,
so, too, do off-grid systems empower
those without electric refrigeration and
lighting. Along the way, SolarWorld
has led the world industry in rural elec-
trification and sustainable practices.
Anywhere there’s sky
While rooftop systems provide countless homes and businesses with power right where they most need it, such
installations are far from the only kinds of PV projects harnessing photons.
Ground-mounted
systems make sense
where roofs are una-
vailable or inadequate.
Panels are mounted on
racks anchored into the
ground.
Canopy systems can
provide shelter and
produce power in park-
ing lots and exterior
corridors.
Utility-scale systems
come in a variety of
dimensions, but all pro-
duce enough electricity
to power many
buildings.
Tracker systems in-
crease their output
power by moving to
follow the sun’s path.
23
Recycling and reusing A global vision
SolarWorld has led the global PV industry in app-
lying principles of sustainability.
Internally, SolarWorld uses residual and remnant
silicon left in crucible bottoms or cut from ingots
to reform crystal, and it strives in every imaginable
direction to divert waste leaving its operations –
plastic packaging, spent wire, even coffee cups –
into second or new uses.
Externally, SolarWorld pioneered processes and
practices for offering crystalline silicon photo-
voltaic recycling and helped spur the industry to
develop recycling programs. The company accepts
any returns of SolarWorld solar panels that other-
wise might be discarded. Then, the panels under-
go a high-yield process of recovering constituent
materials for reuse.
SolarWorld’s Solar2World program takes aim at
the 2 billion people on the planet who go without
electricity, a number that promises to rise with
population growth. Working with local partners,
the company donates its panels into rural electri-
fication projects in some of the world’s poorest
areas. With SolarWorld’s expansion in the United
States, the Solar2World program there focuses on
Latin America.
“Sustainable develop-
ment is designed to lead
to a situation where
present generations can
satisfy their own needs
without jeopardizing
the potential needs of
future generations.”
Dr.-Ing. E. h. Frank Asbeck,
SolarWorld chairman and CEO
solarworld.com
Locations:
SolarWorld Americas
(Sales and marketing for
USA, Canada, and South and
Central America)
4650 Adohr Lane
Camarillo, CA 93012
Phone:	+1 805 388 6200
Fax:	+1 805 388 6395
customerservice@solarworld-usa.com
SolarWorld Industries America
(U.S. headquarters)
25300 NW Evergreen Road
Hillsboro, OR 97124
Phone:	+1 503 844 3400
Fax:	+1 503 844 3403
customerservice@solarworld-usa.com
Benefits at a glance
 	World-class quality
	 SolarWorld produces the highest-quality solar panels, manufacturing according to U.S. and German quality standards in
fully automated ISO 19001 and 14001 factories.
 	SolarWorld Plus sorting
	 Plus-sorting guarantees the highest system efficiency. Only the panels that achieve the desig­nated nominal
performance or more in performance tests are dispatched.
 	25-year linear performance guarantee and 10-year product warranty*
	 In addition to a 10-year product warranty, SolarWorld provides a 25-year performance guarantee that ensures an
actual performance of at least 97 percent of the nominal power in the first year and an annual decrease of not more
than 0.7 percent in each of the next 24 years.
 	An experienced industry leader
	 With more than 35 years of experience in off-grid solar applications, SolarWorld delivers top products and technical
experience at the highest levels. SolarWorld solar panels are installed in more than 100,000 telecommunications and
industrial systems worldwide. No one else comes close.
* in accordance with the SolarWorld service certificate valid at the time of purchase | www.solarworld-usa.com/warranty
Textandillustrationsreflectthestateoftheartatthetimeofprinting.Subjecttochangewithoutnotice.Validasof:07/2011
SW-02-5024US07-2011

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Solar 101-eng by solar world

  • 1. solarworld.com Energy for you and me How we make solar panels to harness the sun’s abundant power
  • 2. 2 Energy crisis Lifeʼs power plant RETURNING TO THE SUN Over the past two centuries, humans learned to harness fossil fuels on a vast scale to power an industrial revolution. This quantum advance in machine automation, mass production and labor division drove unparalleled improvements in the health, economics and comforts of citizens of industrialized nations. But today, the benefits come at great, unpaid environmental costs. Fossil fuels cannot continue to be humanity’s primary source of energy. It’s time for an energy foundation in harmony with the planet. It’s time for a solar revolution. Perpetually renewing power from the sun has fueled life on Earth since its first spark. From cellular to mammalian forms, the sun has supplied a critical ingredient in the recipe for living beings. More practically, humans have relied on solar power – to warm water, dry clothes and prepare food – as far as history’s record reaches. The sun emits so much energy that solar experts compete to put the output in terms we can grasp. Here’s just one: Earth receives enough solar radiation in an hour to supply the planet’s electrical needs for a year. “Environmental ills and climate change pose global crises for our planet. Any answer to these problems must be powerful. Fortunately, we need only tap the power source of life’s history for answers: the sun and its ample energy.” Dr.-Ing. E. h. Frank Asbeck, SolarWorld chairman and CEO
  • 3. 3 Gathering the sunʼs bounty Now people are re-tapping their roots in a solar world by using panels of photovoltaic (PV) cells to generate power from the sun’s rays. As reliable as the sun itself, the technology is simple and clean. Cells are built on wafers of silicon made from ordinary sand and quartz. Assembled into solar panels and exposed to the sun, the cells directly convert light into electricity – without polluting emissions, resource depletion or moving parts. SolarWorld, extraordinary because it undertakes all phases of PV manufacturing and makes no other products, builds panels in four steps, starting with sand and ending with sun. Turn the page to begin the story behind SolarWorld’s core mission to put the technology to work for homes and businesses around the world. Of the 92 elements, silicon (Si) is the Earth’s most prevalent semiconductor – and second most common element of any kind, after oxygen. Appearing in silicon oxides such as sand (silica), quartz, rock crystal, amethyst, agate, flint, jasper and opal, sili- con makes up about a quarter, by weight, of the Earth’s crust. Photovoltaic manufactur- ing starts with polysilicon, a refinement of silicon materials. Photovoltaic. The word photovoltaic comes from the words photo, meaning light, and volt, meaning electricity. In short, the term PV means electricity from light. PV FACT WORD TO KNOW
  • 4. 4 ROOTS OF A RENEWABLE ENERGY SOURCE 1970s1960s1950s 1954 Bell Labs announces inven- tion of the first modern silicon solar cells, with energy-conversion efficiency of about 6 percent. 1955 Western Electric licences commercial solar cell technolo- gies. 1957 ATT employees Gerald L. Pearson, Daryl M. Chapin and Calvin S. Fuller receive patent US2780765, “Solar Energy Converting Apparatus.” 1958 Hoffman Electronics- Semiconductor Division creates 9%-efficient solar cells. Vanguard 1, the first solar-po- wered satellite, is launched with .1 watt solar panel. 1960 Hoffman Electronics creates a 14%-efficient solar cell. 1961 United Nations stages “Solar Energy in the Developing World” conference. 1962 The Telstar communica- tions satellite is powered by solar cells. 1963 Viable photovoltaic panel is produced out of silicon solar cells. 1964 Yale University Press publishes Farrington Daniels’ landmark book, “Direct Use of the Sun’s Energy.” 1967 Soyuz 1 becomes first manned spacecraft using solar. 1973 Solar cells power Skylab, the first U.S. space station. 1974 A home in New Mexico is the world’s first to be powered only by solar and wind energy. 1975 Engineer and entrepreneur Bill Yerkes creates Solar Technolo- gy International. 1977 Yerkes sells his manufactu- ring startup to Atlantic Richfield Co., forming ARCO Solar, but he remains president. 1979 In Camarillo, Calif., ARCO Solar dedicates world’s largest PV factory to making silicon crystal ingots, wafers, photovoltaic cells and panels. World annual PV array production (MWp) The history of the solar industry and SolarWorld are intermixed, each with one foot squarely positioned in the United States and the other in Germany – the two markets that have led the industry’s development. In the U.S., SolarWorld began as ARCO Solar. Siemens and Shell then owned the unit before SolarWorld acquired it.
  • 5. 5 Pioneering relativity theorist Albert Einstein won the Nobel Prize in 1921 – but not for his renowned relativity equation E=mc². The prize actually celebrated his 1905 discovery of exactly how light caused what was then called the photoelectric effect – essentially, photovolta- ics. Today, SolarWorld issues its annual Einstein Awards to honor PV researchers. Photon: A photon is neither a wave nor a particle, but instead a packet of light energy. Solar radiation arrives on the surface of photovoltaic cells in the form of pho- tons, providing the main energy that activates cells to produce electricity. PV FACT WORD TO KNOW 2000s1990s1980s 0 10,000 1,000 100 10 1990 Siemens acquires ARCO Solar, forming Siemens Solar. 1996 Siemens Solar celebrates 100 MW of installed power from panels made in Camarillo. 1997 Siemens becomes first company to offer 25-year warranty. 1998 SolarWorld forms as start- up business, entering Germany’s burgeoning solar market. 1999 Germany requires utilities to pay “feed-in tariffs” at fixed premium rates to owners of solar systems for power contributed into grid. 2002 Royal Dutch Shell ac- quires Siemens Solar, creating Shell Solar. 2006 SolarWorld aquires Shell Solar. 2007 Investors begin offe- ring free installation in return for long-term power purchase agreements (PPAs), which become common financing arrangements. 2008 SolarWorld opens 480,000-square-foot plant in Hillsboro, investing $500 million to establish 500 MW of annual capacity and 1,000 employees there. Yellow = SolarWorld’s U.S. lineage 1980 ARCO Solar becomes first company to produce more than 1 megawatt of PV panels in one year. A 105.6-kW system is dedicated at Natural Bridges National Monu- ment in Utah, using panels of ARCO Solar, Motorola and Spectrolab. 1982 ARCO Solar commissions world’s first 1 MW grid-connected PV installation in Hisperia, Calif., using panels on 108 dual-axis trackers. 1983 Worldwide photovoltaic pro- duction exceeds 20 MW and sales surpass $250 million. 1985 Australia’s University of New South Wales creates silicon cells with 20% efficiency in laboratory.
  • 6. 6 FROM SAND TO SOLAR PANEL The journey that starts with silicon and ends with a large-scale solar facility is long, with many stops along the way. As one of the largest solar companies in the world, SolarWorld attach- es great importance to the highest quality – at every stage of production. Silicon Solar wafer Silicon is the starting point of our solar production cycle. It is extracted from sand, which is made up primarily of silicon dioxide. As the second most common element of the earth’s crust, there is an almost endless supply. In the second production step, highly pure silicon forms into crystal structure at 2,500 degrees Fah- renheit and it then hardens. The crystallized silicon is then shaped into rectangular columns. These co- lumns are cut into extremely thin slices, or wafers, using state-of-the-art wire-cutting technology. After cleaning and thorough final testing, the mo- nocrystalline and polycrystalline wafers form the basis for the production of solar cells.
  • 7. 7 Solar cells Solar panel Thewafersarefurtherprocessedintosolarcellsinthe third production step. They form the basic element of theresultingsolarpanels.Thecellsalreadypossess all of the technical attributes necessary to generate electricity from sunlight. Positive and negative charge carriers are released in the cells through light radiation, causing electrical current (direct current) to flow. Solar cells are merged into larger units – the panels – in panel production. They are framed and wea- ther-proofed. The solar energy panels are final products, ready to generate power. Sunlight is converted into electrical energy in the panels. The direct current produced this way is converted to alternating current by a device called an inverter so that it can be fed into the utility grid or, if applica- ble, straight into the house.
  • 8. 8 GROWING CRYSTAL FROM ROCK Charging Melting The magic starts with about 250 pounds of polysilicon rocks carefully stacked in a quartz crucible. The only other ingredient is a silicon disk impregnated with a tiny amount of boron. The addition of the boron do- pant ensures that the resulting crystal will bear a pos- itive potential electrical orientation. The crucible is encased within thick walls of insulating graphite and locked inside a cylindrical furnace. As the crystal-growing furnace heats up to tempe- ratures ranging around 2,500 degrees Fahrenheit, its silicon contents liquefy into a shimmering melt. Once computerized monitors register the right temperature and atmospheric conditions, the alchemy begins. A silicon seed crystal, hung from a narrow cable attached to a rotary device atop the furnace, is slowly lowered into the melt. In its monocrystalline process, SolarWorld heats and melts poly- silicon rock until it forms a white-hot liquid, then re-solidifies the molten silicon into a single giant crystal in which all atoms are perfectly aligned in a desired structure and orientation. Quartz crucible Steel furnace encasement enveloping graphite insulation Polysilicon rock with boron-doped silicon disk Polysilicon Seed
  • 9. 9 The method that SolarWorld uses in the United States to grow silicon crystal is known as “Cz” (pronounced CEE-ZEE). Cz is an abbreviation for the Czochral- ski process, named after Polish scientist Jan Czochralski, who discovered the method in 1916 as he researched crystallization rates of metals. Crystal: A crystal is a solid with molecular building blocks, such as atoms or ions, that have arranged themselves in an identically re- peating pattern along all three spatial dimensions. PV FACT WORD TO KNOW Growing Cooling The crucible starts to turn, and the seed crystal begins to rotate in the opposite direction. The siliconmeltfreezesontotheseedcrystal,matching the seed’s crystalline structure. The crystal grows, the cable and seed slowly ascend, and the crystal elongates at a controlled diameter. As the growth depletes the silicon melt, the crucible also rises. Flash forward about 3½ days since the crucible was charged with polysilicon: After hours of cool- ing to about 300 degrees Fahrenheit, the furnace hood and shaft lift away from the crucible encase- ment to reveal a completed cylindrical crystal, ready to move to the second step and next pro- duction room. Crystal emerging from melt Crystal measuring 8 inches wide and about 5 ½ feet long
  • 10. 10 CUTTING CRYSTAL INTO WAFERS Cutting Squaring First, a saw cuts off the crystal’s so-called top and tail, so that a crystal of uniform width remains. Typically, wafering saws draw thin wire bearing a liquid abrasive across the crystal’s surface. (Above, a machine moun- ted with a giant donutlike steel blade does the cutting.) Wire saws also cut the crystal into ingots measuring 2 feet long. Steel holders are mounted on one end of these ingots for the next step. Mounted ingots are placed standing on end in a rack bearing 16 at a time inside another wire- slicing machine. There, wire running in a lattice configuration descends on the ingots to shear off four rounded segments, leaving flat sides. The re- sult: The ingots now have a square cross-section, except for still-rounded corners. A silicon crystal must change shape several times before it winds up as the precisely calibrated wafers that form the foundations of photovoltaic cells. Crystal ingot Saw wire Ingots standing on end beneath wire lattice used to square them
  • 11. 11 Wafering saws use spools of wire to carry the mineral abrasive sili- con carbide, effectively forming a miniscule strand of sandpaper. The spools bear wire measuring about 400 miles long. Stretched out from SolarWorld’s U.S. headquarters in Hillsboro, Ore., the wire would reach roughly to Missoula, Mont. Silicon carbide: Silicon carbide (SiC), silicon bonded with carbon, is another member of the silicon family of materials used in the PV industry. It is a common abrasive in many industries, used in every- thing from grinding to sandblast- ing. At SolarWorld, crushed SiC is mixed into a water slurry and applied to saw wires. Silicon carbide, not wire, actually does the cutting. PV FACT WORD TO KNOW Slicing The next wire saw is more intricate yet. A wire winding hundreds of times between two cylindrical drums forms a web of parallel, tightly spaced seg- ments. As the wire unspools through the machine, ingots mounted side- ways on glass and metal holders are pressed two at a time through the wire web, slicing them into the thickness of slim business cards. Each millimeter of crystal yields about 2½ wafers. Detached from their holders, the wafers are loaded into carriers, or boats, for transport to the next step. About 100 wafers fit within a transport carrier, or boat Saw wire 6”
  • 12. 12 CONVERTING WAFERS INTO CELLS Texturing Diffusing In the only phase requiring a designated clean room, a series of intricate chemical and heat treatments con- verts the blank, grey wafers into productive, blue cells. A so-called texture etch, for instance, removes a tiny la- yer of silicon, relying on the underlying crystal structure to reveal an irregular pattern of pyramids. The surface of pyramids – so small they’re invisible to the naked eye – absorbs more light. Next, wafers are moved in cartridges into long, cy- lindrical, oven-like chambers in which phosphorus is diffused into a thin layer of the wafer surface. The molecular-level impregnation occurs as the wafer surface is exposed to phosphorus gas at a high heat, a step that gives the surface a negative potential electrical orientation. The combination of that layer and the boron-doped layer below cre- ates a positive-negative, or P/N, junction – a criti- cal partition in the functioning of a PV cell. At this point, a wafer is no more capable of producing electricity than a sliver of river rock. The wafer is the main building block of a PV cell, but so far its only notable characteristics are its crystal structure and positive potential orientation. All of that changes in the third, multistep, cell-production phase of PV manufacturing. Chemical bath Clean suits ensure a sterile environment
  • 13. 13 In the PV and semiconductor industries, the word tool has a special meaning. Instead of referring to an implement that can be applied to a manufactur- ing mechanism, tools in these fields refer to entire machines or assembly lines that perform a step or series of steps. In both industries, tools are highly auto- mated so that most workers are employed to install, finetune and operate the tools, rather than lift- ing or moving product. Spider-like devices lift and move wafers and cells on and off conveyor belts for multiple tests along their journey from wafer to cell. Micron: In cell production, manufacturing steps occur in dimensions measured in microns. In the metric system, a micron is one millionth of a meter, or one thousandth of a millimeter. For reference, a human hair measures about 100 microns across. PV FACT WORD TO KNOW Coating Printing The burgeoning, still-grey cells move in trays into heavy vacuum chambers where blue-purple sili- con nitride is deposited onto their tops. The coa- ting with silicon nitride – yet another member of the silicon family of materials – is designed to re- duce reflection even further in the energy-dense blue end of the light spectrum. It leaves the cells with their final, dark color. Now, the cells can optimally gather photons and produce electricity. They lack, however, any me- chanism to collect and forward the power. So, in a series of silkscreen-like steps, metals are printed on both sides of the cell, adding pin-stripe “fin- gers” and bus-bar circuitry. A functioning cell is born–onlysunshineisneededtoproduceelectricity. Drying oven Wafer Printing template
  • 14. 14 STRINGING CELLS INTO PANELS Soldering and laminating Framing At SolarWorld, panel manufacturing is a highly auto- mated process, relying on robust steel robotics to un- dertake the increasingly heavy lifting of assembling lightweight PV cells into panels weighing around 45 pounds apiece. Each robotic tool works within a safety fence that, by design, prevents human access. First, cells are soldered together into strings of 10, using an over- under-over-under pattern of metal connectors to link the cells. Six strings are laid out to form a rectangular matrix of 60 cells. Each matrix is laminated onto special solar glass. To become a solar panel, however, each laminate requires not only a frame to provide protection against weather and other impacts but also a junction box to enable connections among panels or with an inverter-bound conduit. Robots affix those, too. Clean suits ensure a sterile environment Cell string Each phase of production depends on processes with flavors all their own. Careful control of heating and cooling dominates crystal growing. Wafering employs abrasion and cutting. Cell production concentrates on chemistry. Any factory process would be incomplete without a final assembly step, and in PV such a step is known as panel assembly, or moduling.
  • 15. 15 Inspecting and shipping Carefulcleaningandinspectionprovidefinaltouches before each solar panel can be boxed for delivery to homes and businesses. However, inspection does not only take place at the end of the production line. Digitized and automated checks take place at key steps from silicon crystallization through panel assembly, and human inspection of each and every cell and panel. SolarWorld is a manufacturer. It sells Sunmodule™ solar panels mostly through distributors, integrators and contractors. But the company also sells Sunkits® systems – configurations of panels, inverter and parts that include everything that licensed electrical contractors need for specific projects at specific loca- tions. SolarWorld pioneered this approach in the 1990s. Module: Within the industry, solar panels are called modules, because they link together evenly and interchangeably use electri- cal connectors to form a circuit within an array, with a building or with a utility grid. To make a module, cell-matrix laminants are mounted into sturdy aluminum frames. The resulting module is robust enough to withstand 50 mph hailstone impacts and up to 112 pounds per square foot of wind or snow load. WORD TO KNOW PV FACT
  • 16. 16 HOW A PV CELL MAKES ELECTRICITY Under the sun, a photovoltaic cell acts as a photosensitive diode that instantaneously converts light – but not heat – into electricity. Cell cutaway Light-absorbing layer Metal contact N (negative type) P (positive type) P/N juction Metal back Positive doping Negative doping (1) Recall that in the crystallization step a small amount of the dopant boron was added to the polysilicon chunks before they were melted. Boron lacks one elec- tron and therefore takes on an electron from silicon as an acceptor. Because the electron is missing, leaving an electron hole, the semiconductor becomes p-con- ductive (positive-conductive). (2) Remember that in cell production phosphorus was applied to those layers of the silicon wafer closest to the surface. This dopant, as compared with silicon, has one extra electron, which it can easily release. Thus the silicon becomes n-conductive (negative- conductive). 1 2
  • 17. 17 Electron PhotonA B C D E It takes all kinds of workers to produce PV, ranging from doc- toral engineers troubleshooting arcane problems to entry-level machine operators learning basic process steps. Within SolarWorld, the four stages of production run as semi-autonomous but interde- pendent factories, all with teams of production engineers, mainte- nance engineers, technicians and operators. Conversion efficiency: This measure gauges the percentage of solar (light) power reaching a panel that is converted into elec- trical power. Conventional cells now range in the high percentage teens. Theoretical and labora- tory conversion rates typically are much higher than rates from mass production. PV FACT WORD TO KNOW Cell layers Sun activation The top, phosphorus-diffused silicon layer therefore carries free electrons – unan- chored particles with negative charges. The thicker, boron-doped bottom layer contains holes, or absences of electrons, that also can move freely. In effect, precise manufacturing has instilled an electronic imbalance between the two layers. A) Photons bombard and penetrate the cell. B) They activate electrons, knocking them loose in both silicon layers. C) Some electrons in the bottom layer sling-shot to the top of the cell. D) These electrons flow into metal contacts as electricity, moving into a circuit throughout a 60-cell panel. E) Electrons flow back into the cell via a solid contact layer at the bottom, creating a closed loop or circuit.
  • 18. 18 Powering homes and businesses Current leaving a panel, or array of panels, passes through a wire conduit leading to an inverter. These devices, which are shaped like suitcases and come in various sizes, invert direct current, which flows with a fixed current and voltage, into alternating current, which flows with oscillating current and voltage. Appliances worldwide operate on AC. From the inverter, the solar-generated power feeds into circuitry of a household, business or power plant and onto the region’s electrical grid. A remote, or independent, power sy- stem also can form a self-contained circuit without connecting to the grid. The off-grid system, however, requires batteries to store power for times, such as night, when panels do not capture enough light energy from the sun. Inverter PV panels InverterFuse boxElectrical grid Electrical devices (TV etc.) SOAK UP THE SAVINGS The sun provides abundant clean energy every single day, even when it’s cloudy – and it never sends a bill. The sun provides enough energy to serve the entire world’s energy needs hundreds of times over.
  • 19. 19 Environmental benefits Solar panels reduce the amount of electricity coming from fossil fuels by supplying your home with clean, renewable energy from the sun. By providing more energy and lasting longer than other brands, SolarWorld Sunmodule™ pa- nels are the best choice for cutting your carbon footprint down to size while maintaining a comfortable lifestyle. SolarWorld Sunmodule panels are made from pure silicon, glass and aluminum. Our manufacturing processes avoid or minimize the use of toxic materials such as cadmium and arsenic, which are used in many low-grade thin film panels. SolarWorld factories strive to continuously improve these processes and lead the industry in sustai- nable manufacturing practices. SolarWorld pioneered the high-yield process of recapturing the main components of silicon, glass and aluminum so that at the end of their useful lives Sunmodules can be reprocessed for reuse, instead of relegated to landfills. For products that can last more than 30 years, that’s thinking ahead. * CO₂ emissions avoided over 25 years: 94 tons * Equivalent miles not driven: 306,376 * Equivalent trees planted: 1.6 acres * Based on a 3 kilowatt system in Southern California. GOOD FOR THE PLANET
  • 20. 20 Solar energy’s present YOU ENTER THE EQUATION Grid parity – the point where energy costs the same whether from solar technology or fossil fuels – has arrived in many U.S. markets. It’s about time, too. Though fossils have gotten us where we are today, they also have caused enormous environmental harms. The time has arrived to use slivers of rock – silicon – to reliably produce electricity for decades rather than burning up tons of rock and oil extracted from the Earth just one time. To promote energy market competition, various government and nonprofit agencies offer an array of incentives for solar purchases. However, the cost of solar has already fallen so much that in some markets, those agencies are starting to phase out some incentives. PV technology is largely a U.S. original. But foreign ingenuity has grasped the industryʼs leadership by applying market mechanisms that jumpstart higher investment returns. Creating higher demand, these policies build economies of scale that force down pricing. But it takes people – you – to make choices for a better planet. Now the U.S. is reawakening to the promise of solar energy.
  • 21. 21 Solar market incentives Incentives vary among nations, states and even cities, but they typically fall into these categories: Rebates: Some organizations distribute outright reimbursements for a portion of system costs. Tax incentives: The U.S. government and several states may offer investment tax credits or accounting provisions allowing extraordinary terms for asset depreciation. On Jan. 1, 2009, for instance, the federal government remo- ved a $2,000 cap on a 30 percent credit for residential systems. Net metering: This alternative to feed-in tariffs allows solar power producers to generate and use power with the same pricing and according to a single meter. When a home system, for instance, makes more power than it uses, its meter rolls backward. Feed-in tariffs: Dozens of countries have implemented feed-in tariff systems – set premium rates that utilities are required to pay for power from solar systems. The rates remain fixed for a set number of years, perhaps 20. A power producer, such as a homeowner or business, separately pays normal market rates for power from the grid. So how much power does a typical PV sys- tem produce – and at what cost? A modest rooftop system for a home might combine 1.5-3 kW in panels and produce the equiva- lent of about one-third of the home’s power needs. In some locations, the ultimate costs to the system owners – figuring in all incentives – might amount to 30 cents on the dollar. In that case, a hypothetical system priced at $25,000 actually would cost about $7,500. Returns on investment in many cases exceed average typical interest on certificates of deposit. Falling solar prices will cross rising prices of fossil fuels With government incentives, then without, rising solar demand and falling unit pricing are leading to grid parity. Insolation: Sunlight varies by region. Insolation is a measure of the solar radia- tion energy in a given region. It is usually expressed as the intensity of light energy per unit of land area. As a whole, the U.S., especially the sunny Southwest and South- east, offers strong insolation. By compari- son, Germany, the PV industry’s leader, gets little better sun than Alaska. PV FACT WORD TO KNOW Priceperwatt NowTime Solar with incentives Solar Fossil fuels
  • 22. 22 FOR ROOFTOPS AND BEYOND These days, PV technology is extend- ing beyond rooftops into locations that have never known the benefits of electricity. As on-grid applications bring cleaner power to wired homes, so, too, do off-grid systems empower those without electric refrigeration and lighting. Along the way, SolarWorld has led the world industry in rural elec- trification and sustainable practices. Anywhere there’s sky While rooftop systems provide countless homes and businesses with power right where they most need it, such installations are far from the only kinds of PV projects harnessing photons. Ground-mounted systems make sense where roofs are una- vailable or inadequate. Panels are mounted on racks anchored into the ground. Canopy systems can provide shelter and produce power in park- ing lots and exterior corridors. Utility-scale systems come in a variety of dimensions, but all pro- duce enough electricity to power many buildings. Tracker systems in- crease their output power by moving to follow the sun’s path.
  • 23. 23 Recycling and reusing A global vision SolarWorld has led the global PV industry in app- lying principles of sustainability. Internally, SolarWorld uses residual and remnant silicon left in crucible bottoms or cut from ingots to reform crystal, and it strives in every imaginable direction to divert waste leaving its operations – plastic packaging, spent wire, even coffee cups – into second or new uses. Externally, SolarWorld pioneered processes and practices for offering crystalline silicon photo- voltaic recycling and helped spur the industry to develop recycling programs. The company accepts any returns of SolarWorld solar panels that other- wise might be discarded. Then, the panels under- go a high-yield process of recovering constituent materials for reuse. SolarWorld’s Solar2World program takes aim at the 2 billion people on the planet who go without electricity, a number that promises to rise with population growth. Working with local partners, the company donates its panels into rural electri- fication projects in some of the world’s poorest areas. With SolarWorld’s expansion in the United States, the Solar2World program there focuses on Latin America. “Sustainable develop- ment is designed to lead to a situation where present generations can satisfy their own needs without jeopardizing the potential needs of future generations.” Dr.-Ing. E. h. Frank Asbeck, SolarWorld chairman and CEO
  • 24. solarworld.com Locations: SolarWorld Americas (Sales and marketing for USA, Canada, and South and Central America) 4650 Adohr Lane Camarillo, CA 93012 Phone: +1 805 388 6200 Fax: +1 805 388 6395 customerservice@solarworld-usa.com SolarWorld Industries America (U.S. headquarters) 25300 NW Evergreen Road Hillsboro, OR 97124 Phone: +1 503 844 3400 Fax: +1 503 844 3403 customerservice@solarworld-usa.com Benefits at a glance World-class quality SolarWorld produces the highest-quality solar panels, manufacturing according to U.S. and German quality standards in fully automated ISO 19001 and 14001 factories. SolarWorld Plus sorting Plus-sorting guarantees the highest system efficiency. Only the panels that achieve the desig­nated nominal performance or more in performance tests are dispatched. 25-year linear performance guarantee and 10-year product warranty* In addition to a 10-year product warranty, SolarWorld provides a 25-year performance guarantee that ensures an actual performance of at least 97 percent of the nominal power in the first year and an annual decrease of not more than 0.7 percent in each of the next 24 years. An experienced industry leader With more than 35 years of experience in off-grid solar applications, SolarWorld delivers top products and technical experience at the highest levels. SolarWorld solar panels are installed in more than 100,000 telecommunications and industrial systems worldwide. No one else comes close. * in accordance with the SolarWorld service certificate valid at the time of purchase | www.solarworld-usa.com/warranty Textandillustrationsreflectthestateoftheartatthetimeofprinting.Subjecttochangewithoutnotice.Validasof:07/2011 SW-02-5024US07-2011